DOI: 10.

1515/SBEEF-2016-0006
FOUR-AXIS CNC MACHINE WITH MICROCONTROLLER FOR CUTTING
POLYSTYRENE WITH HOT WIRE

HELGA SILAGHI, VIORICA SPOIALĂ, SIMONA VERONICA ABRUDAN CACIORA, D. SPOIALĂ

University of Oradea, Romania, Department of Control Systems Engineering and Management,
Faculty of Electrical Engineering and Information Technology, University Street, 1, 410087 Oradea, Romania
E-Mail: [email protected], [email protected], [email protected]

Abstract. Numerically controlled machines require precise First, is related the mechanical and actuation solution of
control, because it is always necessary to know the placement the machine. Then, is presented the electrical diagram of
of the effector. Control involves the use of electric motors that the microcontroller board, the block diagram of the
can be checked with precision. Therefore stepper motors are system, the control software, an example of use and the
preferred. A further advance in stepper control is to
incorporate a reaction mechanism for the rotor (for example,
conclusions.
an encoder) so as communication is optimal for generating
the torque, depending on the position of the rotor. This turns 2. MECHANICAL AND ACTUATION SOLUTION
the motor into a servo mechanism with very high torque and OF THE MACHINE
very good position resolution. An advance in this technique is
to operate the motor in a closed loop only if the error of rotor
positioning becomes too high. This will allow the system to Figure 1 presents the mechanical solution chosen for the
avoid oscillation while searching for a position, a problem CNC.
that commonly occurs with servos. The supervision of a
numerically controlled tool is limited to the control of electric
motors that actuate mechanical assemblies. Control can be
implemented by using specialized integrated circuits or
microcontrollers. This paper presents a numerically
controlled (CNC) machine with microcontroller.

Keywords: numerically controlled machine, microcontroller,

stepper motor, cutting

1. INTRODUCTION

In a CNC machine, the number of motors that can be

individually driven for the tool positional control, means
the number of axis [8].
Figure 1. Four axis CNC machine
For example, a simple CNC lathe has only two axes for
positional control of the tool. These axis are the X and the The device we have chosen, though not suitable for
Z axes. Therefore it is a two axes machine. production at industrial scale, has enough accuracy, given
its metallic structure and the fact that its guides are based
Another example is a simple vertical milling centre on precision shafts, the transmission of motion being
(VMC), that is a 3 axes milling machine. This machine acquired by means of trapezoidal threaded screws.
can be used to machine planer and some convex shaped
3D jobs [5]. The assemblies specific to each axis slide on precision
shafts by means of graphite bronze bushings.
Although, this cannot machine a helical groove of varying
thickness on the curved surface of a cylinder. For this, we The motors move the assemblies by means of trapezoidal
need an additional rotary axis which rotates the job as the threaded screws [1]. The choice of trapezoidal threaded
VMC provides the other tool motions. screws is the most common compromise at this level,
ensuring the required rapidity of the movement, without
So, a VMC that has an additional rotary axes is a 4-Axis losing too much engine torque [2].
machine. This paper presents the implementation of a
four-axis CNC machine with microcontroller for cutting Though obviously not the most efficient solution, it is the
polystyrene with hot wire. best compromise for this project, which aims to reach a
semi-professional level.
ISSN 2286-2455 Scientific Bulletin of the Electrical Engineering Faculty – Year 17 No.1 (36)

The device will be able to accurately cut shapes of any

kind in small, medium or even large-density polystyrene,
though at the cost of loosing some speed in the last case.

Despite the fact that their power is not really appropriate

for an application of this kind, stepper motors have been
chosen by reason of their low price; however, in
conjunction with the mechanical solution chosen
(threaded rods acting as reducers), the engines are able to
cope with the physical movement of the cutter.

The chosen motors allow for both unipolar and bipolar

equipment in circuit. Though easier to control in the
unipolar version, they have been used as bipolar motors,
since more torque can be generated in this way [4].

For facilitating control, we have used specialized

integrated circuits. We started from the assumption that,
if a high torque is not necessary, those integrated control Figure 2. Electrical diagram of the microcontroller board
circuits will always enable us to choose another method
for generating control waves so as to reduce power
consumption, thus making the use of supply/control
circuits less demanding [9]. The motors in question have
been chosen on grounds of such versatility.

A microcontroller has been chosen as initial test solution.

It communicates via a serial data transmission protocol
with the program generating commands on the computer
[3].

We have implemented a computer program that allows for

the introduction of basic instructions (formulating a set of
actions for the plant item) and sending instructions for
interpretation to the microcontroller. The microcontroller
interprets those commands and generates the actual
signals for moving the engines that operate the working Figure 3. The block diagram of the system
head.
A 5V voltage regulator for power, an oscillator (20 MHz
We have chosen a PIC16F870 microcontroller [7]. It quartz and associated capacitors) are also represented
operates at a frequency of 20 MHz, which is sufficient for above. Besides the two port C terminals that are connected
the current application. The microcontroller has the to the LEDs, there are two other C port terminals, used for
possibility of generating interrupts, analog inputs, and serial communication. Eight outputs of port B and four
three input/output ports. outputs of port C (12 altogether - 4 for each engine)
remain available for motor control signals.
We also needed a circuit for the amplification and, where
applicable, for the inversion of the current applied to the The block diagram indicating the main interconnection
coils of motors. We have chosen L 298 circuit, namely a elements of the CNC machine is shown in Figure 3.
double-lead lag H circuit, capable of voltages up to 46V Control instructions come from a computer by means of
and currents of 4A. some user-interface software [6]. These abstract
instructions will be sent to the CNC machine.
3. THE ELECTRICAL DIAGRAM OF THE
MICROCONTROLLER BOARD First signals received via serial communication will go
through an interface circuit in order to be turned from
The diagram presented in Figure 2 shows the standard RS-232 to a logical level, a level that the
microcontroller, the B and C ports, with protection microcontroller can work on. Once the abstract
resistors (for test purposes, two LEDs have been commands have been interpreted, the microcontroller
connected to two of the eight C port terminals), the A port generates low power control signals.
that has no protection resistors as these inputs also serve
as analogue/digital converters for the microcontroller. These signals go further to control circuits, which are
largely made up of L298 integrated circuits. If necessary,
these power circuits amplify and reverse the current,
Scientific Bulletin of the Electrical Engineering Faculty – Year 17 No.1 (36) ISSN 2286-2455

applying it to the motor terminals. It can be seen that there

is a two-way communication between the microcontroller
and the PC, as a protocol is used, where the
microcontroller will signal the computer whether
instructions were successfully received or if errors
occurred.

4. THE IMPLEMENTATION OF THE 4-AXIS

NUMERICAL MACHINE FOR CUTTING
POLISTYRENE WITH HOT WIRE

For the mechanical part of the machine we used, as base

material, steel profiles with a thickness of 3 mm.

Cost reasons determined our choice of steel profiles

instead of aluminum.
Figure 4. The FoamWorks control software
Steel made the machine heavier but also more stable on
the work bench, the only disadvantage becoming relevant When operating the system, problems that arose were
when the device had to be transported. mainly related to the L 298 amplifier circuit.
Processing consisted in drilling and cutting metal profiles
on professional machine tools, in order to ensure the
parallel and exact placement of precision shafts, of
trapezoidal threaded screws and of motors.

Precision shafts and trapezoidal threaded screws also

needed turning operations.

Since metal was chosen as working material, precision

was crucial in designing the machine, so as to ensure that
no restoration of specific parts during the final assembly
phase might be necessary (a time consuming and
relatively expensive process).

Therefore the entire machine was designed in a CAD

(Computer Aided Design) environment. In this way we
could see and correct any problems during the early
stages. Figure 5. The JediCut control software

FoamWorks (Figure 4) and JediCut (Figure 5) software The original designed card had no diode and thus the coils
were used for direct machine control through computer of engines eased back around the circuit, which generated
parallel ports because they allow a much broader set of a lot of heat and ultimately burnt the circuit, although the
instructions and thus the device becomes more versatile. 2.5 amps value was not reached – the maximum value,
according to catalog sheets of the integrated circuit.
Both software presented above function in a similar way.
They allow for the uploading of files containing An alternative we tried was decreasing the motor control
sequences of coordinates for each of the two towers (x1, pulse width.
y1 respectively x2, y2).
This solution was not effective since the motors no longer
Depending on the set speed, the software calculates the had the necessary force to move the mechanical
number and speed of control motor impulses, thus moving assemblies. The final solution was to equip the circuit
the machine and implicitly the copper-nickel hot wire that with auxiliary components, diodes and 2 comparators for
cuts polystyrene. each coil; when detecting a current that was higher that
the one allowed by coils, the comparators disabled voltage
on that particular coil.

The microcontroller and the L298 integrated circuit

proved to ensure a safe and reliable way to implement
control. In Figure 6 is shown the printed circuit card for
microcontroller.
ISSN 2286-2455 Scientific Bulletin of the Electrical Engineering Faculty – Year 17 No.1 (36)

At the end of the operation, or if an error has occurred, the

response section will show a corresponding message.

Instead of lineto (x, y, z) command, one could have used

the command line (X1, Y1, Z1, X2, Y2, Z2) with the same
result. Order lineto () is preferable when lines to be
followed are one after the other.

So we succeded that the supervision of a numerically

controlled tool to be limited to the control of electric
motors that actuate mechanical assemblies.

5. CONCLUSIONS

Nowadays, the need for precision has become proeminent

in all areas of activity. We have reached the level where
human beings are no longer able to manufacture, by
Figure 6. Printed circuit card for microcontroller traditional methods, components that would meet the
rigors needed for obtaining parts that may be subsequently
The device created for the purpose of this project is used in advanced systems. Here computer-assisted
relatively simplistic with very few instructions. processing becomes useful. This will ensure a perfect
identical result every time, which would be better and
Thus, for using the machine, it has to be connected to a more accurate than what can be obtained using traditional
PC and to a serial port. Since serial ports start to become methods.
less and less directly accessible on the back of the
motherboard, one can opt for a USB to RS-232 adapter. If Technology is advancing rapidly. Initially, numerically
this adapter is installed correctly it will be seen by the controlled machines were only available at industrial level
operating system as a serial port. and at prices far beyond the possibilities of a common
customer; now CNC machines are used by hobbyist as
The control program needs to install NET framework on well. This development has been stimulated by the
the computer on which it is desired to run. presence of more and more manufacturers of related
components, designed to enable ordinary people to build
Once the sequence of instructions required is introduced, such machines. Electronic control is becoming
"Send" button is pushed and the device starts working increasingly simpler and cheaper.
effectively.
Another factor that helps in the development of this area
After successfully completing the instructions, an is the existence of a community interested in the
appropriate message appears or, if operations have not numerical control of machines. This community is
been successfully performed an error is signaled. growing constantly as it is relatively easy to find such a
device on a small scale, but with high reliability and
4.1 Example of use precision.

As example we shall assume that we want to engrave, on For the command part we used a microcontroller, along
a piece of material, the outline of a rectangle with the size with all options that such a circuit can provide.
of 10x5 cm, having an etching depth of 4 mm. The initial
corner of the rectangle will be 10 centimeters away from We tried and managed to find the components that are
the edges. We assume that the processed material has a needed for amplifying current in such an application.
thickness of 5 cm. Once the component was found (IC L298), we managed
to understand its operation and linked it to the rest of the
Depending on the chosen head for the cutter, more or system.
fewer passes to etch a trench with a depth of 4 mm will be
necessary. In case we use a little cutter, multiple passes However there are still obstacles in building a CNC
through the material, at successively greater depths, are machine. The quality of operation is dependent upon the
required. In this case we assume that the cutter installed range of potential compromises every designer/builder is
can grave at a depth of 2 mm at a time. Thus we need two ready to accept. Although building such a machine has
passes to get the final depth of 4 mm. To ensure that errors become available to the general public, it still involves a
are not transmitted further if stepper motors lose steps, we significant financial effort.
shall use the home function at some point in the middle of
the program.
Scientific Bulletin of the Electrical Engineering Faculty – Year 17 No.1 (36) ISSN 2286-2455

The purpose of this scientific paper has been to achieve a [5] D.S. Bernstein, Rules Rule – Real Time
4-axis CNC machine, aimed at the semi- professional Engineering, IEEE Control Systems Magazine, vol.
level, able to carry the specific functions of 31, no. 3, pp. 6-7. 2011.
[6] J.Y. Fiset, Human-Machine Interface Design for
6. REFERENCES Process Control Applications, ISA Press, USA,
2008.
[1] Viorica Spoială, Helga Silaghi, Acţionări electrice [7] Popa M., Microprocesoare şi microcontrolere,
speciale, Editura Universităţii din Oradea, 2010. Editura Politehnică, Timişoara, 1998.
[2] V. Iancu, D. Spoială, Viorica Spoială, Maşini [8] Elena Maria Marginean, Programarea și operarea
electrice şi sisteme de acţionări electrice, vol.II, Ed. mașinilor-unelte cu comandă numerică. Teste și
Universităţii din Oradea, 2006. aplicații, Editura Transilvania, Cluj-Napoca, 2015.
[3] Daniela E. Popescu, Arhitectura și organizarea [9] S. Dale, H. Silaghi, D. Zmaranda, U. Rohde,
sistemelor conventionale de calcul, Editura Intelligent Design Environment for Second-Order
Universitatii din Oradea, 2002. Positioning Systems, International Journal of
[4] R. Islam, et al., Permanent-magnet synchronous Computers, Communications & Control, Vol. 10,
motor magnet designs with skewing for torque ripple Nr. 2, April, 2015, ISSN 1841-9836, pp. 165-173,
and cogging torque reduction, IEEE Transactions on 2015.
Industry Applications, vol. 45, pp. 152-160, 2009.