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CNC controllers are devices that control machines and processes. They range in
capability from simple point-to-point linear control to highly complex algorithms that
involve multiple axes of control. CNC controllers can be used to control various types of
machine shop equipment. These include horizontal mills, vertical mills, lathes and
turning centers, grinders, electro discharge machines (EDM), welding machines, and
inspection machines. The number of axes controlled by CNC controllers can range
anywhere from one to five, with some CNC controllers configured to control greater than
six axes. Mounting types for CNC controllers include board, stand alone, desktop,
pendant, pedestal, and rack mount. Some units may have integral displays, touch screen
displays, and keypads for control and programming.
Industrial communications options for CNC controllers include ARCNet, CANBus,
ControlNET, Data Highway Plus, DeviceNet, Ethernet 10/100 Base-T, parallel, PROFIBUS,
SERCOS, Universal Serial Bus (USB), serial (RS232, RS422, RS485), and web-enabled.
Communications language choices include bitmap, conversational, DXF file, G/M codes,
Hewlett Packard graphics language, and ladder logic. A bit map (often spelled "bitmap")
defines a display space and the color for each pixel or "bit" in the display space.
Conversational language is a higher level, easy to learn programming tool. It performs
the same functions as the standard G-code commands. Drawing eXchange Format (DXF)
file that was created as a standard to freely exchange 2 and 3 dimensional drawings
between different CAD programs. It basically represents a shape as a wire frame mesh of
x, y, z coordinates. G-code is the programming language for the Computer Numerically
Controlled (CNC) machine tools that can be downloaded to the controller to operate the
machine. M-code is the standard machine tool codes that are normally used to switch on
the spindle, coolant or auxiliary devices. Hewlett Packard Graphical Language (HPGL)
was originally created to send 2 dimensional drawing information to pen plotters, but has
since become a good standard for the exchange of 2 dimensional drawing information
between CAD programs. Ladder logic is a programming language used to program
programmable logic controllers (PLC). This graphical language closely resembles
electrical relay logic diagrams.
CNC controllers have several choices for operation. These include polar coordinate
command, cutter compensation, linear and circular interpolation, stored pitch error,
helical interpolation, canned cycles, rigid tapping, and auto-scaling. Polar coordinate
command is a numerical control system in which all the coordinates are referred to a
certain pole. The position is defined by the polar radius and polar angle. Cutter
compensation is the distance you want the CNC control to offset for the tool radius away
from the programmed path. Linear and circular interpolation is the programmed path of
the machine, which appears to be straight or curved, but is actually a series of very
small steps along that path. Machine precision can be remarkably improved through such
features as stored pitch error compensation, which corrects for lead screw pitch error and
other mechanical positioning errors. Helical interpolation is a technique used to make
large diameter holes in workpieces. It allows for high metal removal rates with a
minimum of tool wear. There are machine routines like drilling, deep drilling, reaming,
tapping, boring, etc. that involve a series of machine operations but are specified by a
single G-code with appropriate parameters. Rigid tapping is a CNC tapping feature where
the tap is fed into the work piece at the precise rate needed for a perfect tapped hole. It
also needs to retract at the same precise rate otherwise it will shave the hole and create
an out of spec tapped hole. Auto scaling translates the parameters of the CNC program
to fit the work piece.
Features common to CNC controllers include alarm and event monitoring, behind tape
reader, diskette floppy storage, tape storage, zip disk storage, multi-program storage,
self diagnostics, simultaneous control, tape reader, and teach mode.
Encoder interface closes the loop on control
The EnDat interface can transmit position values from incremental and absolute
encoders as well as transmitting or updating information stored in the encoder, or saving
new information.
Note: A free brochure or catalogue is available from http://www.heidenhain.co.uk on the
products in this news release.
Digital drive systems and feedback loops with position encoders for measured value
acquisition require fast data transfer with high transmission reliability from the encoders.
Further data, such as drive-specific parameters, compensation tables, etc must also be
made available. For high system reliability, the encoders must be integrated in routines
for error detection and have diagnostic capabilities.
The EnDat interface from Heidenhain is a digital, bidirectional interface for encoders.
It is capable both of transmitting position values from incremental and absolute encoders
as well as transmitting or updating information stored in the encoder, or saving new
information.
Thanks to the serial transmission method only four signal lines are required.
The data are transmitted in synchronism with the clock signal from the subsequent
electronics.
The type of transmission (position values, parameters, diagnostics etc) is selected by
mode commands that the subsequent electronics send to the encoder.
The EnDat interface provides everything needed to reduce system cost per axis up to
50% - and at the same time improve the technical standard.
The most significant benefits are: cost optimisation, improved quality and higher
availability.
Measurement technology is key to automation
Advances in machine accuracy, on-machine touch probing technology and noncontact
tool setting provide powerful tools for automating and speeding mould machining, says
Barry Rogers.
Note: A free brochure or catalogue is available from http://www.renishaw.com on the
products in this news release.
Drives to faster, leaner, more flexible manufacturing are shifting industry focus away
from traditional post-process quality control. The most expensive, non-value-added
process in most shops is part inspection. Inspecting good parts - parts that meet all print
specifications - is a waste of time, money and manpower.
Three different Renishaw NC systems enable installation on nearly any size and
configuration of machine tool without impinging on the work envelope.
These proven, affordable control technologies can allow greater automation of mould
machining with greater process control.
They can make it possible for mouldmakers to produce moulds faster, with greater
geometric and dimensional accuracy, and less operator intervention, rework or manual
finishing. Request a free brochure from http://www.renishaw.com
High Speed Milling Machines
High speed machining is characterized by low cutting forces and high metal removal.
High Speed Milling is a technique used in the CNC Machining Industry that combines high
spindle speeds with increased feed rates. This results in a high chip-forming rate and
lower milling forces, producing an improved surface quality finish and closer tolerances.
In high speed milling, the electronics can make all the difference. The right CNC coupled
with other elements of the control system can let a slower machine mill a given form
faster than a machine with a higher top feed rates.
1. High Speed Uses
High-speed CNC milling is used, for example, to machine the titanium rotors of the first
high-pressure compressor stages of the EJ200 engine. High speed CNC milling allows
cost-effective milling of the different airfoil geometry from the solids. By subsequent
finishing operations the planned surface finish is achieved. The CNC milling which caters
to high speed must be structured with an axis movement system that is suitable for CNC
machining.
2. Axis Movement
The high-speed CNC milling machines required for the process must be fitted with an
axis movement system suitable for machining blisks, which should be at least 5 axes
simultaneously, depending on the milling task involved and an efficiently high-speed
control system.
3. 3D Surfaces
High Speed CNC milling machines working on 3D surfaces in any materials produce a
finer surface finish and higher accuracy in less time that the traditional milling machine.
Acceleration is the most critical factor that affects the high speed machining. Since one
or more axis are always increasing or decreasing velocity in a 3-D cut, ultimate feed rate
is directly related to acceleration
4. What Can A High Speed Control Possibly Do?
A CNC milling machine which possesses a higher structural stiffness has a greater
potential acceleration rate. Box shaped high speed CNC milling machine, like Bridge and
Gantry is the mostly widely used types of High speed CNC milling tools. The overhead
type Gantry exudes the highest stiffness, acceleration and accuracy among other high
speed CNC milling tools. Due to its scalability, this machine type is available in sizes to
match the work piece, from small to large.
In usual terms, it simply gives you the ability to finish one task faster and move along to
the next sooner, making work output higher. In drilling and tapping, this can result in
faster hole-to-hole times, quicker spindle reversals for tapping, and substantial cycletime reductions. The most dramatic benefits, though, come in 3D designs machining.
Few, drilling and tapping jobs require a million lines of machine codes. In molds, dies,
patterns, and prototypes, complex surfaces comprising a million or more line segments
are not at all uncommon. Saving just a fraction of a second per move can result in