Archive for the ‘Motion Control’ Category

Beckhoff Automation  presented a new generation of more powerful CNC systems with PC- and EtherCAT-based control technology at the EMO 2007 in Germany.

The EtherCAT real-time Ethernet system enables high speed communication between the PC controller and the digital drives.

Additional process optimisation is offered by the XFC technology, which allows fast, deterministic reactions. In this way, the user is presented with completely new possibilities to improve the quality of his machine and to shorten reaction times.

Manufacturers from all over the world presented a wide range of machine tools and production systems for cutting and forming processes, as well as precision tools and controllers for the entire production technology.

At the EMO 2007, Beckhoff presented its range of products from the fields of IPC, I/O, motion and drives.

In the field of metalworking, PC-based PLC, motion control and CNC solutions are used, for example, in processing centres and lathes and in sheet metal processing, grinding, sawing and cutting machines.

In principle, the Beckhoff solution comprises:

• A modern industrial PC as an open control platform
• Software NC/CNC for Motion Control and interpolating path movements
• An open, flexible and configurable .NET-based HMI solution
• EtherCAT as a fast communication medium for I/Os and drives
• EtherCAT I/Os for high precision control of actuators and fast sensor signal recording, to integrated measurement technology and condition monitoring
• EtherCAT servo drives from the AX5000 series with a corresponding range of motors

A new generation of Industrial PCs is available for the EtherCAT-based control concept.

Instead of additional, expensive fieldbus cards, these IPCs contain two Ethernet interfaces for automation and IT applications. While the 100 MBit Ethernet port offers optimum performance for all EtherCAT control tasks, a gigabit port is available for connecting the higher-level network.

The C69xx control cabinet PC series offers a slimline, modern controller platform.

The Industrial PCs in robust, ultra-compact aluminium housings are equipped with new generation processors and are optionally available without cooling fans or mechanically moved parts.

Software replaces hardware-oriented controller systems:

Besides high-end PCs, Beckhoff’s scalable control system with Embedded PCs also offers powerful solutions. One example of this is the combination of a CX1020, Windows CE-based operating system and TwinCAT NC I for interpolating path movements in up to 3 axes.

The DIN rail mountable Embedded PCs additionally offer the advantage that the Beckhoff Bus Terminals and EtherCAT Terminals can be mounted directly side by side.

On the software side, Beckhoff offers two solutions for interpolating path movements in the TwinCAT NC I and TwinCAT CNC: TwinCAT NC I is the modular CNC solution for up to 31 channels, each with up to three main and five auxiliary axes. TwinCAT CNC is the classic, powerful CNC application for up to 64 path axes/spindles in up to twelve channels.

In addition, this package offers spline and transformation functionality (5-axis functionality) as an option. The basis of both CNC systems is the fast TwinCAT PLC system.

Optimised control and communication architecture:

Beckhoff presented an innovation for the metalworking industry at the EMO in XFC technology (eXtreme Fast Control Technology), a fast control solution.

XFC is based on an optimised control and communication architecture comprising an advanced Industrial PC, ultra-fast I/O terminals, the EtherCAT high-speed Ethernet system and the TwinCAT automation software.

In addition to optimised cycle time, XFC also offers improved temporal accuracy and enhanced resolution. In this way, the user is presented with completely new possibilities to improve the quality of his machine and to shorten reaction times.

Measuring tasks or documentation of parts quality can simply be integrated in the machine control without additional, costly special devices.

In the field of machine tools, XFC technology offers wide variety of applications for process optimisation, such as:

• Oversampling for structure-borne sound analysis for integrated tool
• Monitoring high precision recording of measuring probes
• High mutual synchronicity of axes (important for the precision of interpolating movements)

 

Goto suppliers website

14 November 2007

CAD (Computer-aided design)
Geometry authoring tool that involves software and sometimes special-purpose hardware. Current packages range from 2D vector based drafting systems to 3D solid and surface modellers.

CAM (Computer-aided manufacturing)
Considered as an NC programming tool wherein 3D models of components generated in CAD software are used to generate CNC code to drive numerical controlled machine tools

CNC (computer numerical control)
Refers specifically to a computer "controller" that reads G-code instructions and drives the machine tool.

CAD/CAM part programming
The computer calculation and creation of a toolpath based on part geometry information created in CAD.

Canned cycle
A predetermined machining sequence used to simplify programming.

Data
Information processed as the basis for calculations.

Database
Computer storage that holds data and is searchable

Detail Drawing
A drawing of a part giving a complete and exact description of its form, dimensions, and construction

Dimension
The desired measurement of a part

Documentation
A CAD process in which a part design is converted to a computer file or hard copy for reference and storage purposes.

Drawing Exchange Format
DXF. A standard storage format for personal computer-based CAD/CAM platforms

Driver
That portion of the electronic package that receives the stepping sequence from the translator and provides the switching of the windings in the stepper motor.

G-Code
Common name for the programming language that controls NC and CNC machine tools

Geometric Modeling
A modeling process in which a designer creates lines and text that represents the shape of a desired part. Geometric modeling is the first step in CAD.

Geometry
The measurement, properties, and relationships of the lines and points of an object that make up its shape

M Code
A code used to signal an action from a miscellaneous group of commands. M codes change cutting tools, turn on or turn off the coolant, spindle, or work piece clamps, etc.

Machine Control Data
Manufacturing instructions defined in CAM and enacted on a CNC machine.

Machine Control Unit
A small, powerful computer that controls and operates a CNC machine

Machine Tool
Powered mechanical device, typically used to fabricate metal components of machines by machining

Machining
The selective removal of metal or material

Numerical Control
The use of computers and special program instructions to execute the sequence of machining operations to make a part.

Part Program
A series of numerical instructions used by a CNC machine to perform the necessary sequence of operations to machine a specific work piece.

Personal Computer
PC. A computer designed for an individual user and commercial software. Desktops, laptops, and notebook computers are PCs.

Plotter
A large printer used to print blueprints. These output devices support vector graphics, unlike dot matrix and laser printers.

Post Processor
A software link in the CAD/CAM chain that communicates instructions from CAM to a CNC machine

Preliminary Blueprint
A design representing the rough dimensions of a specific part

Primitives or Primitive
Basic shapes such as cubes, spheres, cylinders, blocks, and cones that are combined in solid modeling to create a model of a part.

Prototype
The original test model of a part

Raster Image
A form of graphics in which closely spaced rows of dots form an image on a computer screen. Also known as bit-mapped graphics.

Ramping
The process of controlling the pulse frequency to accelerate or decelerate a stepper motor. Ramping increases the ability to drive larger loads at greater speeds by slowing the first series of pulses allowing the motor to overcome inertial loads and reduces overshooting by slowing the motor down more gradually than an unramped motor.

Scanner
A computer device that converts hard copy drawings into digital form

Software
The coded instructions, formulas, and operations that structure the actions of a computer

Solid Modeling
A type of geometric modeling based on solids in which all visible surfaces of a part are shown. In addition, solid modeling describes interior volume, mass, and weight.

Sub-Program
Acting as a part programming shortcut, a part program sequence that is called on as needed. Also called a subroutine.

Surface Modeling
A type of geometric modeling based on geometry only, in which all visible surfaces of a part are shown regardless of volume definition.

Step Angle
The angular increment the motor shaft will turn each time the windings (coils) are energized. The angle is specified in degrees. For a 200 step per revolution motor the step angle will be 1.8 degrees.

Step per revolution
The total number of steps to rotate the motor shaft 360 degrees. For CNC, 200 or 400 steps per revolution are usually used.

Stepper motor
A device that translates electrical pulses into precise mechanical movement. The output shaft may deliver rotary or linear motion.

Title Block
A portion of a blueprint that contains information such as the company name, part name, part number, designer, scale, and material.

Tolerance
A blueprint specification indicating an unwanted but acceptable deviation from a given dimension

Toolpath
The series of coordinate positions that determine the movement of a tool during a machining operation.

Translator
An electronic device that converts pulses into the correct switching sequence, which will operate the motor one step for each pulse received.

Unipolar
A bifilar wound motor. The current flows only in one direction through each winding. Normally there are two winding per bobbin and eight bobbins per motor. Usually is a 5, 6 or eight wire motor. One or more common leads are used per winding. Has less torque than a bipolar stepper motor but is simpler to drive. Bipolar stepper motor- just two windings. The electronic controls reverse the current alternately between the coils. This motor has more torque but requires more electronic controls.

Vector Graphics
A form of graphics that uses geometric formulas to represent images. Vector graphic images are more easily manipulated than raster graphics when dealing with CNC.

Wire Frame Modeling
A type of geometric modeling in which the edges of a part are represented by solid lines

Working Drawing
A drawing of a part providing data for manufacturing

X-Axis
An axis that is left or right. All movement left of a zero point is minus (-X), all movement right of the zero point is plus (+X).

Y-axis
An axis that is at right angles to the X-axis and intersect the zero point of the X-axis. All movement further away from the zero point is plus (+Y). All movement closer than the zero point is minus (-Y).

Z-axis
An axis that is vertically perpendicular to the X-Y zero point. All movement above the zero point is positive (+Z) while all movement below the zero point is (-Z).

Some technology allowed humans to use machines and program codes to do things that had been done manually. CNC is one of these technologies.

CNC routers have been of great help in many fields (signage- making, 3D moldings and furniture, just to name a few). In that regard, it would be very helpful for its users to know how to get the best deal and quality on their next purchase of CNC routers.

Here are some tips on how you can get the best CNC routers.

1. Buying CNC routers from a manufacturer would be more advisable than buying from distributors.

Buying from a manufacturer will give consumers the following advantages -

- The guarantee that the sales representative knows a lot about the product. Who would know the product better than the manufacturers themselves?

- Consumers can buy the items at a cheaper price too, since there are no third parties or go- betweens involved in the transaction.

Just make sure that you know the nearest service center of the company so that you know where to go to in case you need follow- up services from them.

2. Visit multiple stores to try the different CNC machines.

- It would be advisable that you have materials that you can work on when you try the machines. Bring these materials home to see that of the products can give the quality of workmanship that you are looking for.

- Also, it would be advantageous if you can also check the machines ease of usage and your comfort while you are using the product. These things will help a lot in deciding that router you will use.

3. It is advisable to buy a new CNC router.

New CNC routers are more efficient, and the quality of work can be assured. Of course, not all circumstances would allow businesses the endeavors of having a new CNC router.

In case you would buy used CNC routers, here are the things that you need to look for -

- At least one year warranty from the seller just as an assurance that you would not have to shoulder repair expenses within that period.

- Make sure that all of the upgrades necessary for the machine have been done.

- Ask if it would be possible for repairs to be done after a year and ask how much it would cost.

4. Consult your vendor regarding your CNC router needs so that you will not buy something less than what you are expecting or something more that can add up to your expenses.

5. Test the durability and the reliability of the CNC routers.

These are the two qualities that a CNC router must be able to meet. All the parts of the router should be sturdy enough to carry on the heavy work. Minimal vibrations must be felt during operations, and the cuts must be precise, accurate and smooth. You must know these things before buying the product, and not after you purchase it.

6. Get the software that is easy to learn, manipulate, program and fix during errors.

When using CNC routers, operators will be dealing with programs and codes that tell the machine what to do. That is why it is a basic requirement for the operators to be accustomed to the software that he is using. Most of these things he will learn during trainings and product testing.

7. Consider workspace and the jobs to be done in buying CNC routers.

Materials that CNC routers are working on vary in characteristics such as hardness. Your CNC routers may do the job easily on this product, will have a hard time working on another. These things must be taken into consideration when buying CNC routers.

Also, workspace is another issue. Make sure that your workspace can accommodate the machine that you will be buying.

8. Price is relevant to the CNC router and the future profit that it can bring you.

Do not get a CNC router just because it is cheap. Think long term.

Your CNC router is the key in making the most out of your business. So give it your best shot to follow these tips to get the best CNC router to cater to your needs!

 

About the Author:

For more great cnc router related articles and resources check out http://cncportal.info

 

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Since we are dealing with machines that do work for us, we need to control those machines somehow. We need to control them for safety reasons as well. If you give a machine improper commands it can easily get out of control and cause harm to you or the part you are machining. We want to give appropriate commands to our machines, at appropriate times so they are not "out of control". 

The language that these machines use is called G-code. G-code has been around since the early 60’s. There are a number of variations of G-code, but most are very similar to one another.  See the previous section for a sample of G-Code. 

We will need to use a computer to talk with our CNC machine. Our computer will send signals to our CNC machine. In-between our computer and our CNC machine sits a controller. A controller converts commands into signals that are used to control the motion of our machine.

As these signals are sent out of the controller, they go to either stepper or servo motors. This is how we create motion. These motors drive our various axis on our CNC machine. While we are moving our axis, there is generally a cutting tool of some sort removing material. This is the machining process coupled with CNC.

Here is a link to Haas.  They are a well known manufacturer of CNC Machines.  They make various mills and lathes.  Some of their machines are used on shows like American Chopper.

Haas Automation, Inc. – CNC Machine Tools – The Leader in CNC Machine

Manufactures CNC vertical and horizontal machining centers, CNC lathes and rotary tables.

Here is the table of contents to the book I recently wrote about CNC Basics.  The book’s title is "Learn CNC Secrets."

Learn CNC Secrets Table of Contents

CNC Safety. 9

A few ideas to keep you safe in the shop: 10

Foreword. 11

CNC Knowledge Levels    11

One last note before we get going: 12

CNC Intro. 13

Questions, Questions and a few more Questions. 13

My CNC Story    13

My Initial Thoughts on CNC        14

Little Did I know             15

Other things I had to learn along the way: 15

So, where am I at today?    16

CNC Machines I own today:  16

CNC Hobby Growth Story    17

Why do people get into CNC?    17

Production CNC – Professional CNC – Manufacturing CNC. 18

Here are a few jobs on the professional side of the house: 18

Hobby CNC     18

Here are a few elements that have brought people into the CNC Fold:  19

What personal attributes will help you with CNC?. 20

CNC Process Overview: 22

Quick Explanation of the Process. 22

There are basically five elements to a CNC Project that you need to know:  22

Design    23

Here are some important elements of design that need to be answered:  23

CAD     25

3-D Design    25

Here are some examples of 3-D drafting/design software: 25

2-D Design    25

Here are some examples of 2-D drafting/design software: 26

CAM      26

Here are some examples of CAM software: 26

Using CAM Software    27

Here is an example of some G-Code: 27

Control  27

Here is a brief description of the two types of motors generally used in CNC:  28

Machine Controllers    29

Machining    30

Here is a list of common tooling: 31

CNC Process Conclusion    32

The five things to master with CNC are: 32

Design. 33

Introduction to Design    33

Where do good design ideas come from?. 33

Know what you want before you build it 34

What are the limits?    34

Part vs. Art   35

Designing on Paper   35

Designing with a Computer   35

My Design Computer Setup    36

Design Software. 37

What I used to do                     37

Why use Design Software?    37

Here are some advantages of using Design Software: 37

Here are some disadvantages of using Design Software: 37

My Definition of Design Software  38

Here are some examples of work for “Creative” Design 38

Commonly used Creative Design Software. 40

What is your Vector, Victor?    40

Vector Images:  41

Raster Images:  41

Raster to Vector Software    42

File Types You Will Deal With    42

Examples of Different File Types  43

What do I really need to know?    44

CAD. 45

What is CAD?    45

Print Reading and Drafting    46

How do I translate my design into the computer?. 48

Different Design Views    48

The main print or design views are: 48

Here are some photo examples of the different design views: 49

Tools in CAD     51

How do I choose the right CAD program for me?. 53

Types of CAD     53

2D CAD     53

2.5D CAD     54

3D CAD     54

2D, 2.5D and 3D Photo Examples  54

CAD Design Process    56

Designing Parts    56

Designing Sub Assemblies    57

Designing Groups    57

Designing the Machine    57

FMEA Analysis?  What?    58

CAD Software Price Points    59

Hobby CAD Software    59

Professional CAD Software    59

Examples of Commercial CAD Software Programs. 59

What is CAD/CAM?    60

CAD/CAM Article    60

CAM.. 64

What is CAM?    64

How do I pick a CAM program?    65

The different types of CAM Software. 65

Here are the most common types of CAM Software. 66

What are tool paths and how do you create them?. 66

Process of CAM      67

Here are the CAM Steps:  67

Define Material  68

Define Stock Size    68

Define Coordinates    69

Define Tool  70

Define Feeds and Speeds    70

Simulate Machining    72

Tool Paths    73

Post Process    75

So what does CAM Software cost?. 76

Hobby CAM Software    76

Professional CAM Software    76

CAM Software Photos:  77

CAM Programs    78

Art CAM Programs    78

Art CAM Program Examples    79

Machining Simulators    79

CNC Simulator Examples:  79

G-Code. 80

What is G-Code?    80

You will see many variations of the G-Code name like: 80

Are there other “Codes?”    80

Here are some examples of G-Codes. 81

Why does G-Code Change?    81

What is an M-Code?    82

G-Code Example    82

2” Square G-Code    84

Do I need to be a G-Code Expert?. 84

Post Processing??? – Now you have me worried.  With all the variations in G-Codes and M-Codes, how will I ever keep it straight?… 85

Here are some screen shots of lists of post processors that you can select in your CAM Program       86

Controlling. 88

Definition    88

Control Computer   88

How is the Control Computer used?. 89

CNC Control Software    89

Quick List of control software    90

Machine Controllers    91

Here are some example controller prices. 92

Prices    92

Buying a completed CNC Machine. 93

Here are some examples of some Machine Controllers. 94

Internal Machine Controller Parts. 97

Control Pendants    98

Photos of Pendants    99

Machining. 101

Machining Overview      101

Machining    101

Here are a few of them:  101

Different types of machining    103

Here are a few examples:  103

Chips?    105

Different Sources of Tooling:  106

Photos of Different Types of CNC Machines: 107

Keeping your shop clean    115

Here are some examples:  115

Tool Offset   116

Zeroing the machine out   117

The final “Part”    117

CNC Mainstream.. 120

How do you know we hit the mainstream?. 120

End Results of CNC. 121

CNC Glossary. 126

 

From time to time I will get an email from an expert telling me this or that is not perfectly, technically correct.  Usually I agree with them.  What I have tried to present is how I learned CNC and how I made this stuff work in my mind.  Think of it as a Layman’s Guide to CNC vs. a PHD Doctoral Thesis with years of Data Collection and Analysis on the topic.  My point is always to teach, not gain recognition in scholarly journals.