BHEL AN OVERVIEW Established more than 40 years ago, BHEL is the largest engineering and manufacturing enterprise in India

a in the energy related/infrastructure sector today. The company has grown in stature over the years with continued inflow of orders, manufacturing prowess and continued thrust on technology leading to a strong presence in domestic and international markets as a major supplier of power plant equipment besides establishing substantial inroads in select segments of products in the industrial sector and railways. Bucking the uncertainties surrounding the global economic recovery, BHEL has registered during 2009-10, a top line growth of 22% with a turnover of INR 34,154 Crore and net profit rising by 37% to INR 4,311 Crore over the previous year. Order inflow during 2009-10 was at INR 59,037 Crore with total orders in hand as on 31st March, 2010 of INR 1,44,312 Crore. The company has realized the capacity to deliver 15000 MW per annum and the capacity expansion program to 20000 MW per annum by 2012 is underway. Currently, 74% of the power generated in the country is through BHEL sets. BHEL caters to core sectors of the Indian Economy viz., Power Generation and Transmission, Transportation, Renewable Energy, Defense etc. The wide network of BHELs 15 manufacturing Divisions, 4 Power Sector Regional Centers, 8 Service Centers, 15 Regional Offices, 4 Overseas Offices, 1 subsidiary and a large number of project sites spread all over India and abroad enables the company to promptly serves its customers and provide them with the suitable products, systems and services efficiently and at competitive process. The company has its footprints in more than 70 countries all over the world. The company has entered into a number of strategic Joint Ventures in the supercritical segment to leverage equipment sales besides strategic partnerships with technology leaders for business enhancement in transmission and transportation sectors. The Quality Systems as per ISO-9000 have taken deep roots in BHEL. The company has made significant achievements in Total Quality Management (TQM). With six CII-EXIM Commendations secured during 2009-10, BHEL stands highest among public and private sector companies in the country. In recognition of BHELs excellent performance on sustainability development, the CII-ITC Sustainability Award 2009 was conferred on BHELs Hyderabad unit. In recognition of BHELs contribution to the greening of the Lakshadweep Islands, BHEL was awarded the India Power-Jury Award 2009. For the fourth consecutive year, BHELs

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BHEL AN OVERVIEW

Established more than 40 years ago, BHEL is the largest engineering and manufacturing enterprise in India in the energy related/infrastructure sector today. The company has grown in stature over the years with continued inflow of orders, manufacturing prowess and continued thrust on technology leading to a strong presence in domestic and international markets as a major supplier of power plant equipment besides establishing substantial inroads in select segments of products in the industrial sector and railways. Bucking the uncertainties surrounding the global economic recovery, BHEL has registered during 2009-10, a top line growth of 22% with a turnover of INR 34,154 Crore and net profit rising by 37% to INR 4,311 Crore over the previous year. Order inflow during 2009-10 was at INR 59,037 Crore with total orders in hand as on 31st March, 2010 of INR 1,44,312 Crore. The company has realized the capacity to deliver 15000 MW per annum and the capacity expansion program to 20000 MW per annum by 2012 is underway. Currently, 74% of the power generated in the country is through BHEL sets. BHEL caters to core sectors of the Indian Economy viz., Power Generation and Transmission, Transportation, Renewable Energy, Defense etc. The wide network of BHELs 15 manufacturing Divisions, 4 Power Sector Regional Centers, 8 Service Centers, 15 Regional Offices, 4 Overseas Offices, 1 subsidiary and a large number of project sites spread all over India and abroad enables the company to promptly serves its customers and provide them with the suitable products, systems and services efficiently and at competitive process. The company has its footprints in more than 70 countries all over the world. The company has entered into a number of strategic Joint Ventures in the supercritical segment to leverage equipment sales besides strategic partnerships with technology leaders for business enhancement in transmission and transportation sectors. The Quality Systems as per ISO-9000 have taken deep roots in BHEL. The company has made significant achievements in Total Quality Management (TQM). With six CII-EXIM Commendations secured during 2009-10, BHEL stands highest among public and private sector companies in the country. In recognition of BHELs excellent performance on sustainability development, the CII-ITC Sustainability Award 2009 was conferred on BHELs Hyderabad unit. In recognition of BHELs contribution to the greening of the Lakshadweep Islands, BHEL was awarded the India Power-Jury Award 2009. For the fourth consecutive year, BHELs
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performance was recognized by the prestigious publication Forbes Asia, which featured BHEL in its fourth annual Fabulous 50 list of the Best of Asia-Pacifics Publicly-Traded Companies with revenues or market capitalization of at least USD 5 billion, having highest long term profitability and sales & earnings growth. BHEL is one of the only four Indian companies, ranked at 590, in The Global Innovation 1000 of Booz & Co., a list of 1000 publicly-traded companies which are the biggest spenders on R&D in the world. Significantly, BHEL won the EEPCs Top Export Award for the nineteenth year in succession. BHEL is the only Indian PSU to be recognized for the second time as Star PSU Company of the year by leading business daily Business Standard.

BOWL MILLS COMPRESSOR ELECTRICAL MACHINE GAS&STEAM TURBINES HEAT EXCHANGERS OIL RIGS PUMPS SWITCHGEAR

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INTRODUCTION
Industrialization has triggered rapid advances in technology all over the world has placed the need for machine tools to be controlled to very high levels of accuracy. Thus the concept of Computer Numerical Control arose which has revolutionized the machine tooling and made it possible to machine intricate jobs with high accuracy.

Machine tools are now controlled by CNC systems. The basic advantage of this over conventional machines is the flexibility being offered by the CNC system. This control system is a closed loop position control system where the position of the machine tool is controlled. The control system interfaced with the machine tool issues appropriate signals to various drives of the machine tool, which results in precise motion of these axes for accurate machining. The drives used are either DC or AC drives which provide better speed control features using electronic control with thyristor stacks.

The numerical data (set of commands) is fed into the control system through a suitable input medium (either alphanumeric keyboard of control system or floppy diskette). The data is stored in the data storage area and all the comparisons are computed in the computational area and distributed in respective servo drive axis. The servo drive gets activated and moves the axis slides and spindle. The position feedback transducer at each slide monitors the instantaneous position of the slide and gives the feedback to the control system where the instantaneous slide position is compared with the commanded position.

The CNC machine basically entails three main regions

The control system The drives (driving elements) and The machine tool

In the dissection that follows a complete insight into these functions of the CNC system have been taken up with the interfacing of each to the other.
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INTRODUCTION TO CNC MACHINES

INTRODUCTION

Controlling a machine tool by means of prepared program, which consists of blocks, or series of commands/numbers, is known as numerical control. Numerical Control [NC] for machine tools was introduced in 1950 by Prof. John T Parsons. The first CNC machine was built at the Massachusetts institute of technology [MIT] in 1953 by joint efforts of US Air force, MIT and the Parsons Corporation.

NC is nothing but position control of machine tools by recorded information called part program, which is a set of coded instructions given as numbers for automatic control of machine tool in a predetermined sequence. Numerical control can be defined as a technique of controlling the position of a machine tool by the direct insertion of numerical data at some point (command point) of the control system. The functions that are controlled on the machine tool are position of slide members, spindle speed, tool selection etc. At first the numerical control was used to produce geometrically complex parts, but later used for added efficiency in medium batch production. Presently numerical controls are employed in all sections of production.

Rapid developments in the field of electronics such as integrated circuits, large scaleintegrated circuits and development of minicomputer lead to the development of minicomputer based CNC systems. Further development and the electronic chip revolution have used in the current generation compact and powerful microprocessor based CNC systems.

FUNCTIONS OF A CONTROL SYSTEM

Automatic control systems in one form or another form can be applied to machine tool, in order to effect control over all the machine functions. The following are some of the more important functions, which can be controlled by control system.

(a) (b)

Displacement of machine slides Angular rotation of circular table

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(c) (d) (e) (f) (g) (h) (i) (j)

Start / Stop of the main spindle Changing of spindle speed Reverse spindle direction Changing the feed rate of machine slides Rotate tool turret Change tool Coolant ON / OFF Lock table in position

ADVANTAGES OF CNC TECHNOLOGY

Most of the advantages derived from CNC technology are because of high level of automation and high flexibility of CNC systems and their ability to combine multifunction machining requirements in minimum number of workstations and setups.

The most significant advantages are

1) REDUCED LEAD TIME

Lead-time is the time between the receipt of the design drawing and the receipt of the finished part. This time is reduced as preplanning is done away from the machine tool.

2) GREATER FLEXIBILITY

One of the most significant advantages of CNC over conventional NC is its flexibility. This flexibility provides the opportunity to introduce new control options like new interpolation schemes with relative ease and at low cost.

3) USER WRITTEN PROGRAMS

One of the possibilities not originally anticipated for CNC was the generation of specialized programs by the user. These programs generally take the form of MACRO subroutines stored in
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the CNC memory, which can be called by the part program to execute frequently using cutting sequence.

4) PROGRAM EDITING AT THE MACHINE SITE

The CNC program can be corrected and even optimized for tool path, speeds, and feeds during the program tryout at the site of the machine tool.

Apart from the above advantages increased machine utilization, greater quality control, high accuracy and repeatability, lesser material handling and reduced inspection can be achieved with CNC technology.

APPLICATIONS OF CNC

CNC has been applied to all types of machine tools from simple swing machines to complex contour grinding machines. Major applications are:

1. Metal cutting / fuming machines. 2. Machines employing non traditional such as EDM, plasma arc, laser beam, ion beam, ultrasonic, high speed water jet machines etc. 3. Tool handling system. 4. Work handling system 5. Welding machines. 6. Heat treatment equipment. 7. Assembly, testing and dispatch equipment.

CONSTRUCTIONAL FEATURES OF CNC MACHINES

1. Slideways 2. Spindle drive 3. Feed drives 4. Position measuring transducers

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5. Tool magazines and automatic tool changers 6. Automatic work changers 7. Lubrication system 8. Coolant system 9. Chip handling system

SLIDEWAYS

The CNC machines use

a. b.

Anti-friction bearing elements like regulating packs, regulating ball bushings A combination of anti-friction bearing elements and non-metallic linear elements which provides low friction and necessary damping.

SPINDLE DRIVE

CNC machines commonly have high spindle power and wide speed range. They have sharp variation of spindle speeds. Availability of full power at and above a particular speed, which is as low as possible, is desired. The spindle speeds are usually obtained through a 2 or 3 step gearbox for selection. Some machines use direct drive from the motor through belting with out any intermediate gearbox. They use DC motor with silicon controlled rectifier (SCR) drive or AC motor with variable frequency drive.

FEED DRIVES

Precision pre-loaded ball screws commonly activate the slides of CNC machines and driven by servomotors. The feed drives commonly used are: DC servomotor with silicon controlled rectifier (SCR) or pulse width modulated (PWM) drives Brush less DC servomotor with PWM drive
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AC motor with variable frequency drives.

Direct coupling of servomotor to ball screws is desirable to provide stiff drives.

POSITION MEASURING TRANSDUCERS

Position measuring transducers give instantaneous position of the slides and feed back to the control system. Position measuring devices can be gradually classified as

1. Direct measuring devices Linear devices for linear positioning Rotary devices for rotary positioning

Indirect measuring devices Rotary devices for linear positioning Linear devices for rotary positioning

Commonly used position-measuring devices are

1. Linear devices Linear Inductosyns Grating encoders Magnetic scales

2. Rotary devices Rotary Inductosyns Optical encoders Brushless synchronous resolvers

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TOOL MAGAZINES AND AUTOMATIC TOOL CHANGERS

Tool magazines can be generally classified as

1. Drum type, which is usually limited to 40 tools 2. Looped chain type, which can hold large number of tools

Two types of tool change arms commonly used are

1 2

Single gripper arm Double gripper arm

Double gripper arm usually executes a faster tool change since it does not have to wait for tool search. Required tool will be searched earlier and kept in ready position for quick interchange.

AUTOMATIC WORK CHANGERS (AWC)

Present day CNC machines are equipped with suitable work changers to facilitate rapid automatic changes to work pieces and thereby reducing the ideal time of the machine and increase productivity.

The most common work changers used with CNC machines are:

Dual pallet changers Shuttle type Indexing type

Multiple pallet pool type

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Rotary indexing type Conveyor type

LUBRICATION SYSTEM

Present day CNC machines are using lubrication system for free movement of slide members. Following are the features of the lubrication system of CNC machines.

1 2

Centralized lubrication system Automatic shutting off the machine and visual or audible alarm in the event of lubrication failure

Timer based system which periodically lubricate all points

COOLANT SYSTEM

CNC machines are provided with flood or mist coolant systems. Mist coolant is more efficient and can reach the point of cutting surfaces being machined. Some machines have coolant fed tooling to enable the coolant to reach the point of cutting.

CHIP HANDLING

Since CNC machines are high productive machines with high utilization factors, lot of chips is generated. Suitable chip handling systems are usually provided with CNC machines. Chips can cause lot of problems particularly during unmanned machining. Hence proper chip handling systems are provided with CNC machines.

CNC SYSTEM FEATURES

A CNC system can be interfaced to machine tools in order to effect control over machine functions. In order to perform these functions, a CNC system is characterized by a number of features. These features can be broadly classified as follows:

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Control system features Memory features Programming features PLC features Diagnostic features

CONTROL SYSTEM FEATURES

These features provide information about the characteristics of the CNC system and its capabilities. Currently there are three types of architecture are being used in CNC

(a) Minicomputer based system

uses 16-bit mini-processor as integral part of the CNC system

(b) Single Microprocessor based system (c) Multi microprocessor based system are

: :

uses 16-bit microprocessors in this system, the control functions

carried microprocessors,

out

by

set

of

each doing an assigned task. This is nothing but parallel processing. Both hardware and software structures are modular flexibility of the system thereby enhancing the

MEMORY FEATURES

Various memories are used in appropriate design application. Memories like EPROMS are used for storage of executive program and machine constants. RAMs are used for storage of part programs and as intermediate working area for the microprocessors.
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PROGRAMMING FEATURES

The programming features of a CNC system are useful in efficient use of the system. They can be as follows

Rapid positioning Linear interpolation Circular interpolation Thread cutting Canned cycles Multiple part programs upto 32, identifiable by names Diameter programming Direct spindle speed programming Variable lead thread cutting Sub routines and repeat loops upto a nesting level of 10 Graphics while machining Block number search

Absolute / incremental programming Sub programs Help menu for canned cycles Program management Variable parametric programming

PLC FEATURES

It is a software feature that does the interfacing of CNC system to machine tool. It provides the direct control of machine functions like spindle on/off, lubrication control etc. Signal
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from/to are of binary type. The PLCs available today are microprocessor-based units, which are integrated into the CNC system. The PLC has memory to store the control/interface program. Number of inputs/outputs Memory capacity High speed execution i.e. processing time in the order of milliseconds Software timers and counters Data exchange between CNC and PLC

DIAGNOSTIC FEATURES

For faults or error conditions, these are software programs, which check the functionality of the CNC system at various levels. These features include

Real time diagnostics Online diagnostics

: :

checks the DC power supply voltages, line voltages etc. active during machine operation. Messages are either readable from CRT display or from status indicators

Offline diagnostics

these are to be loaded which check the different areas of the

system and respond with error codes/description on the CRT

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display.

CNC SYSTEM ORGANISATION

CNC SYSTEMS

A CNC system is one, which uses a dedicated computer system to perform some or all the basic NC functions in accordance with control program stored in the memory of the computer. This control program in the memory is the system software or executive software. With the advancement of microelectronics and other high fabrication techniques the CNC system are microprocessor based in design.

MACHINE TOOL CONTROL

In a CNC system, a microcomputer is employed for machine tool control. The NC program called part program is fed as input (command) to the control system. The system acts upon this input by means of the executive programs and generates suitable actuating signals to the drive units for displacement of slide members. The part program thus contains all machining sequences that are necessary to do machining. The part program also contains information such as feedrate of axes feeds, starting or stopping of spindle motor, selection of spindle speeds, tool selection, coolant control etc. The CNC system controlling the machine tool operates as a closed loop control system. To ensure precise positioning of machine tool slides, position feed back devices are used. These devices provide information about the actual position of the machine tool slide. In the control system, the actual position is compared with the commanded position and the
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error between actual and commanded positions activates the respective drive motor to achieve precise positioning.

INPUT / OUTPUT DEVICES

The NC part program can be fed to and/or taken from the control system in a number of ways. The following are the commonly used devices that are used for part program entry. Alphanumeric keyboard of control system or Manual Data Input Floppy diskette Magnetic cassette RS 232 communication Programming system connected to the CNC system

FUNCTIONS OF A CNC SYSTEM

The major functions of a CNC system can be listed below

1. Reading and interpretation of a part program (set of commands) 2. Calculation and generation of motion command 3. Processing of the feedback information 4. Controlling auxiliary functions such as tool indexing, spindle on/off, coolant on/off etc. 5. Information to the operator likes part program, feedrate, spindle speed, alarm messages etc.

CLASSIFICATION OF CNC SYSTEMS

The CNC system can be classified on the basis of Control of path motions Feed back

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CLASSIFICATION BASED ON CONTROL OF PATH MOTIONS Point to Point control system

The principal function of position control system is positioning of machine tool from one specified position to another position. The path from one point to another is neither defined nor controlled in this type of systems and there is no mutual functional relationship between the starting and final positions.

Y Final Position

Starting Position X Continuous path control system

The continuous path control system calls for co-ordinated, inter-related motions of different axes of the machine tool. This means that the position of several slides must be controlled on the machine tool so that their relative positions and velocity must be established at every point and continuously through out the entire operation. Y

Error

Correct path

Incorrect path

X
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CLASSIFICATION BASED ON FEEDBACK SYSTEM

The CNC system can be classified into two groups Open loop control system Closed loop control system

OPEN LOOP CONTROL SYSTEM

In this system the machine slides are commanded and moved to a position but the information of the actual movement of the slide is not fedback to control system. There is no check on the actual position reached with reference to the desired position as directed by the command. The feed drive used is a stepper motor or electro hydraulic stepper motor. When a single pulse is given to these motors, they move through discrete angles thus achieving the desired position. The disadvantage of this type of system is that there is no check on the final position reached.

Command

Control System

Amp

Lead Screw
LOAD

CLOSED LOOP CONTROL SYSTEM

In a closed loop control system, a positionmeasuring device is used to feed the information regarding the actual position of the machine tool back to the system. The control system compares the actual position with the input command continuously and the difference between these two positions is processed and amplified to drive the slides until the commanded
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position is reached i.e. till this difference or error between final and commanded position is reduced to zero. Command

Lead Screw Control System Amp

M LOAD

Scale

Positional feedback signal

BLOCK DIAGRAM OF A CNC SYSTEM The block diagram of a typical CNC system is shown in the figure. The microprocessor along with associated hardware does the function of data storage, motion path calculation, command generation etc. The intelligence needed for the execution of these functions is in the form of a series of instructions to the microprocessor and is called executive program, which resides in memory. The output interface has provision for connecting external peripheral devices needed for data transfer. The operators control panel and CRT is used as a media by which the operator communicates with the system. The axis interface does the function of command generation and feedback signal processing. The peripheral to machine interface (PMI) does the machine oriented functions like spindle speed decoding, tool functions and miscellaneous functions like coolant switching and lubrication control, interfacing with the push buttons, limit switches, pressure switches, float switches, proximity switches.

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Set of commands

Operator Control Panel and CRT

Microprocessor Memory and Associated H / W

Panel Interface Axis Drive Axis interface

M

I / O interface C N C System

Feedback

Peripheral to Machine (PMI) Interface

To electrical panel of machine

Block Diagram of a typical CNC system

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CNC SYSTEM ELEMENTS

ELEMENTS OF A CNC SYSTEM

The basic elements of a CNC system are

Control panel Control circuits Power supply

CONTROL PANEL

System control panel consists of display unit, alphanumeric keyboard, status indicators. The machine control panel consist rotary switches for axis selection, feed override, spindle speed override etc. and pushbuttons for jogging, feed hold, cycle start, coolant ON etc. The keyboard of the CNC system is used to input data. It consists of selected or all alphanumeric characters, special characters keys such as %, /, [,] and special function keys such as end of block, cancel, cursor controls etc. Some of the important status information like axis home, over travel, in position, servo error, program end, and program stop in the CNC system is to be displayed by means of light emitting diodes (LEDS) which may be in Red, Green or Yellow colors.

CONTROL CIRCUITS

In latest CNC systems where microprocessors are used for control, the processor boards and other logic boards are housed on a single logic rack. In the master PCB system, a big PCB
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containing the processor and memory deices is directly mounted in the enclosure. Additional boards like memory board, programmable controller board, interface board are plunged onto the main board. All the interface connections are made on the same board through suitable connector arrangements.

To implement various decisions, logic gates such as AND, OR, NAND, NOT, XOR are being used in control circuits. Monostable multivibrator circuits, shift registers, counters are used in counting and timers are used timings circuits. The application of tri-state logic circuit is a must in the CNC circuits as data lines from different devices are clubbed together as a bus and at a specific time, a selected device can be enabled to send or receive data by means of tri-state logic devices. Other devices such as decoders, DACs, line drivers and receivers, operational amplifiers etc. are used in CNC for various functions.

POWER SUPPLIES

The CNC system requires a power supply for its operation. Generally custom-built power supplies are used. They must be highly reliable and have in built protections and must have low ripple voltage at output for a typical CNC system.

The voltages as mentioned below are required + 5 V DC 5% 10 to 30 A. 12 V DC 5% 2 to 5 A. + 24 V DC 10% 5 to 10 A.

These power supplies should have over voltage and short circuit protection. Switching mode power supplies are highly efficient and smaller in size and find use in any CNC systems. The various protections that a power supply should possess are given below.

Over voltage protection. Under voltage protection. Short circuit protection.

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Line voltage transients suppression.

In addition to the above basic elements the CNC system must be interfaced with following devices. Driving devices Feedback devices

DRIVING DEVICES

Driving elements for CNC system are usually DC or AC servomotors or stepper motors. The type selected is determined by the power requirements of the machine tool, the power source available and the desired dynamic torque characteristics. Generally DC servomotor is used for driving the machine tool. The armature supply to the servomotor is given by electronic drives, which contains thyristor stacks.

DC servomotors

These are designed specially for high dynamics. In CNC applications they have to accelerate to the rated speed within a few milliseconds only to decelerate a shorter time later just as quick. And of course the target position has to be reached exactly with an error of a few hundredths of millimeter. They have the advantage of high dynamics and accuracy, full stall torque, and compact motors with high power density. The good control behavior of these motors allows the optimal adaptation to the application i.e. positioning without overshoot. The high power density is achieved by permanent magnets.

Varying the armature voltage can control the speed of the DC servomotors. For varying the armature voltage servo amplifiers/drives are used.

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FEEDBACK DEVICES The feedback devices allow the control system to compare the machines actual position with the commanded position. The result of this comparison provides the ability of position control. The standard feedback devices are either digital transducers or analog transducers whose output is converted digital form. Transducers may either of linear type such as linear scale or of rotary type such as rotary encoders. Rotary encoders are frequently used with CNC systems.

Rotary encoder

The rotary encoder is a shaft driven device delivering electrical pulses at its output terminal. The pulse frequency is directly proportional to shaft speed. The encoder consists of a glass disc marked with a precise circular pattern of alternate clear and opaque segments on its periphery. The disc is mounted on the shaft. A fixed infra red light source is provided on one side of the disc and a photodiode is provided on the other side. As the disc rotates, light is periodically permitted to fall on the photodiode, to produce required output signal, which is approximately sinusoidal signal of millivolts. Internal amplifiers are supplied to amplify the photodiode output to a level suitable for feeding associated logic circuitry. The amplified signal is fed to Schmitt trigger to convert it into a proper square wave.

Using two photodiodes reading the same disc may sense the direction of rotation. The diodes are so that signal outputs are provided with a 90 phase shift to each other. Direction of rotation can be determined by external circuitry, fed by the quadrature sequence of pulses.

Infrared light source

photodiode

Shaft Rotating disc

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THE FAGOR 8030 MGI CNC SYSTEM

The FAGOR series of CNC control systems are of high accuracy, low cost, high performance and fixed software with high-speed microprocessors and semiconductor devices to enhance reliability and significantly improve the cost/performance ratio.

In FAGOR 8030 MGI CNC system

M stands for modular design G stands dynamic graphics I stands for integrated PLC system

Power supply requirements of this CNC are as follows

High performance switching power supply Universal power supply with any input between 100 V AC and 240 V AC ( 10%) AC frequency 50 60 Hz 2% during very short periods Power rated 160 W max. (both CNC and monitor) Protection : Short circuit protection

This FAGOR 8030 MGI CNC system is basically modular in design and contains the following PCBs (Printed Circuit Boards).

1. Power supply PCB 2. CRT PCB 3. The main CPU PCB 4. Input/output PCB 5. Feedback adaptor PCB 6. Keyboard 7. Dynamic graphics board (Optional)
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Power supply board: The power supply board contains following circuits

5V, 3A chopped power supply with voltage protection, which is used to internal TTL circuit 12V, 3A chopped power supply with voltage protection, which is used to internal TTL circuit -5V, 0.5A power supply, which is, used for linear sine wave feedback devices 15V, 0.5 A power supply, which is, used for analog output for drives 3.6V lithium rechargeable battery is used maintaining the RAM data when the systems power OFF Battery voltage monitoring circuit, which gives information to CPU for displaying battery alarm

CRT board of 32

This PCB contains driver circuit, which is able to drive display of 16 lines characters of different types on 8 monochrome CRT depending on the

selected mode of operation. CRT 8 monochrome Anti-glare 600 lines 50-60 Hz positive

Monitor Screen Resolution

: : :

Deflection Phosphor Display surface Horizontal Sync.

: : : :

90 PLA (amber) 146 X 119 mm 19.2 kHz positive

Vertical Sync. :

The main CPU board slave

It contains three 8-bit microprocessors (8085) in master-

connection.

Central Processor processor

This is the master processor that is accessing with interpolated

and CRT processor and it executes the part program, tool table and machine parameters
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CRT Processor

It is controlling the keyboard and giving information pressed keys (keyboard scanning). It generates video signals and vertical/horizontal synchronization pulses, which are used to drive the CRT display.

Interpolated Processor : the

It takes the PLC execution and internal input/output information to

central processor.

Input/output board :

Interpolated processor monitors this board. It contains the following electronic circuitry.

Analog output circuit within 10V for four axes drives and spindle Provision for RS232 communication Logic inputs/outputs to/from CNC Feedback input for sine or square wave signals 16-bit counters for counting the pulses which are coming from feedback adaptor board

Feedback adaptor board

It is used for only conditioning of the feedback pulses from encoder and supplied to the input/output board.

Keyboard

It contains the alphanumeric keys and some special keys for feeding part programs and PLC programs and for giving special commands.

General Characteristics of the System Three 8-bit microprocessors 512 KB of part program memory 2 communication lines: RS 232C and RS 485
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6 feedback inputs up to 5 axes + spindle encoder + electronic handwheel Resolution of 0.001 mm. Or 0.0001 inches Multiplying factor of up to 100 for sine wave feedback signals Feedrates from 0.001 mm/min up to 65535 mm/min Maximum axis travel 8388.607 mm 6 analog outputs: 10 V Maximum consumption in normal operation: Central unit 75 W Monitor 85 W

Electrical Characteristics of feedback inputs

+5 V power consumption -5 V power consumption

: :

750 mA 300 mA

(250 mA per axis) (250 mA per axis)

Operating levels for square wave signals

Maximum frequency

200 kHz 950 nsec 90 20 2.4V < V < 5V -5V < V < 0.8V 7V 3 mA

Maximum separation between flanks : Phase shift High threshold (logic 1) Low threshold (logic 0) V max. Maximum input current : : : : :

Operating levels for sine wave signals

Maximum frequency Peak to peak voltage Input current

: : :

25 kHz 2V < V < 6V 1 mA

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Features of FAGOR CNC system

Axis control

Axes involved in linear interpolation Axes involved in circular interpolation Least input increment

: : :

3 2 0.001 mm

Lead screw backlash compensation with sign Stored pitch error compensation 30 points (for each axis) One machine home per axis with home searching direction Spindle control

Operation 0 65535 mm/min

Rapid traverse rate

Automatic acceleration and deceleration MDI operation Single block execution Dry run Handwheel interface that can be managed by PLC Self diagnostics and error messages

Programming features

Rapid positioning Linear interpolation Canned cycles Multiple programs up to 32 identifiable by names Sub programs Absolute / incremental programming
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Sub routines and repeat loops up to a nesting level of 10

Other features

New 1, 2, 5, 10 resolution values for sine wave feedback signals for each axis PLCI registers access from CNC VGA monitor Management of feedback with coded Io Spindle inhibit by PLC Rapid key simulation by PLC Initialization of machine parameters after memory loss

Block diagram of FAGOR 8030 CNC

This CNC consists of 3 independent interconnected modules. They are

Central Unit Monitor / Keyboard Operator Panel

CENTRAL UNIT

MONITOR/KEYBOARD

OPERATOR PANEL

An 8 monochrome amber monitor or CRT screen is used to display the required information A keyboard which permits communication with the CNC

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An operator panel containing the necessary keys to work in JOG mode as well as the Cycle Start / Stop keys.

The operator panel is connected to the monitor/keyboard module through a cable. Both operator panel and monitor/keyboard are connected to central unit with video cable and keyboard cable.

The following connectors are connected to this CNC.

Apart from keyboard connector and video signal connector, there are four feedback connectors namely A1 to A4 for four axes (X, Y, Z and W), connector A5 for fifth axis (V-axis) feedback and connector A6 for interfacing handwheel or spindle encoder. RS 232 and RS 485 connectors for data transfer between CNC and Personal Computer, connectors I/O1 to I/O2 for PLC input/output connectors and connector I/O3 for analog reference signals for electronic drives.

Connectors A1 to A4 are 15-pin D type female connectors. They are used to connect feedback signals. They accept square wave signals or sine wave signals.

Pin

Signal

Function

1 2 3 4 5 6 7 8 9 10

A A B B Io Io Ac Bc +5V

Differential square wave signals

Machine reference signals (Marker pulses)

Sine wave feedback signals

Power supply to the feedback system

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11 12 13 14 15

0V

-5 V

CHASSIS

Shield

RS 232C connector details

Pin

Signal

Function

1 2 3 4 5 6 7 8

FG TD RD RTS CTS DSR GND ----9 DTR

Shield Transmit Data Receive Data Request to send clear to send Data send ready Ground not connected Data Terminal ready

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DRIVES
Drives are devices by which the speed of a motor can be controlled. These are essential for the CNC machines for precise axis movement and spindle rotation. The CNC system controls the drive by supplying them with the required input and receiving feedback signals from position feedback transducers. Drives are used in motor speed control for smoother, versatile control and to achieve specific torque speed characteristics.

ELECTRONICALLY CONTROLLED DRIVE

In this, the drive regulates the speed of the motor through control of armature voltage by varying the DC voltage applied to the motor. This control is accomplished by selecting a point on the AC input sine wave at which SCR begins to conduct. For effective speed control, feedbacks are provided. These feedbacks are negative i.e. opposite in sign to the input signal.

To control the motor speed, velocity command and tacho generator signals are summed, amplified and applied to the input of the inner current loop. The inner current loop sums up both the current feedback and velocity error signals. The difference error is amplified and used to control the gating of the power bridge circuit.

Ref. Signal (from CNC)

AC input

SPEED REGULAT OR

CURRENT REGULAT OR

FIRING CIRCUI T

POWER

BRIDGE

F I E L D

T Velocity feedback

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SPEED REGUALTOR

This serves the function of regulating the drive motor speed by comparing the feedback signal from tachogenerator and reference signal. The error signal between the reference and feedback can be compensated to provide optimum drive response using a preset. This error signal is amplified and the amplified output is fed to the next block, i.e. current regulator.

CURR ENT REGULATOR

It regulates the armature current by supplying a voltage signal to the both forward and reverse firing circuits. This is accomplished by comparing the current reference signal of the speed regulator and with a feedback signal from the armature current of motor. The error that results from the comparison of these signals is then amplified and suitably compensated and fed to the firing circuit of the drive.

FIRING CIRCUIT

The amplified output of the current regulator is used as an input to the firing circuit. The SCR gate pulse is phase shifted relative to the AC line so that the SCRs produce a variable output voltage from the Power Bridge. The output of the drive is then fed to the armature of the motor. Effective speed control is obtained since the feedback signals provide a closed loop operation where the difference between output and input i.e. the error is the actuating signal.

POWER BRIDGE

This is the converter i.e. controlled rectifier that converts AC mains supply to the variable DC voltage, that is fed to the armature of the motor. The variable output can be obtained by changing the firing angle (conduction period) of the SCRs. The SCRs can be connected either as half controlled bridge configuration or as full controlled bridge configuration.

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K G A G

K G A

K
F I E L D

A
MOTOR

K G G

K G

Block Diagram of Power Bridge

PROGRAMMABLE LOGIC CONTROLLER

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INTRODUCTION

Programmable logic controller (PLC System) is a computer system, basically designed to perform logical decision making for industrial control applications. The simplicity of reprogramming a PLC system, when modifications were required in the existing control, as compared to the cumbersome process of rewiring a hardwired control panel has been widely accepted. The PLC system is composed of electronic circuitry with a microprocessor centered.

In hardwired control, it is the wiring between individual elements such as sensor contacts, valves, solenoids etc. that defines the control program. Any modifications to the program involve rewiring the circuit.

In PLC systems, the construction of the controller and wiring are independent of program execution.

Advantages of using PLC system over conventional electrical relay panels Solid state devices are used for maximum reliability Easily reprogrammed with programming unit PLC program can be reusable Indicator lights provided at major diagnostic points to simplify troubleshooting Very compact and rugged design leading to less down time Hardware costs less than installed relays

As far as sequence of execution concerned, all sequences are executed parellelly at the same time in the case electrical relay panel, whereas in PLC system the execution is sequential and repeated cyclically known as PLC scan. However, the PLC scan time is in the order of milliseconds.
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The programmable logic control (PLC) is a software tool to handle majority of digital inputs and outputs. It enables the outputs depends upon the program configured for that particular machine tool. It executes the PLC program to control machine tool operations involving digital inputs and digital outputs.

The PLC system consists of programmable controller as well as sensors (input elements), actuators (output elements).

It consists of CPU module with processor, memory, input/output modules, power supply module and bus system i.e. path for transmission of control signals.

Address bus Data bus Control bus activities

: : :

Select the address (memory locations) on the individual members It carries data (contents of the memory location Transfers control and timing signals for the synchronization of CPUs

within the programmable controller

The power supply module generates internal voltages from the main supply for powering of electronic circuitry of the programmable controller

The processor of the controller scans the inputs, depending upon the stored program and the result of scanning operation, the actuators are switched ON or OFF.

BLOCK DIAGRAM OF PLC

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INTRODUCTION TO FAGOR PLC

In the FAGOR series of CNC systems, the programmable logic controller (PLC system) is integrated to CNC. The PLC software is integrated into the CNC software and the PLC program is stored in the internal memory (EEPROM) of the CNC. No extra hardware is needed to execute the PLC program. The microprocessor used by the CNC system is used by the PLC to execute PLC program on time sharing basis. The PLC program can be entered using CNC keyboard or through a programming system and executed on a machine tool. The edited PLC program must be compiled before it is executed. Once the program has been complied, the PLC will generate an executable code, which will be stored in its internal memory.

The PLC may be considered as being located between the CNC and the Machine tool.

CNC Outputs Inputs

I42-I104 PLC O1-O24

O25-O64 I1-I41

I/O 1 I/O 2 Connectors

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To electrical panel of the machine tool

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