Numerical Control of

Production Systems
Dr MD Sameer
Assistant Professor
MED
KITSW
Numerical control (NC)
 NC is a form of programmable automation in which the
mechanical actions of a machine tool or other equipment are
controlled by a program containing coded alphanumeric data.
 The alphanumeric data represent relative positions between
a work head and a work part as well as other instructions
needed to operate the machine.
 The work head is a cutting tool or other processing
apparatus, and the work part is the object being processed.
When the current job is completed, the program of
instructions can be changed to process a new job.
 The capability to change the program makes NC suitable for
low and medium production. It is much easier to write new
programs than to make major alterations in the processing
equipment.
Numerical control (NC)
 Numerical control can be applied to a wide
variety of processes.
The applications divide into two categories:
(1) machine tool applications, such as drilling,
milling, turning, and other metal working; and
(2) other applications, such as assembly, rapid
prototyping, and inspection.
 The common operating feature of NC in all
of these applications is control of the work
head movement relative to the work part.
Basic Components of an NC
System
An NC system consists of three basic
components:
(1) a part program of instructions,
(2) a machine control unit, and
(3) processing equipment.
The general relationship among the three
components is illustrated in Figure
Basic components of an NC system.
Part program
 The part program is the set of detailed step-by-step
commands that direct the actions of the processing
equipment.
 In machine tool applications, the person who
prepares the program is called a part programmer.
 In these applications, the individual commands refer
to positions of a cutting tool relative to the
worktable on which the work part is fixtured.
Additional instructions are usually included, such as
spindle speed, feed rate, cutting tool selection, and
other functions.
 The program is coded on a suitable medium for
submission to the machine control unit.
Part program
 For many years, the common medium was 1-
in wide punched tape, using a standard
format that could be interpreted by the
machine control unit.
 Today, punched tape has largely been
replaced by newer storage technologies in
modern machine shops.
 These technologies include magnetic tape,
diskettes, and electronic transfer of part
programs from a computer.
Machine control unit (MCU)
 In modern NC technology, the machine
control unit (MCU) is a microcomputer and
related control hardware that stores the
program of instructions and executes it by
converting each command into mechanical
actions of the processing equipment, one
command at a time.
 The related hardware of the MCU includes
components to interface with the processing
equipment and feedback control elements.
Machine control unit (MCU)
 The MCU also includes one or more reading
devices for entering part programs into memory.
 Software residing in the MCU includes control
system software, calculation algorithms, and
translation software to convert the NC part
program into a usable format for the MCU.
 Because the MCU is a computer, the term
computer numerical control (CNC) is used to
distinguish this type of NC from its technological
ancestors that were based entirely on hardwired
electronics.
 Today, virtually all new MCUs are based on
computer technology.
Processing Equipment
 The third basic component of an NC system is
the processing equipment that performs the
actual productive work (e.g., machining).
 It accomplishes the processing steps to transform
the starting workpiece into a completed part.
 Its operation is directed by the MCU, which in
turn is driven by instructions contained in the
part program.
 In the most common example of NC, machining,
the processing equipment consists of the
worktable and spindle as well as the motors and
controls to drive them.
Motion Control Systems
 Some NC processes are performed at
discrete locations on the work part (e.g.,
drilling and spot welding).
 If the work head is moving, it may be
necessary to follow a straight line path or
a circular or other curvilinear path.
 These different types of movement are
accomplished by the motion control
system, whose features are explained
below.
APPLICATIONS OF NC
 Machine Tool Applications
Figure :The
four common
machining
operations are
(a) turning, (b)
drilling, (c) milling
(d) Grinding
 Machine Tool Applications

Figure (a) Four-axis CNC horizontal milling machine with safety panels
installed and
(b) with safety panels removed to show typical axis configuration for the
horizontal spindle.
NC Applications
 Following part characteristics have been
identified as most suited to the application
of NC
1. Batch production.
2. Repeat orders
3. Complex part geometry
4. Much metal needs to be removed from the
work part.
5. Many separate machining operations on the
part
6. The part is expensive.
NC for Other Metalworking
Processes
 Punch presses for sheet metal hole
punching.
 Presses for sheet metal bending.
 Welding machines.
 Thermal cutting machines, such as oxy-fuel
cutting, laser cutting, and plasma arc
cutting.
 Tube bending and wire bending machines.
 Wire EDM.
Other NC Applications
 Rapid prototyping and additive manufacturing.
 Water jet cutters and abrasive water jet cutters.
 Component placement machines.
 Coordinate measuring machines.
 Wood routers and granite cutters.
 Tape laying machines for polymer composites.
 Filament winding machines for polymer
composites.
Advantages and Disadvantages
of NC
Advantages of NC.
 Nonproductive time is reduced.
 Greater accuracy and repeatability.
 Lower scrap rates.
 Inspection requirements are reduced.
 More complex part geometries are possible.
 Engineering changes can be accommodated more gracefully.
 Simpler fixtures.
 Shorter manufacturing lead times.
 Reduced parts inventory.
 Less floor space.
 Operator skill requirements are reduced.
Disadvantages of NC.
• Higher investment cost
• Higher maintenance effort.
• Part programming.
• Higher utilization of NC equipment.
Computers and Numerical
Control
 Since the introduction of NC in 1952,
there have been dramatic advances in
digital computer technology.
 The physical size and cost of a digital
computer have been significantly reduced
at same time its computational capabilities
have substantially increased.
Features of CNC
 Storage of more than one part program
 Various forms of program input(punched,
magnetic, floppy diskettes, RS 232
communication)
 Program editing at the machine tool
 Fixed cycles and programming subroutines
 Interpolation
 Acceleration and deceleration computations
 Communications interface
The CNC Machine Control
Unit
 The MCU is the hardware that
distinguishes CNC from conventional
NC.
The CNC Machine Control
Unit
 The MCU is the hardware that distinguishes CNC from
conventional NC.
 The general configuration of the MCU in a CNC system is
illustrated in Figure .
 The MCU consists of the following components and
subsystems:
(1) central processing unit,
(2) memory,
(3) I/O interface,
(4) controls for machine tool axes and spindle speed, and
(5) sequence controls for other machine tool functions. These
subsystems are interconnected by means of a system bus,
which communicates data and signals among the components
of the network.
Central Processing Unit.
 The central processing unit (CPU) is the brain of
the MCU.
 It manages the other components in the MCU
based on software contained in main memory.
 The CPU can be divided into three sections:
(1) control section,
(2) Arithmetic logic unit, and
(3) immediate access memory.
 The control section retrieves commands and data
from memory and generates signals to activate
other components in the MCU.
Central Processing Unit/
Machine Control Unit
Memory.
 The immediate access memory in the CPU is not intended
for storing CNC software.
 A much greater storage capacity is required for the various
programs and data needed to operate the CNC system.
 As with most other computer systems, CNC memory can
be divided into two categories: .
(1) main memory and
(2) secondary memory.
 Main memory consists of ROM (read-only memory) and
RAM (random access memory) devices.
 These programs are usually installed by the manufacturer of
the MCU.
 NC part programs are stored in RAM devices.
 Current programs in RAM can be erased and replaced by
new programs as jobs are changed.
Input/Output Interface.
 The I/O interface provides communication between
the various components of the CNC system, other
computer systems, and the machine operator.
 As its name suggests, the I/O interface transmits and
receives data and signals to and from external devices,
several of which are indicated in Figure
 . This is used to enter commands related to part
program editing.
 MCU operating mode (e.g., program control vs.
manual control), speeds and feeds, cutting fluid pump
on/off, and similar functions.
 The display is used to indicate current status of the
program as it is being executed and to warn the
operator of any malfunctions in the system.
Controls for Machine Tool Axes
and Spindle Speed.
 These are hardware components that control the
position and velocity (feed rate) of each machine
axis as well as the rotational speed of the
machine tool spindle.
 Depending on the type of machine tool, the
spindle is used to drive either
(1) the workpiece, as in turning, or
(2) a rotating cutter, as in milling and drilling.
Spindle speed is a programmed parameter.
Components for spindle speed control in the MCU
usually consist of a drive control circuit and a
feedback sensor interface.
Sequence Controls for Other
Machine Tool Functions.
 In addition to control of table position, feed
rate, and spindle speed, several additional
functions are accomplished under part
program control.
 These auxiliary functions generally involve
on/off (binary) actuations, interlocks, and
discrete numerical data.
 The functions include cutting fluid control,
fixture clamping, emergency warnings, and
interlock communications for robot loading
and unloading of the machine tool.
CNC Software
 The NC computer operates by means of
software. There are three types of software
programs used in CNC systems:
(1) operating system software,
(2) machine interface software, and
(3) application software.
 The principal function of the operating
system software is to interpret the NC part
programs and generate the corresponding
control signals to drive the machine tool
axes.
CNC Software
 Operating system software consists of the following:
(1) an editor, which permits the Machine operator to
input and edit NC part programs and perform
other file management functions;
(2) a control program, which decodes the part program
instructions, performs interpolation and
acceleration/deceleration calculations, and
accomplishes other related functions to produce
the coordinate control signals for each axis; and
(3) an executive program, which manages the execution
of the CNC software as well as the I/O operations
of the MCU.
Distributed Numerical Control
Digital computers have been used to implement
NC. This section describes two approaches:
(1) direct numerical control and
(2) distributed numerical control.
 Direct numerical control (DNC) was the first
attempt to use a digital computer to control NC
machines.
 It was in the late 1960s, before the advent of
CNC.
 As initially implemented, direct numerical control
involved the control of a number of machine
tools by a single (mainframe) computer through
direct connection and in real time.
General configuration of a DNC system. Connection to
MCU is behind the tape reader. Key: BTR = behind the tape
reader, MCU = machine control unit.
Distributed Numerical Control
 Instead of using a punched tape reader to
enter the part program into the MCU, the
program was transmitted to the MCU
directly from the computer, one block of
instructions at a time.
 An instruction block provides the commands
for one complete move of the machine tool,
including location coordinates, speeds, feeds,
and other data.
 This mode of operation was referred to by
the term behind the tape reader (BTR).
Distributed Numerical Control
 The DNC computer provided instruction
blocks to the machine tool on demand;
when a machine needed control commands,
they were communicated to it immediately.
 . The system consisted of four components:
(1) central computer,
(2) bulk memory at the central computer site,
(3) set of controlled machines, and
(4) telecommunications lines to connect the
machines to the central computer.
DNC
 In operation, the computer called the required part
program from bulk memory and sent it (one block at
a time) to the designated machine tool.
 This procedure was replicated for all machine tools
under direct control of the computer.
 In addition to transmitting data to the machines, the
central computer also received data back from the
machines to indicate operating performance in the
shop (e.g., number of machining cycles completed,
machine utilization, and breakdowns).
 A central objective of DNC was to achieve two-way
communication between the machines and the
central computer.
DNC
 The distributed NC approach permits easier and less
costly installation of the overall system, because the
individual CNC machines can be put into service and
distributed NC can be added later. Redundant
computers improve system reliability compared with
the original DNC.
 The new DNC permits two-way communication of data
between the shop floor and the central computer,
which was one of the important features included in the
old DNC.
 However, improvements in data collection devices as
well as advances in computer and communications
technologies have expanded the range and flexibility of
the information that can be gathered and disseminated.
DNC
 Comparison between NC, CNC
and DNC machine tools
1. The part program is fed to
the machine through the
tapes or other such media.