Numerical Control is the machining process that uses a predefined set of

alphanumeric code to control the action of the particular tool. These alphanumeric codes
contain the information for the movement of the tool.
Numerical control, popularly known as the NC is very commonly used in the machine tools.
Numerical control is defined as the form of programmable automation, in which the process is
controlled by the number, letters, and symbols. In case of the machine tools this
programmable automation is used for the operation of the machines.
The components of an NC machine are Program of instructions, machine control unit(MCU)
and the machine tool.

As the name says program of instructions, the programmer plans the sequence of operations
to be taken place and writes it using numerical codes. These codes are punched in the punch
cards also called tape readers. These codes are sent to the machine control unit that
continuously converts the codes into machine tool movement. The machine tool is the main
component of the NC machine as it executes the program written. The block diagram for NC
machine is shown below

CNC stands for 'computer numerical control’

It is a computerized manufacturing process in which pre-programmed software and code
controls the movement of production equipment
CNC machines are used for various machining operations like shearing, flame or plasma
cutting, punching, laser cutting, forming, and welding and many other applications. To bring
the plates to their final shape CNC lasers and CNC plasma cutters are used commonly.
Just like the NC machine, CNC machine is used for the various manufacturing process, mostly
metal cutting processes. The machine tool in CNC is controlled by the programs written just
like the NC machine.

Now, the difference is that in NC machine the programs are fed into the punch cards and in
CNC machine the programs are written with the help of keyboard that is directly fed to the
computers.
These programs are stored in the computer memory which can be used for different parts and
these are not needed to be repeated many times. The programs can be easily edited according
to the requirement. The block diagram for CNC machine is as shown.

Working Of CNC Machine-

The CNC machine works with the execution of the programs at the machine tool. The program
is customized with CNC machining language called G-codes or M codes. Using these codes the
description of the operation that is to be perform is written. The description of coordinates,
the location of the machine tool, speed and feed rates.
At first from the 2D drawing the program is written and loaded in the computer for a trial run
which is called cutting air. In this trial run program, the mistakes of a programmer can be
rectified thereby saving the time and machine work, wastage of metal. If the trial run runs
successfully, the program is run for the final machining operation.
Comparison NC VS CNC

DESCRIPTION NC MACHINE CNC MACHINE

FULL FORM Numeric Control Computer Numeical

Machine Control Machine
CONCEPT Programs are stored in Programs are written
punch card and the through the computer
MCU processes it for and stored in the
the movement of memory for machine
machine tool tool operation

STORAGE Punch cards are used Directly stored in

computer memory

CODES Numeric, symbols, G-codes and M-codes

letters

FLEXIBILITY/COMPUTATIONAL less high

ABILITY

MAINTENANCE AND COST Less maintenance so High maintenance so

the the maintenance the the maintenance
cost is less cost is high

PROGRAM EXECUTION Requires more time Requires less time for

for executing the the program execution
program

ACCURACY Less compared to High

CNC

OPERATOR SKILL Highly skilled Semi-skilled operators

operator is required
Can run for 24 hours

RUNNING TIME Cannot run

continously
NEED OF CNC MACHINE (advantageous)
1. Increase in productivity
The use of CNCs has allowed manufacturers to work at a much faster pace to deliver the same
standard of products and without the added need for skilled labor resources.

2. Saves time and money

CNCs can work long hours, producing many customer orders in less time than labor-intensive
manufacturing.

3. Eliminates human errors

Errors such as cutting the aluminum too short, or the glass too big, can lead to a decrease in
profits, especially in a time where every Money counts. When you use CNCs, the machine is
programmed to deliver the product, as per the design data, and thus eliminating all chance of
human error.

4. Decreases material wastes

The CNC machines are precise, eliminate human error and therefore decrease the materials
wasted. This saves your business money not only in reducing wastage but also in the
compounded time spent on reworks.

5. Safe and easy to use

With CNC machines operators do not need to get close to the cutting tools which decrease
occupational health and safety accidents. This is a win for the business and for staff.

6. Future-proofing your business

Introducing CNC into your business allows you to adapt to changing designs, building codes,
and standards. This allows your business to keep up with the changing world of manufacturing
and keep you in the front of technology advances in the window and door industry.

7. Free up the skilled labor you do have for specialist skilled work
CNC machines help to reduce the labor required for the most basic administrative tasks, most
of which can easily be automated. This will free up the skilled labor you do have to focus on
their specific area of skill rather than menial administrative tasks.

8. Mitigating business risk

Software and automation implementation also formally captures business processes rather
than leaving these open to risk. “Tribal knowledge” is just one risk where only a select few
people in your business understand the processes as they have this in their head.

9. Opening the labor pool to include the lower-skilled tier of employees

CNC automation is set up and managed through your software. There is no need to employ
highly skilled machinists to manufacture windows and doors in your production line anymore.
All the data required to manufacture the order is already pre-defined and provided from one
true data source.

10. Less time and money spent on staff training

With your CNCs automated to produce orders in your manufacturing facility, you don’t need to
train up any new staff or carry of the cost of training staff on setting up and running your
CNCs. You require less staff and fewer training hours for the staff to use the CNC machines .

Industrial Applications Of CNC Machining

While the large manufacturing machines are not cheap, there are smaller, more affordable
variations. Not too dissimilar from home 3D printing machines reducing in size and cost, the
CNC industry is also seeing a similar trend. The reduction in size has resulted in a wider range
of applications. But before we digress and talk about CNC machines versus 3D printing, let’s
look at the industries using CNC machining:

Metal Removal Applications

CNC machines are extensively used in industries where metal removal is required. The
machines remove excess metal from raw materials to create complex parts. A good example is
the automotive industries where gears, shafts and other complex parts are carved from raw
materials. CNC machines are also used in the manufacturing industry for producing
rectangular, square, rounded and even threaded jobs. These machines can control and carry
out all processes, including milling, grinding, turning, boring and reaming, among others, using
specific machine tools for each task.

Metal Fabrication Industry

Many industries require thin plates for different purposes. These industries use CNC machines
for a number of machining operations to create these plates. They include plasma or flame
cutting, laser cutting, shearing, forming and welding. CNC plasma or laser cutters are used for
shaping metal, while CNC turret presses are used for operations like punching holes. CNC press
brakes carry out other operations with very high-precision, including bending metal plates.

Cabinet manufacturing
Cabinet manufacturing is one of the most common applications for CNC machines, whether
used to create customized or more standard pieces. In addition to cabinetry, CNCs help shops
produce closet sets, Shaker and Raised Panel Doors, countertops, chairs, tables, and more with
immense precision and unrivaled efficiency
Electrical Discharge Machining Applications

Electrical Discharge Machines, or EDMs, produce sparks that remove metal from the raw
material and burn away the excess metal. CNC automation carries out EDM machining in two
ways – first through Wire EDM and second through Vertical EDM. The fabrication industry use
CNC automated Wire EDM to punch and die combinations to create die sets. CNC automated
Vertical EDM requires an electrode in the same size and shape as the cavity that needs carving
out.

PLC Communication networks may be used in control systems to pass data between field
devices and PLCs, between different PLCs, or between PLCs and personal computers used for
operator interface, data processing and storage, or management information.

The programmable logic controller's (PLC's) ability to support a range of communication methods makes it an ideal
control and data acquisition device for a wide variety of industrial automation and facility control applications
PLC networks provide you with a variety of networking options to meet specific control and communications
requirements. Typical options include remote I/O, peer-to-peer, and host computer communications, as well as LANs.
These networks can provide reliable and cost-effective communications between as few as two or as many as several
hundred PLCs, computers, and other intelligent devices.

Many PLC vendors offer proprietary networking systems that are unique and will not communicate with another make
of PLC. This is because of the different communications protocols, command sequences, error-checking schemes, and
communications media used by each manufacturer.

However, it is possible to make different PLCs "talk" to one another; what's required is an ASCII interface for the
connection(s), along with considerable work with software.

Network Topologies
PLC network topology depicts the physical and logical organization of a
communication network. There are five distinct network topologies that
commonly exist: bus, ring, mesh, star, and tree.
Physical vs Logical Topology
The five topologies can be grouped under two main hierarchies:

Physical Topology

A physical topology is the arrangement of a network’s nodes and the

connections that connect them. This comprises the connections between
network nodes and their physical arrangement.

Logical Topology

A logical topology is the way data packets are routed over the network.
The network’s logical topology is based on the protocols used by the
data moving over it.

Five Types of Network Topologies

For computer networks, there are five primary topologies: star, mesh,
bus, ring, and tree. Each one is categorized according on the
arrangement of the nodes. The terminals are organized in a circular or
starlike pattern in these topologies. A hybrid network is one that
employs two or more topologies.

Star Topology

Each device in a star topology is connected to a central hub via a point-

to-point link, which serves as the single switching device. This network
is centralized, meaning that all devices connect to a central device. This
provides simplicity because there is only one way to connect to each
device in the network.

Additionally, the centralized nature of the network achieves isolation of

each device, meaning that each device is only able to communicate with
devices that are directly connected to it. This allows for the free-flowing
exchange of data between devices.

The star topology is the simplest and cheapest topology. Each device
runs independently, and a node’s failure to communicate with the central
hub has no effect on other nodes. The downside of a star architecture is
that network transmission is heavily reliant on the central hub. If a single
node fails, the network as a whole becomes inoperable.

Advantages of the Star Topology

 The network’s design enables each computer to have its own cable
connection, which means that if one computer is damaged or a
cable breaks, the other computers will remain unaffected.
 Modifying, troubleshooting, and maintaining the network is simple.
Mesh Topology
A mesh topology is a sort of network topology in which each device in
the network is connected to every other device. This topology is
typically used in tiny networks where each device must communicate
with the others. Each device in a mesh network is connected to every
other device, resulting in a web-like appearance. Mesh topologies are
more costly and difficult to configure than other topologies.

Bus Topology

In a bus topology, all devices are connected to a single cable. This

enables the transmission of data from one device to another. While all
devices on the network can hear all messages, only addressed devices
will reply to them.

Even if one bus fails, communication can continue via a redundant bus.
At any given time, only one device may utilize the shared transmission
link. Each device that wishes to communicate data must first wait its
turn and then transmit. The receiving device makes a copy of the
traveling packet’s address. This topology is extremely adaptable and can
support a large number of devices operating at varying data rates. A
cable break can render a significant chunk of the network inoperable.

Bus Topology Advantages

 This architecture is quite inexpensive and straightforward to build.

 The bus topology is one of the simplest and most cost-effective
topologies to implement.
 While it is generally slower and depends on the primary cable, it
can easily be linearly expanded without interrupting the network.
Ring Topology

A ring topology is a network topology in which each node is connected

to two more nodes. Additionally, the first and last nodes are connected.
The network data is routed through each node in the ring until it reaches
the destination node.

A central server is not required to manage connectivity between the

nodes in a ring topology. As a result, it is a more robust and efficient
network topology. The network’s capacity to transport data effectively is
critical to its proper operation. However, the failure of a single station
can render the entire network unworkable. Station alterations have an
effect on the network’s operation. A ring topology is well-suited for
networks with infrequent reconfigurations.

Ring Topology Key Advantages

 Requires no central device.

 Adding nodes has no impact on network performance.
 Relatively cheap and straightforward to implement.
Dual Ring Topology

The dual ring topology is distinguished by the presence of two

connections between each node. In the two rings produced, data flows in
opposite directions. The rings are not connected, and data flows in
opposing directions via them. In the event that one ring fails, the other
serves as a backup for data transfer.

Tree Topology

The tree topology architecture features a central bus that is connected to

by star-shaped hubs. Essentially, it is a hybrid topology comprised of the
bus and star topologies and reflects the use of the term “wide area
network.”
Industrial Networks

In large SCADA systems, there is usually a communications network of some type connecting
the individual PLCs to the operator interface equipment at the central control room.

There may also be networks used at lower levels in the control system architecture, for
communications between different PLCs in the same subsystem or industrial facility, as well as
for communications between field devices and individual PLCs.

The below figure shows the various levels of network communications in a typical
large SCADA system.

Although not widely applied to SCADA systems, two terms that are commonly used with
respect to management information systems communication are local area network (LAN) and
wide area network (WAN). A LAN consists of all of the devices, typically PCs and servers within
a particular industrial facility or site.

A WAN is created by providing a connection between LANs, typically over a long geographic
distance using telecommunications industrial facilities. Large SCADA systems may be required
to interface to LANs or WANs to provide data transfer to management information systems or
to permit internet access to SCADA system data.
I/O bus networks allow PLCs to communicate with I/O devices in a manner similar
to how local area networks let supervisory PLCs communicate with individual PLCs
.This configuration decentralizes control in the PLC system, yielding larger and
faster control systems. The topology, or physical architecture, of an I/O bus
network follows the bus or extended bus (tree) configuration, which lets field
devices (e.g., limit, photoelectric, and proximity switches) connect directly to
either a PLC or to a local area network bus. Remember that a bus is simply a
collection of lines that transmit data and/or power. The basic function of an I/O
bus network is to communicate information with, as well as supply power to, the
field devices that are connected to the bus /In an I/O bus network, the PLC drives
the field devices directly, without the use of I/O modules; therefore, the PLC
connects to and communicates with each field I/O device according to the bus’s
protocol. In essence, PLCs connect with I/O bus networks in a manner similar to
the way they connect with remote I/O, except that PLCs in an I/O bus use an I/O
bus network scanner. An I/O bus network scanner reads and writes to each field
device address, as well as decodes the information contained in the network
information packet. A large, tree topology bus network (i.e., a network with many
branches) may have up to 2048 or more connected discrete field device

I/O bus networks can be separated into two different categories—one that deals
with low-level devices that are typical of discrete manufacturing operations and
another that handles high-level devices found in process industries. These bus
network categories are:

• device bus networks

• process bus networks

Device bus network—A network that allows low-level I/O devices that transmit
relatively small amounts of information to communicate directly with a PLC
Process bus network—a network that allows high-level analog I/O devices that
transmit large amounts of information to communicate directly with a PLC
Device bus networks interface with low-level information devices (e.g., push buttons, limit
switches, etc.), which primarily transmit data relating to the state of the device (ON/OFF) and
its operational status (e.g., operating OK). These networks generally process only a few bits to
several bytes of data at a time. Process bus networks, on the other hand, connect with high-
level information devices (e.g., smart process valves, flow meters, etc.), which are typically
used in process control applications. Process bus networks handle large amounts of data
(several hundred bytes), consisting of information about the process, as well as the field
devices themselves.. The majority of devices used in process bus networks are analog, while
most devices used in device bus networks are discrete. However, device bus networks
sometimes include analog devices, such as thermocouples and variable speed drives, that
transmit only a few bytes of information

Modbus protocol Device net

Modbus
Modbus is a protocol that is used for transmitting information over a serial lines or Ethernet,
based on master-slave technology.
Modbus protocol is defined as a master/slave protocol, meaning a device operating as a
master will poll one or more devices operating as a slave. This means a slave device cannot
volunteer information; it must wait to be asked for it. The master will write data to a slave
device’s registers, and read data from a slave device’s registers. A register address or register
reference is always in the context of the slave’s registers.

Here we have two types of devices in this communication. The devices which request
information are called Modbus Master and the devices which provide the information are
called Modbus Slaves.

DeviceNet is a network protocol used in the automation industry to interconnect control

devices for data exchange. It utilizes the Common Industrial Protocol over a Controller Area
Network media layer and defines an application layer to cover a range of device profiles.
Typical applications include information exchange, safety devices, and large I/O control
networks.

DeviceNet, A low-level application-layer protocol for industrial application.

 In DeviceNet network You can connect up to 64 nodes. Each node can contain simple
sensors or process related instrument or programmable logic controller (PLC).
 DeviceNet Follow Controller Area Network (CAN) standard,devices to communicate with
each other.
 Bosch created it in 1985 to replace own wiring. And in 1990, Allen-Bradley-Rockwell
 Automation created DeviceNet as an application layer protocol based on this standard.
 Allan-Bradley select CAN as the DeviceNet’s physical layer This network also allows
different topologies(trunk and drop down topologies),different cables and more
 In Process automation you can find devicenet with simple sensors and Field instrument
and actuator
  DeviceNet mostly uses a trunkline-dropline topology, where small lines connect
devices.and small line connect with main line. These small lines should not run more
than six meters from the trunkline.

The ControlNet network is a high-speed deterministic network used for the transmission of
time-critical application information. It provides real-time control and messaging services for
peer-to-peer communication. As a high-speed link between controller and I/O devices, it
combines the capabilities of existing networks. ControlNet is a state-of-the-art open network
providing: • bandwidth for I/O, real-time interlocking, peer-to-peer messaging and
programming— all on the same link • deterministic, repeatable performance for both discrete
and process applications

ControlNet utilizes the Common Industrial Protocol (CIP) for the upper layers of the Open
Systems Interconnection or “OSI model” that has seven layers: Physical, data link, network,
transport, session, presentation, and application.

The designers of ControlNet adapted the CIP layers of transport, network, data link and
physical to fit the needs of the ControlNet network.

It also provides for critical messaging that does not rely on timing to be executed without
interfering with the transport of control and I/O data.

The types of devices that the ControlNet network talks to are Programmable Logic Controllers,
I/O chassis, HMIs, personal computers, drives, and robots.

It is typically used for redundant applications and/or applications that work best with
scheduled communications.
What’s the Difference Between DeviceNet and
ControlNet?

Network Positives Negatives

Low cost

Widespread Limited bandwidth

acceptance Limited cable distance
DeviceNet High reliability Limited message size
Efficient use of Connects up to 64 devices, compared to 99 devices with
bandwidth ControlNet
Power on network

High speed

Strictly scheduled High-cost of hardware

ControlNet Deterministic data Difficult to troubleshoot compared to DeviceNet

transfer
Signal only - no power
Redundant cables
support

What is DeviceNet?

Many companies just starting a digital transformation plan might only be looking for data to
see where a connected device or advanced automation would offer the greatest ROI. This
might require multiple sensors or simple devices that need two things; a connection and
power.
DeviceNet offers power and signal in a single cable to connect up to 64 devices that each have
a specific node address. Power and signal in one cable can save on cost. Additionally, a trunk
and drop line architecture make integrating new devices relatively easy compared to
Ethernet/IP which often requires individual wires for each device. Additionally, DeviceNet’s
architecture and individual node addresses work well for maintenance and troubleshooting.

Actuator Sensor Interface (AS-Interface or ASi) is an industrial networking solution

(physical layer, data access method and protocol) used in PLC, DCS and PC-based automation
systems. It is designed for connecting simple field I/O devices (e.g. binary ON/OFF devices such
as actuators, sensors, rotary encoders, analog inputs and outputs, push buttons, and valve
position sensors) in discrete manufacturing and process applications using a single two-
conductor cable

The ASi protocol is a simple interface system for connecting sensors and actuators with only
two wires. It has very high-speed communication, very reliable, and has high levels of noise
immunity to make it useful for a large variety of field device connections. It is very cost-
effective due to a large-scale reduction in wiring and complexity.
What makes it simple is a single unshielded two wire conductor cable; that makes the overall
electrical design constraints simple and easy to manage.
ASi protocol works in master-slave format. It consists of an ASi master module that can
communicate with up to 62 slave IO modules
Actuator Sensor Interface in PLC
Refer to the below image, which is the system architecture of an ASi protocol layout.
It consists of four main components.
They are
 Master module,
 Slave module,
 Power supply, and
 Interface cables.

Master Module
The master module is the main component that communicates the data to PLC on
any Fieldbus network (Ethernet or Modbus layer).
Slave Modules
The slave modules are the actual modules where the IO’s are connected. Each slave device is
identified by a device ID.
Power Supply
The power supply is the heart of the system which provides power to the whole ASi network.
It provides a constant 30V voltage to the line for master and slave devices
Interface System
Coming to the main thing that is special about this protocol; is the cable interface system.
Normally, two standard cables are used in this system
Thus, it can be seen that the ASi protocol is a largely useful protocol for IO handling in today’s
times of large networks. They reduce wiring to a very large extent and also the complexity of
the system.
Foundation Fieldbus (styled FOUNDATION Fieldbus) is an all-
digital, serial, two-way communications system that serves as the base-level network in a plant
or factory automation environment. It is an open architecture, developed and administered by
FieldComm Group.[1][2]
It is targeted for applications using basic and advanced regulatory control, and for much of the
discrete control associated with those functions. Foundation Fieldbus technology is mostly
used in process industries, but has recently been implemented in powerplants.
Two related implementations of Foundation Fieldbus have been introduced to meet different
needs within the process automation environment. These two implementations use different
physical media and communication speeds.

 Foundation Fieldbus H1 - Operates at 31.25 kbit/s and is generally used to connect to field
devices and host systems. It provides communication and power over standard stranded
twisted-pair wiring in both conventional and intrinsic safety applications. H1 is currently
the most common implementation.
 HSE (High-speed Ethernet) - Operates at 100/1000 Mbit/s and generally connects
input/output subsystems, host systems, linking devices and gateways. It doesn't currently
provide power over the cable, although work is under way to address this using the
IEEE802.3af Power over Ethernet (PoE) standard.
Foundation Fieldbus was originally intended as a replacement for the 4-20 mA standard, and
today it coexists alongside other technologies such as Modbus, Profibus, and Industrial
Ethernet. Foundation Fieldbus today enjoys a growing installed base in many heavy process
applications such as refining, petrochemicals, power generation, and even food and beverage,
pharmaceuticals, and nuclear applications

Benefits
 Distributed control, meaning that control is not done by the monitoring computer. It is
brought down into the devices themselves.
 Open standard, meaning that a customer can choose products from different vendors. The
Fieldbus Foundation is the organization that defines the FOUNDATION Fieldbus specification
and certifies products to be compliant with the standard. This guarantees that products
from different vendors can be used interchangeably. The Fieldbus Foundation standardized
the way the user canbring new devices into the network, set them up, and configure them.
The building block in this system is the Device Description (DD). The DD tells everything
about the device and its functionality. The DD lets you put an FF-certified device onto the
network, import the vendor-supplied DD file into your configuration, and be ready to run.
Any company with the proper resources can make an FF device (if it passes the
Interoperability Test) that will work with all other FF-certified devices and software.
 The ability to use existing 4-20 mA wiring.
 Drastically reduced wiring costs. You only need one twisted wire pair that will carry multiple
signals AND power, and you can drop devices off the network at any point. Since FF requires
only a single set of wires to connect multiple devices, this dramatically reduces wiring costs
from 4-20 mA systems, which required one pair of wires per device. Note that most, but not
all devices have the option of being bus powered.
 Reduced need for controllers and other hardware.

What is a PROFIBUS Protocol?

PROFIBUS defines the technical features of a serial field bus system, by which distributed
digital automation devices, from field to cell level, can be networked together.
It is a multi-master system and so allows the combined operation on one bus of several
automation, engineering, and visualization systems with remote peripherals.
Protocol Architecture
This protocol depends on Master-Slave architecture:
Master
Master determines data traffic on the bus and can send messages without an external request
if it is in possession of the bus access token.
Masters are also described as active stations.
Slave
The slave is a peripheral device, such as input and output devices, valves, drives, and
transmitters. They do not receive a token authorizing bus access.
This means that they can only acknowledge messages received or, at the request of a master,
send messages to it. Slaves are described as passive stations.
They only require a small portion of the bus protocol, which means they make implementation
possible with little effort.