i

Dedication

This work is dedicated to the AKISSEH’S and ESSONE’S family.

 ii

Acknowledgements

Words are often inadequate to express one’s deep regards. An understanding to a piece of
work like this is never the outcome of the efforts of a single person. I take this opportunity to
express my profound sense of gratitude and respect to all those who helped me through the
duration of this thesis:

The Almighty God for the health, strength, wisdom and life He gave me to accomplish this
thesis. Let all Glory be given to Him.

I express gratitude to my jury panel: the president of jury; Prof. MBIHI Jean, the rapporteur;
Dr. BOUM Alexandre T., the member1; Dr. MOFFO LONLA Bertrand and member2; Dr.
PAUNE Felix for their cross examination and corrections to my research work.

Cordial thanks and tributes to my supervisor; Dr. MOFFO LONLA B. and Co-supervisors;
Dr. BOUM Alexander for their availability, scientific aid, encouragements and multiform
supports during my research. Many thanks go to DR. GAMOM Christian for valuable
guidance, supervision and consistent follow-up during this thesis as a Co-supervisor.

I’m indebted to my lovely parents, Mr. AKISSEH MAKOGE Ernest and Mrs. AKISSEH
MPONGESONE Felicia for their great support materially, financially and in prayers during
this thesis.

Great thanks to my grand mum ESSONE Margaret NTUBE for her love and care. To My
Uncles; Mr. ESSONE Makoly, Mr. ESSONE Edgar and my aunts; Ma AKISSEH Mary, Mrs
ESSONE Doreen, Mrs ESSONE Rose, Mrs. ESSONE Gladys I say I am grateful.

Not forgetting my lovely brothers; AKISSEH SONE Stanley, AKISSEH Chris, AKISSEH
NGUNDE, and lovely sisters Mrs. BESSONG AKISSEH Mabelle, ESSONE Darrel, ESSONE
Tina, AKISSEH DIONE Ruth for their love, care and prayers.

I use this opportunity to say thanks to my love NGWESSE Majoir MECHANE for her love,
prayers and being there for me all this while.

To my friends and classmates thanks for the collaboration.

 iii

Abstract

Recently, the world is witnessing a rapid growth in the technological domain as the have been
the production of open source software and hardware components. The significant increase in
the use of Computer Numerical Control (CNC) systems in the manufacturing sector has boost
up the productivity despite the expensive and complex nature of the machines tools like the
Lathe, Mills, Routers, and Grinders. This research work discusses the “Implementation of a
low cost CNC machine with a DCM based servo-motor for plotter movement”. Due to the cost
and complexity in the CNC system, this work is aimed at producing a low cost CNC machine
using the Arduino UNO which is also to control a servo-motor based on the duty cycle
modulation (DCM) techniques for the plotter movement. The mechanical framework was
produced out of wood mounted together with the linear rail and ball bearing which help to
effect the linear motions (Front and Back, left and right). The system is made of X,Y, and Z
axis, where two stepper motors and their drivers were used to move the X-axis and Y-axis,
while the servo-motor for Z-axis for plotter movement. An Arduino UNO was used to control
the stepper motors with the help of the stepper motor drivers and also produce switching
periodic output pulses with a simple digital duty-cycle modulation programme loaded in the
flash memory to control the servo-motor after interpreting the streamed G-code received from
the USB port of the laptop. The system was realized following a methodology by dividing in
three subsystems; program instruction, electrical and electronic system and the mechanical
system.
At the end of the research work, my objectives of realizing a low cost CNC Machine and also
testing the possibility of implementing DCM techniques on this machine was attained by the
proper functioning of the prototype.

Key words: CNC Machine, G-code, Arduino Uno, Duty cycle modulation, servo-motor,
 iv

Résumé
Récemment, le monde a assisté à une croissance rapide dans le domaine technologique, avec
la production de logiciels et de composants matériels à code source ouvert. L'augmentation
significative de l'utilisation des systèmes de commande numérique par ordinateur (CNC) dans
le secteur de la fabrication a permis d'accroître la productivité malgré la nature coûteuse et
complexe des machines-outils telles que les tours, les fraises, les routeurs et les rectifieuses.
Ce travail de recherche aborde «la mise en œuvre d’une machine à commande numérique à
faible coût avec un servo-moteur à base de MRC pour le déplacement du traceur». En raison
du coût et de la complexité du système CNC, ce travail vise à produire une machine CNC peu
coûteuse utilisant l’Arduino UNO, qui commande également un servo-moteur basé sur les
techniques de modulation de rapport cyclique (MRC) pour le mouvement du traceur.
L'ossature mécanique a été réalisée en bois, montée avec le rail linéaire et le roulement à billes
qui permettent d'effectuer les mouvements linéaires (avant et arrière, gauche et droite). Le
système est constitué des axes X, Y et Z, où deux moteurs pas à pas et leurs pilotes ont été
utilisés pour déplacer les axes X et Y, tandis que le servo-moteur de l'axe Z pour le
déplacement du traceur. Un Arduino UNO a été utilisé pour contrôler les moteurs pas à pas à
l’aide des pilotes de moteur pas-à-pas et également pour produire des impulsions de sortie
périodiques avec un simple programme de modulation de rapport cyclique numérique chargé
dans la mémoire flash afin de contrôler le servomoteur après interprétation du signal G
transmis. -code reçu du port USB de l'ordinateur portable. Le système a été réalisé suivant une
méthodologie en divisant en trois sous-systèmes; instruction de programme, système
électrique et électronique et système mécanique.
À la fin du travail de recherche, mes objectifs de réaliser une machine CNC économique et de
tester la possibilité de mettre en œuvre les techniques MRC sur cette machine ont été atteints
par le bon fonctionnement du prototype.

Mots clés: machine à commande numérique, G-code, Arduino Uno, Modulation Rapport
cyclique (MRC), servo-moteur.
 v

List of figures

Figure I.1: Block Diagram of Open Loop System…………………………………………......6

Figure I.2: Block diagram of a Close Loop System…………………………………………....7
Figure I.3: 15L Slant-PRO CNC Lathe………………………………………………………..8
Figure I.4: CNC milling machine………………………………………………………………9
Figure I.5: CNC router………………………………………………………………………..10
Figure I.6: CNC Grinding machine…………………………………………………………...11
Figure II.1: General block diagram of the proposed system………………………………….18
Figure II.2: Presentation of the Arduino Uno board………………………………………….20
Figure II.3: ATMega328 microcontroller……………………………………………………..21
Figure II.4: The GRBL Board…………………………………………………………………22
Figure II.5: Shows the drivers mounted on the GRBL board…………………………………23
Figure II.6: stepper motor NEMA17………………………………………………………….24
Figure II.7: The servomotor…………………………………………………………………...25
Figure II.8: System design…………………………………………………………………….26
Figure II.9: Lead screw………………………………………………………………………..27
Figure II.10: Ball bearing……………………………………………………………………...27
Figure II.11: The Linear rail…………………………………………………………………..28
Figure II.12: Point-to-point tool movement…………………………………………………...29
Figure II.13: Continuous path tool movement………………………………………………..29
Figure II.14: The simulation of the experimental test of DCM based servo-motor…………..30
Figure III.1: The base of the machine…………………………………………………………35
Figure III.2: Electrical and electronic system…………………………………………………36
Figure III.3: The algorithm of the DCM servo-system………………………………………..37
Figure III.4: The X-axis and Y-axis movement using the Brensenham algorithm……………38
Figure III.5: The realized frame……………………………………………………………….39
Figure III.6: Programme of instruction………………………………………………………..40
Figure III.7: the F-Engrave interface………………………………………………………….41
Figure III.8: Universal G-Sender……………………………………………………………...42
Figure IV.1: The experimental simulation…………………………………………………….43
Figure IV.2: Results of the simulated DCM servomotor system……………………………...44
Figure IV.3: The realized work piece…………………………………………………………45
 vi

List of tables

Table II.1: stepper motor driver characteristics……….……………………………………...23

Table III.1: machine dimensions……………………………………………………………..32
Table IV.1: The list of materials for the realization of the machine…………………………46
 vii

List of abbreviations

CNC : Computer Numerical Controller

DCM : Duty Cycle Modulation
USB : Universal Serial Bus
PC : Personal Computer
G-Code : Generic Code
MRC : Modulation Rapport Cyclique
GRBL : G-code Interpreter
PWM : Pulse Width Modulation
CAD : Computer-aided design
CAM : Computer-aided Manufacturing
NC : Numerical Control
GUI : Graphical User Interface
PCB : Printed Circuited Board
DNC : Direct Numerical Control
FPGA : Field Programmable Gate Arrey.
AC : Alternating Current
DC : Direct Current
RAM : Random Access Memory
EEPROM : Electrically Erasable Programmable Read-Only Memory
NURBS : Non-uniform rational B-Spline interpolation
MAAC : Multi axis automatic controller
FFPIV : Feed-Forward Proportional-Integral-Velocity
PID : Proportional Integral Derivative
GUI : Graphical User Interface
 viii

Before proposal

Before the proposal of this research work, I have always had the desire to carry out a research
work on a topic that can lead to the production of a prototype that can be of great impact to the
nation. I then asked myself several questions like;
 Why this particular topic?
 Is it worth the attention?
 What steps do I need to take to explore the topic?
 what methods and tools will I use to carry out the research work?
 The availability of the tools.
I then looked at current state of knowledge and any recent debates on the topic to be able to
know what others have done. I then looked what new can be added to engineering science. But
in the course of researching more about the CNC machine, I realized several works have be
done on it but based on the PWM when using servor-motors. So I was ignited to use the DCM
modulation scheme which will make the research a resourceful one at the nationally and
internationally research Journal since as a practical process is going to be elaborated on the
scheme.
 ix

Table of contents

Dedication ................................................................................................................................................. i
Acknowledgements ...................................................................................................................................ii
Abstract ....................................................................................................................................................iii
Résumé.....................................................................................................................................................iv
List of figures ............................................................................................................................................v
List of tables.............................................................................................................................................vi
List of abbreviations................................................................................................................................vii
Before proposal ......................................................................................................................................viii
Table of contents ......................................................................................................................................ix
General introduction................................................................................................................................. 1
1. Framework for the preparation of the M2R thesis. .......................................................................... 2
1.1 Institutional framework. ................................................................................................................. 2
1.2 Partnership framework.................................................................................................................... 2
2. Scientific context of the studied theme. ........................................................................................... 3
2.1 The scientific context of the studied theme at the international level. ......................................... 3
2.2 The scientific context of the theme at the national level. ............................................................. 3
2.3 Motivations and key issues of the studied theme............................................................................ 3
3 Objectives of the research and organization of report...................................................................... 3
3.1 Objectives of the research .............................................................................................................. 4
3.2 Organizational layout and overview of thesis. ............................................................................. 4
CHAPTER I ............................................................................................................................................. 5
LITERATURE REVIEW IN THE IMPLEMENTATION OF A LOW COST CNC MACHINE WITH
A DCM BASED SERVO-MOTOR FOR PLOTTER MOVEMENT...................................................... 5
I.0 Introduction..................................................................................................................................... 5
I.1 The CNC Machine .......................................................................................................................... 5
I.2 The history of CNC machines......................................................................................................... 5
I.2.1 Concept of the CNC system......................................................................................................... 6
 x

I.2.1.1 The Open-Loop System ............................................................................................................ 6

I.2.1.2 The Close Loop System ............................................................................................................ 7
I.3 CNC machine tools. ........................................................................................................................ 7
I.3.1 The CNC lathe machine................................................................................................................ 8
I.3.2 The CNC milling machine. ........................................................................................................... 8
I.3.3 The CNC Router. .......................................................................................................................... 9
I.3.4 The CNC grinding machine. ...................................................................................................... 10
I.4 The low CNC machine................................................................................................................... 11
I.5 The Duty-Cycle Modulation (DCM) Techniques......................................................................... 16
I.6 Conclusion .................................................................................................................................... 17
CHAPTER II.......................................................................................................................................... 18
METHODS AND MATERIALS FOR THE DESIGN AND SIMULATION ...................................... 18
II.0 Introduction ................................................................................................................................. 18
II.2 General block diagram of the proposed system........................................................................... 18
II.2.1 The laptop................................................................................................................................. 19
II.2.1.1 Programme of instruction ...................................................................................................... 19
II.2.1.1 G-CODE................................................................................................................................ 19
II.2.2 The Arduino Microcontroller. .................................................................................................. 19
II.2.2.1 The ATMega328 Microcontroller ......................................................................................... 20
II.2.3 The GRBL. ................................................................................................................................ 21
II.2.4 The stepper motor driver. ......................................................................................................... 22
II.2.3 The stepper motor..................................................................................................................... 24
II.2.4 The Servomotor ........................................................................................................................ 25
II.2.5 The mechanical system of the CNC machine........................................................................... 25
II.2.6 The lead screw. ......................................................................................................................... 27
II.2.7 Ball bearing .............................................................................................................................. 27
II.2.8 The Linear rail. ......................................................................................................................... 28
II.3 The principle of motion for the mechanism ................................................................................ 28
II.3.1 The point-to-point system......................................................................................................... 28
II.3.2 Continuous path system (Straight cut and contouring systems)................................................ 29
 xi

II.4 The servo- motor system. ............................................................................................................ 30

II.4.1 The simulation of the experimental test of DCM based servo-motor....................................... 30
II.5 Conclusion................................................................................................................................... 31
CHAPTER III......................................................................................................................................... 32
METHODS AND MATERIALS FOR THE REALIZATION .............................................................. 32
III.0 Introduction ................................................................................................................................ 32
III.1 Mechanical system ..................................................................................................................... 32
III.1.1 The design calculation............................................................................................................. 33
III.1.2 The realized basement. ............................................................................................................ 35
III.2 The Electrical and electronic system.......................................................................................... 35
III.2.1 The algorithm of the DCM servo-system................................................................................ 37
III.2.2 The X-axis and Y-axis movement using the Brensenham algorithm...................................... 37
III.3 The realization steps................................................................................................................... 39
III.4 Programme of instruction........................................................................................................... 40
III.4.1 Steps for machine operation.................................................................................................... 42
CHAPTER IV ........................................................................................................................................ 43
RESULTS OBTAINED, DISCUSSIONS AND OUTLOOK ............................................................... 43
IV.0 Introduction................................................................................................................................. 43
IV.1 The results of the DCM servo-system........................................................................................ 43
IV.2 The implemented low cost CNC machine with a DCM based servo-motor for router movement.
................................................................................................................................................................ 45
IV.2.1 The advantages of the prototype. ............................................................................................ 45
IV.2.2 The list of materials for the realization of the machine........................................................... 46
IV.3 Conclusion ................................................................................................................................. 46
General conclusion................................................................................................................................. 47
Reference………………………………………………………………………………………………………………………………………….49
 1

General introduction

The CNC machine stands for Computer Numerical Control machine, used in the
manufacturing sector and involves the use of computers to control machine tools. Tools that
can be controlled in this manner include lathes, mills, routers and grinders. Computer
Numerical Control (CNC) machines are a vital part of today’s manufacturing industry as it is
fast, accurate, and adaptable. Computer Numerical Control is different from typical PCs in the
type of software used to control the machine, which is specially customized and programmed
with G-Code which is a specific CNC machine language that allows precise control of features
like speed, location, coordination and feed rate.

The CNC machines meets up the requirements of today’s industry, which are to produce large
quantity and quality products with low production and installation cost. These tasks can be
easily completed by the machines which are controlled by computers to make work easier with
ultra-precision and less human caused errors. Different kinds of CNC machines cover an
extremely large variety. Their numbers are rapidly increasing, as the technology development
advances. It is hard to identify all the applications but their machining principle is the same.
Due to the rapid growth of technology the usage & utilization of CNC machine in industries
are increased. The fabrication of low cost CNC machine is used to reduce cost and complexity
of machines.

However, with the dramatic increase of industrial varieties and the growing demand of
miniature products, these general purpose machine tools are efficient, either in terms of
machine time or cost, in manufacturing products with special sizes and precision requirements.
There are several advantages of using small machines to produce small sized objects. With a
smaller machine size, space is saved. The energy required to operate the machine is reduced as
well. It now requires less material and components to make the machine, hence bringing down
the cost greatly. The weight of moving component also comes down so that during operation,
the vibration and noise, as well as pollution to the environment, are markedly reduced. As the
machine becomes denser and lighter, it becomes more portable. The layout of the
manufacturing plant can be more flexible. The productivity and manufacturing speed also
increases due to possible faster operation.

The existing CNC machines with axis controlled by servo-motors, have a principle of
operation of which they are controlled by sending an electrical pulse of variable width, or
pulse width modulation (PWM), through the control wire. But the research work will look at a
new scheme of which the signal which will be received by the servo-motor for the plotter
movement, will be the Duty Cycle Modulation (DCM) signal. The duty-cycle modulation
 2

(DCM) is used in industrial electronics, as a special signal processing technique with a

switching periodic output wave. This ignited the desire to research on designing a servo-
system for the CNC Machine. This paper focuses on the implementation of a low cost CNC
machine with a DCM based servo-motor for router movement.

This research work was carried out under the auspices of a recognized state university and was
done within a period of six months under the strict supervision of recognized lecturers. The
research work has got much significance at the international and national level by contributing
something new to science. Due to the quest as a young researcher, I was ignited to implement
a new scheme based on DCM. The research work was aimed at implementing the scheme on a
prototype, which was achieved at the end of the research and a report is writing following the
Methodology and thesis writing guide of M2R in Engineering Sciences.

1. Framework for the preparation of the M2R thesis.

Haven gotten a research topic, the objectives and methodology were outlined. For me to have
been able to go through this research work, it was due to the acquired knowledge, facilitation
and assistance put in place by some structures. This structures have a framework within which
dynamic scientist are been trained to be researchers in the field of engineering.

1.1 Institutional framework.

The University of Douala-Doctorate School for pure and applied sciences-Doctorate training
unit for engineering sciences-laboratory for computer and automatic engineering. This
institution offered courses which helped me during the designing of the prototype and so many
articles have been writing on the domain of DCM by some senior lecturers of this institution
which was of great help to me. The seminar on Methodology and Ethics of scientific research
was of great help to me as it gave me directions on how to go on with my research and to
come up with a good report.

1.2 Partnership framework.

In the course of my work, I was successfully guided by my supervisors and I had to also use
the Engineering garage laboratory in Bamenda which was of great help to me as I used some
of the machines in building the mechanical frame of the CNC machine and testing some parts.
I did receive some contributive ideas from my fellow mates which assisted me.
 3

2. Scientific context of the studied theme.

The study of my research has got some significance which can contribute to the fast growing
technological age, internationally and nationally in facilitating the production of some low
cost machines for industries. In the domain of scientific research, it plays a big role on
implementing the DCM based servo-motor scheme on systems.

2.1 The scientific context of the studied theme at the international level.

With the advancement of technology today, the duty circle modulation is a technique that has
rarely been used by researchers and the implemented system consists of a simple digital duty-
cycle modulation program loaded in the flash memory of a microcontroller to send pulses to a
servo-motor.

2.2 The scientific context of the theme at the national level.

The scientific context of the theme at the national level views the implementation of a low cost
CNC machine, and the study of the DCM technique as a special signal processing technique
with a switching periodic output wave.

2.3 Motivations and key issues of the studied theme.

The Low cost CNC machines are perfect for offering, preparing students especially in the field
of Engineering on the grounds that the cost and upkeep of the machine is low. The little size
and small weight makes it compact, portable and the segments can effortlessly be dismantled
or gather. The size, space and vitality required for the machine is additionally lessened. It
presently requires just small quantity of materials and parts to build the machine and the
utilization of the low cost DCM technique, consequently cuts down the cost extraordinarily.
The key issues studied are: the CNC operating principles, the operating principle of stepper
motors in a CNC machine and the DCM technique on how to control a servo-motor

3 Objectives of the research and organization of report.

This study has as general objective to implement a low cost CNC machine with a DCM based
servo-motor for router movement.
 4

3.1 Objectives of the research.

 To design and fabricate the mechanical framework of the machine.

 To design and implement the electrical and electronic wiring of the system.
 To write the small DCM code to operate the servo-mechanism system.
 To be able to use/manipulate the CAD and CAM to generate the design vector image.
 To develop and install the programme instructions of the machine.

3.2 Organizational layout and overview of thesis.

The organizational layout of the thesis report is as follows:

 The General introduction.

 Chapter I; looks at the literature review in the implementation of a low cost wireless
controlled CNC machine with a DCM based servo-motor for plotter movement.
 Chapter II; studies the methods and materials for the design and simulation of the
system.
 Chapter III; show the methods and materials for the realization of the machine.
 Chapter IV; gives the results obtained, discussions and outlook of the machine.
 The general conclusion of the thesis report.

From the above, we have seen a brief definition of a CNC machine, the importance of a low
cost CNC machine. Further saw the significant to the study internationally and nationally, the
institutional framework, the motivations and the scope of the report. In next chapter above, we
shall be looking at the literature review in the implementation of a low cost CNC machine
with a DCM based servo-motor for plotter movement. This chapter will explain the history of
CNC machines, its advantages, the related works of low cost CNC machines and the Duty
Cycle Modulation scheme.
 5

CHAPTER I
LITERATURE REVIEW IN THE IMPLEMENTATION OF A
LOW COST CNC MACHINE WITH A DCM BASED SERVO-
MOTOR FOR PLOTTER MOVEMENT.

I.0 Introduction.

In this chapter we are going to look at what a CNC machine is all about; beginning from its
definition, the historical background, types of CNC machine tools, the technological and
scientific aspects of some low cost CNC machine that has been research on recently.

I.1 The CNC Machine.

The word “CNC” stands for Computer Numerical Control. This modern concept of technology
were numerical control machine with added feature of an onboard computer has eased the
manufacturing and production in industries as it uses computers to control machine tools.
However, this concept comes from the early numerical control (NC) which is a programmable
automation in which processes are controlled by numbers, letters and symbols. This program
is translated into the appropriate electrical signals for input to motors that runs the machine.
The CNC machine has brought significant contribution to the manufacturing industries as it
has made possible the automation of the machining process with flexibility, accuracy and fast
production of items. The mills, lathe, routers and grinders are some of the machine tools which
have been fabricated. [1]

I.2 The history of CNC machines.

Historically, Computer Numerical Control is an extension of what was once known as

Numerical control. It refers to the concept of controlling automated machine tools via
programmable computers. In 1775, John Wilkinson produced a cannon boring machine
(lathe), by 1881, Eli Whitney fabricated the milling machine, by 1947 Mr. John Parsons began
experimenting for using 3-axis curvature data to control the machine tool motion for the
production for aircraft components and in 1949 parson succeeded in producing his first NC
Machine. Also, as the designs were constantly being improved, changes in the drawing were
frequently made. Thus, in their search for methods of faster production, an Air Force study
contract was awarded to the Parsons Corporation. The servo mechanisms laboratory of the
 6

Massachusetts Institute of Technology (MIT) was the subcontractor. In 1951, MIT took over
the complete job, and in 1952, the prototype of today’s NC machine, a modified Cincinnati
Hydrotel Milling Machine, was successfully demonstrated. Finally in 1955, after refinements
NC became available in industries and the term numerical control was originated at MIT.
Today we have modern CNC machine tools which are now be moved to low cost machines
due to technology evolution. [2]

I.2.1 Concept of the CNC system.

The CNC machine as any other control system has got two ways of manufacturing the
systems, which are the open-loop or the close loop system.

I.2.1.1 The Open-Loop System.

The open loop systems, are systems with no feedback as they have no access to the real time
data about the performance of the system and therefore no immediate corrective action can be
taken in case of system disturbance. Their primary drawback is the lack of feedback system to
check whether the program position and velocity has been achieved. The system can be
affected by load, temperature, humidity, or lubrication which can course the actual output to
be different from the desired output. The open loop system is generally used where the
accuracy requirements are not critical like point-to-point system. Very few continuous-path
system utilize open-loop[36]

Figure I.1: Block Diagram of Open Loop System.

 7

I.2.1.2 The Close Loop System.

The Close loop systems, are systems which have feedback devices to closely monitor the
output in case of any disturbance for possible corrections. With this an accurate system is
achievable. The advantage of a close-loop system is that it has feedback subsystems to
monitor the actual output and correct any discrepancy from the programmed input. The
feedback system could either be analog or digital. For the analog systems, they will measure
the variables such as position and velocity in terms of voltage levels and the digital system
will monitor output variations by means of electrical pulses. Another added advantages or
credit of a close loop system is that they are very powerful and accurate because they are
capale of monitoring operating conditions through feedback subsystems and automatically
compensate for any variation in real time. The close loop system would require more control
devices and circuitry in order for them to implement both position and velocity control. The
above makes them more complex and mor expensive than the open loop system.[36]

Figure I.2: Block diagram of a Close Loop System.

I.3 CNC machine tools.

Over the years now many CNC machine tools have been produced by many engineers and are
being used all over the world by manufacturing and production companies. There is a grows
variety of CNC tools but I will limit on the most popular and widely used. The tools are large
scale tools and are very expensive but accurate.
 8

I.3.1 The CNC lathe machine.

A lathe machine is a machine that will rotate a workpiece about an axis of rotation to perform
various operations such as cutting, sanding, knurling, drilling, deformation, facing, and
turning, with tools that are applied to the workpiece to create an object with symmetry about
that axis. This lathe machines are sophisticated and very expensive but can perform a whole
lot.

Figure I.3: 15L Slant-PRO CNC Lathe [3]

I.3.2 The CNC milling machine.

Milling machines are CNC machine tools designed to machine materials like; metal, wood,
and other solid materials. The milling machine can be positioned either vertically or
horizontally oriented to carve out materials based on a pre-existing design from the CAD. The
different tools used on a milling machine is based on the material and desired shape by the
user, for materials like wood and steel have different physical properties, therefore they will
use different tool bits.
 9

Figure I.4: CNC milling machine [4]

I.3.3 The CNC Router.

A CNC Router is a computer numerically-controlled machine where the tool paths are
controlled via computer. It can cut and mill various hard materials, such as wood, composites,
aluminum, plastics, and foams. The CNC router is similar in concept to the CNC milling
machine and they typically produce consistent and high-quality work and improve factory
productivity. The CNC Router uses a 3 Axis rotating bit to remove material from stock in
order to shape a part. The 3 Axis means that tool can move simultaneously in all three
directions X, Y and Z by performing the desired task..
 10

Figure I.5: CNC router [5]

I.3.4 The CNC grinding machine.

The CNC grinding machines are tools which achieve material removal on a metallic
workpiece by means of cutting via the rotating grinding wheel. In this machine various
mechanical and electronic systems are used, correspondingly the machines are complex.
Despite the machines high performance, during the actual grinding process the loading and
unloading of the workpieces is often also carried out automatically using automated loading
facilities.
 11

Figure I.6: CNC Grinding machine [6]

I.4 The low CNC machine.

The existing CNC machines are too expensive for small scale industries or personal use due to
their high energy consumption, high maintenance cost, complexity in manipulation, high cost
and are mostly in giant sizes. Recently, they have been a rapid technological growth as they
are many open source hardware and ready to use software. These have led many researchers
recently to focus on the development of low cost CNC machines. This researcher have used
several technological methods and materials like the the PIC microcontrollers, Arduinos,
FPGA which have been contributive to science. We will be looking at some related earlier low
cost CNC machines.

The Design and implementation of FPGA based G-code compatible CNC lathe controller.
This work was done by Mufaddal A. Saifee in 2016, a M. Tech student of Institute of
technology, Nirma university, Ahmedabad, Gujarat, India. The paper was focused on
designing and implementing a G code based, CNC lathe controller in a FPGA. Where he
implemented and validated on Xilinx Artix 7. The implemented CNC lathe controller was able
to achieve the maximum frequency of 52.35MHz. [7]. The Real-Time NURBS interpolation
using FPGA for high speed motion control was presented by Hong-Tzong Y., Ming-Tzong L.
et al. Department of mechanical engineering, National chung cheng university. They proposed
a novel FPGA based motion controller utilizing its high-speed parallel computing power to
realize the Cox-DE Boor algorithm for second and higher degree NURBS(Non-uniform
rational B-Spline interpolation. The motion control algorithm is also embedded in the FPGA
 12

chip to implement real-time control and NURBS interpolation simultaneously for multiaxis
servo systems. The proposed FPGA-based motion controller is capable of performing the
Cox–de Boor algorithm and the IIR (Infinite Impulse Response) control algorithm in about 46
clock cycles, as compared to the 1303 clock cycles by the traditional approach. The Numerical
simulations and experimental tests using an X–Y verify the outstanding computation
performance of the FPGA-based motion controller as seen.[8]. The Real-time motion control
using FPGA was carried out in June 2010 by Baris Ragip M. a Msc in mechanical engineering
student middle east Technical University. He investigated the novel implementation methods
for FPGA based real-time motion control systems. The developed methods where tested one
after the other to assess the performance of the individual design.[9].

Also the design and development of a Novel CNC Controller for improving Machining speed
was studied by Shahrokh Hatefi, Omid Ghahraei et al. In this work they spoke of the many
existing CNC controllers employed in CNC machinery having some limitations and
disadvantages due to their design and used methods. Their research work is based on
designing and modifying a novel multi axis automatic controller (MAAC) for using in CNC
machinery wish they claim to have more advantages compared with used controllers and has
optimized performance.[10]. The Hardware-configuration based on FPGA for open CNC
system is an article writing by Shuanqiang Yang, et al. They studied the drawbacks of existing
open CNC system based on PC and the unresolved problems of preliminary study presented
by the research group, to satisfy the development requirements of low cost, high performance
that means high speed, high precision and the large amount of data processing, configurable
architecture and modularization.[11]. Design and Implementation of motion controller based
on dual core architecture.The paper was written by Lui yun, Lui peng and Lui an cai. They are
innovatively presenting the ARM9 processor-AT91RM9200 and Cyclone series FPGA-
EP316F484 as core to design motion control system for high precision CNC machine tool.
[12]. The FPGA Implementation of Motion Control Interface is a research work done by
Shantanu Telharkar, et al. the paper was aimed at developing a hardware design to control the
motor drivers of a CNC controller. It is described in Verilog entirely and realized on
FPGA.[13]. A dynamically reconfigurable system architecture and FPGA Based servo
controller for distributed machine tool control studied by Kevin David Oldknow a Master
student from the department of mechanical engineering, faculty of graduate studies, The
University of British Columbia, 1996. He presented the design and analysis of a novel system
and protocol for the automatic configuration and dynamic reconfiguration of distrusted
machine tool control systems.[14].

The FPGA implementation of higher degree polynomial acceleration profiles for peak jerk
reduction in servomotors was studied by Roque Alfredo Osornio R. et al. The novelty of this
 13

paper is the development of a multiplier-free recursive algorithm for computationally efficient

polynomial evaluation in profile generation and a low-cost implementation of the digital
structure in field programmable gate array (FPGA). Two experimental setups were prepared in
order to test the polynomial profile generator: the first one with the servomotor at no load and
the second one for the servomotor driving a CNC milling machine axis. From experimental
results it is shown that higher degree polynomial profiles, compared to the standard
trapezoidal speed profile improve the system dynamics by reducing peak jerk in more than one
order of magnitude while precision is maintained the same and on-line operation is
guaranteed. [15].

The design and implementation FFPIV Scheme for closed loop motion control by Ngo Ha
Quang et al. The paper talks on motion controller and consists of DSP which plays a main role
in this design; DPRAM to make sure the rapid and reliable communication with host; FPGA
to handle the task of address decoder and receiving feed-back encoder signal; and several
peripheral logic circuits. In the part of hardware design, overall structure of motion control
system is presented. Then, the Feed-Forward Proportional-Integral-Velocity (FFPIV) scheme
which introduces KV in term of velocity loop to achieve the accurate, smooth and real-time
response is proposed in the software developing part.[16]. The research on Embedded CNC
Device Based on ARM and FPGA by Jiyou Fei, Ran Deng et al. The paper researches the
transplant process of Linux embedded operating system, introduces the cut and transplantation
in S3C2440 hardware platform, analyzes the method that ARM configurate the FPGA,
completes the configuration bus and communication interface design between the TQ2440 and
Mars-XC3S400-F-Core development board, uses EDA software ISE7.1i from Xilinx to
complete the feed motor controller design based on XC3S400 and simulation successes. The
CNC device combined ARM’s high running speed and precision with the internal logic
reconfigurable of FPGA, reducing hardware costs of CNC device, improving the resource
utilization and enhancing the flexibility of the CNC device. [17]

 However from the studies above, there have been several significant contributions to
scientific research, but technologically the FPGA based CNC machines are relatively
costly and alitle complex despite the accuracy in output. Another component that has
been used for the realization of low CNC machines is the PIC.

Building a PCB milling machine by Benny Stromberg. In this Master’s Thesis, he worked on a
closed loop CNC machine in which he used but the microcontrollers to send PWM signals to
the servomotor. The system consist of feedback loop and a PID controller designed and built
to control the servomotor speed and monitor the system.[18]. Design and implementation of
low cost computer numerical control-printed circuit Boards drilling machine which was
designed by Motaz Daadoo et al. The paper focused on producing a drilling machine for small
 14

and medium size industries. The machine has got three stepper motors for the axis and a drill
all controlled by a PIC16F877A microcontroller. [32]

 In regards to the PIC microcontroller system, they built mostly the closed-looped CNC
machines. Recently the availability of open source hardware and software, which are
relatively and considerably cheap and easy to work with like has let to great number of
low cost CNC Machine implementation.

The CNC Machine based on LASER Engraver using Arduino UNO.This project was done by
D. O. Shirsath and A. P. Sale Students from the Department of Electronics &
Telecommunication Engineering of P.V.P.I.T. Budhgaon, Sangli, India with the main aim to
design and implement a two dimensional CNC router which could engrave 2D and Gray
scaled images or pictures with the help of high watt burning laser module on surface which
can be a paper, wood, leather, plastic, foam. They used an arduino and two stepper motors
drivers to control two axis stepper motors. Laser module is kept constant at the Y axis.[19] the
Implementation of low cost three axis CNC machine with network control which was done by
Adel MESSAOUDI and Billal BELHOCINE in 2016, department of Electrical and Electronic
Engineering in the University of M’Hamed BOUGARA, Institute of electrical and electronic
engineering. This work discusses the design and implementation of low cost three dimensional
CNC machine using off-the-shelf components. They built the mechanical system which
contains three axis X, Y and Z where three stepper motors and their drivers were used to move
it. A microcontroller was used to control the stepper motors after interpreting the streamed g-
code received from USB/Serial port of the Raspberry Pi where it offers two ways of
controlling the machine. The system had two methods of control, (machine location) where a
GUI application was developed using Python programming language. The second is a control
via network where Raspberry Pi hosts the web application that was developed using Node.js
and bootstrap framework.[20]

The Design and implementation of CNC Router, This was done by M.Bhavani, V.Jerome,
P.Lenin Raja, B.Vignesh, D.Vignesh in 2017, Department of Mechanical Engineering, New
Prince ShriBhavani College of Engineering and Technology, Chennai, Tamil nadu, India with
the main objective to develop a low cost automatic mini CNC machine for PCB drawing and
drilling, wood engraving and glass cutting. They had three axis X,Y,Z which operated as
follows X stepper motor move left and right Y stepper motor moves front and back and Z
stepper motor up and down as per given dimensions all controlled by their stepper motor
drivers receiving pulses from the arduino.[21]. The wireless CNC Plotter. It was realized by
Poonam Revankar, Shrey Kharde, Hitesh Mangaonkar, Nakul Pawar and Ameya Jadhav. The
system talks of a CNC plotter which does the job of creating easy and complex designs by just
simple software and it is just made out of scrap dvd drives, the idea of using dvd drives strikes
because it consists of two stepper motors which has proper provision of axis. Transmission of
 15

command is done wirelessly using the Zigbee module which makes this system portable. The
design and development of wireless controller for CNC machining by Siti Nadhira Binti M. a
BMech engineering from the University of Malaysia Pahang. His research was based on
controlling 3 axes controller and automated gripper controller during machining process in
CNC machining. it used a remote desktop application for Windows 7 and Windows XP. It is
quite common for a remote desktop application to be used to control a host computer that is
far from the client, connected only via the Internet. This project also used a Visual Basic
programming in developing to control 3 axes and an automated gripper CNC machine.
Program of controller 3 axes and automated gripper was controlled by using execute
programming method

Fabrication of Low cost 3-Axis CNC Router byDr. B.Jayachandraiah et al. This paper
discusses the development of a low cost CNC router which is capable of 3-axis simultaneous
interpolated operation. The lower cost is achieved by incorporating the features of a
standard PC interface with micro-controller based CNC system in an Arduino based
embedded system. the system also features an offline G-Code parser and then interpreted on
the microcontroller from a USB.[24]. Low Cost Mini Multi-Tool CNC Machine. Mukul Gupta
et al. Research is aimed at the suitable selection of measuring parameters for On-machine
measurement systems in order to reach an accurate and reliable quality control of the
mechanical part. This paper deals with the design of automatic mini multi-tool CNC machine
that can perform three machining operations i.e. Drilling, Shaping & Surface Machining. The
system also has a Bluetooth device which permits it to be controlled wirelessly.[25]

The Design of 3-axis Computer Numerical Control (CNC) Router using stepper motors is a
research work writing by S. Vigneshrao, S. Karthik et al. their research focused on the design
of a 3-axis computer numerically-controlled using stepper motor which comprise the use of a
GUI and an Arduino microcontroller to produce PWM outputs in order to run the stepper. The
machine is designed for snapping of wood, plastic sheet and thin sheet of metal alloy by using
a rotating drill bit which its accuracy is much lesser than using a lesser cutter techniques this
machine tool is portable and it’s controlled by computer (PC) [26]. Micro-controller controlled
3 axis CNC Machine for engraving and designing. Tanzim Ahmed k., Mohammed Samiul
Haque S. et al. Bachelor students, BRAC University, Dhaka, Bangladesh. This thesis looks at
the outlined viewpoints and the machinability investigation of low cost CNC machine cum
engraver. The Bluetooth connected to the system makes it an added advantage since the
machine can also be controlled wirelessly with a cell phone. [27]. The Design &
Implementation of an IoT Based 3-axis CNC VMC. Amit Kumar Nandi. This work mainly
deals with implementation of a desktop-sized 3-Axis CNC machine and necessarily adding the
functionality of controlling the machine from anywhere with an Internet Connection. [28]. The
Implementation of a low-cost CNC plotter using spare parts. Mohammad Kumruzzam an
 16

Khan Prince. Et al. This paper presents an affordable model of a CNC plotter machine which
is able to draw a circuit layout on PCB or any other solid surface using simple algorithm and
available components. It has 3-axis in such away, the Z axis which is control by a servo motor
is mounted on the X-axis which control with a stepper motor same like the Y-axis. [29] the
design and Implementation of a low cost three dimensional CNC machine was studied by
Vankata Krishna P. MTech student et al. Proposed a design in which a there is a wire
communication between the PC and a numerical control machine. The machine was designed
with an 8 bit microcontroller based embedded system which controls the three stepper motors
of the X,Y, Z axis. [30]

The Implementation 3-axis CNC Router for small scale industry by R. Ginting, S. Hadiyoso et
al. the paper talks of small scale CNC Machine that can be used in small scale industries for
cutting, engraving and marking on wood. The 3 axis system was built an arduino
microcontroller, three stepper motors for the 3 axis and a spindle drill. [31]. The Design and
Fabrication of 3-axis CNC Milling machine. Sriranga V. Deshpande, P. U. Karthik et al. This
paper talks on the fabrication of a CNC milling machine which comprises the use of an
Arduino microcontroller to produce PWM output to drive the motors. This machine is design
for snapping of wood, plastic sheet and thin sheet. [33]. The Automatic mini CNC machine for
PCB drawing and drilling research by Kajal J. Madekar, Kranti R. Nanaware et al. The paper
is aimed at producing a CNC machine for the purpose of PCB drawing and drilling. The
system is designed with 3 stepper motors and a drilling machine which are controlled by an
Arduino. [34]. The Design and manufacturing of low-cost prototype CNC milling machine for
mass production oriented small scale industry. This work was realized by Bhuvaneshwaree B.
et al. This machine is a close- loop CNC machine as it has got a feedback to monitor the
spindle temperature. It was realized by an Arduino microcontroller behing the main brain of
the system by controlling the stepper motors of various axis ang interpreting the G-code. [35]

I.5 The Duty-Cycle Modulation (DCM) Techniques.

The duty-cycle modulation (DCM) is used in industrial electronics, as a special signal

processing technique with a switching periodic output signal. As an implication, the duty cycle
of the modulated wave evolves according to a known function of the modulating input [37].
Thus, the active need of DCM schemes providing both structural simplicity and high quality,
has motivated the development of a class of low cost DCM circuits presented in [37],
consisting of the use of a single integrated operational circuit and a few passive components.
Following [37], further research works have successfully developed low cost DCM schemes
for a variety of application areas in industrial electronics [38,39,40]. Furthermore, it is shown
in [40] that a duty-cycle modulation (DCM) driver for a buck power converter offers best
characteristics compared to that of a traditional pulse width modulation (PWM). However, the
 17

literature review related to the application of low cost DCM schemes presented above, is
mainly limited to instrumentation and industrial electronics engineering. The new application
area of the low cost DCM scheme studied in this paper is the DCM Based Servo-motor
movement Control using an Arduino. The algorithm of the system is presented in depth in
chapter 3.

From the literature review of related works, it seen that the have been many technological
innovations and some scientific contributions to the optimization of a perfect a low cost CNC
machine. After going through the previews, I realized that all the existing systems have been
operating under the Pulse Width Modulation (PWM). The system I am working on
“Implementation of a low cost CNC machine with a DCM based servo motor for router
movement”. Technologically this system is relatively very fit for the context of low cost,
because of its low characteristics over related works. Scientifically, DCM technique is been
used in other domains but have not been tasted or implemennted in CNC machines, in this
piece of work I am trying to see how possible, how effective and its advantage over the PWM
in CNC machine by controlling the plotter motor. I am trying to initiate the idea of using DCM
technique on CNC machines.

I.6 Conclusion.

In this chapter, we have studied the general concept of CNC maching. Firstly we defined
CNC and then a brief history of CNC machines. We later looked at different types of most
common CNC machines tools and have been discussed by giving their uses. A good number
of articles and thesis related on low cost CNC machines and the duty cycle modulation
techniques have been presented. Finally, from the study of the existing and related low cost
CNC Machines, it was noticed that none of them implemented a system on the DCM scheme.

The next chapter will be based on presenting the methods and materials for the designing of
the proposed system which is the “implementation of a low cost CNC machine with a DCM
based Servo-motor for plotter movement.
 18

CHAPTER II
METHODS AND MATERIALS FOR THE DESIGN AND
SIMULATION

II.0 Introduction.
From the previous chapter, we studied the general concept about CNC machines and our state
of arts. In this chapter we are going to have a detailed block diagram of our system, then
design each block by studying the materials and methods.

II.2 General block diagram of the proposed system.

Figure II.1: General block diagram of the proposed system.

 19

II.2.1 The laptop.

The possibility of linking a PC with the Numerical Control machine gave birth to the
Computer Numerical Control (CNC). In the laptop we have our CAD/CAM software to design
our image or import then generate the G-code. The generated G-codes are been sent to the
microcontroller where it is being interpreted by the GRBL. The machine has also been
configured in such a way we can use the laptop keyboard to control the axis of the CNC
machine by either a forward movement or Backward movement, movement to the left or
movement to the right. The plotter movement can also be controlled Up or Down by the laptop
keyboard.

II.2.1.1 Programme of instruction

The programme instructions are generated by creating some sort of model, drawing, or
representation of the part or object to be machined by using the CAD software which will
convert it to a vector image. This drawing transformed by this CAD is sent to Computer-aided
design (CAD) involves creating computer models defined by geometrical parameters. These
models typically appear on a computer monitor as a three- dimensional representation of a part
or a system of parts, which can be readily altered by changing relevant parameters. CAD
systems enable designers to view objects under a wide variety of representations and to test
these objects by simulating real-world conditions. Computer-aided manufacturing (CAM) uses
geometrical design data to control automated machinery.

II.2.1.1 G-CODE

The G-Code or Geometric Code is the generic name for a control language for CNC machines.
This language is understood by the machine, It is used to tell the machine to move to various
points at a desired speed, control the plotter movement, and other things. It is fairly standard,
and is a useful tool. Since Gcodes are preparatory codes, in a CNC program they begin with
the letter G and direct the machine. This Gcodes are generated by a software installed in the
laptop.

II.2.2 The Arduino Microcontroller.

The Arduino is an open source microcontroller which can be easily programmed, erased and
reprogrammed at any desired instant of time. This board contains a microcontroller which is
able to be programmed to receive data and external objects. Because of its flexibility and low
cost, arduino has become a very popular choice for engineers. On the arduino board, we have
the Reset Button which helps us restart any code that is loaded to the Arduino board, the
 20

AREF which stands for “Anolog Reference” and its used to set an external reference voltage.
Ground Pin all the ground pins on the board function the same, the Digital input/ output pins
which are pin 0-13 can be used for digital input or output, the PWM pins do simulate analog.
The USB connection used for powering on the arduino and uploading sketches, the TX/RX is
the transmitter and receiver data indication. The ATmega Microcontroller is the brain and it is
where the programmes are stored. The power led indicator lights up anytime the board is
plugged in a power source, the voltage regulator controls the amount of voltage going into the
Arduino board. DC power barrel jack is to power the arduino with a power supply. The 3.3V
pin supplies 3.3v to the project while the 5V pin supplies 5V. finally the analog pin converts
signals from analog to digital.

I choose use Arduino because I have as objective to produce a low cost CNC machine and the
arduino has the following advantages.

 It is cheap.
 Easy to use.
 Has a common IDE
 Open source and extensible hardware. e.t.c.

Figure II.2: Presentation of the Arduino Uno board [42]

II.2.2.1 The ATMega328 Microcontroller.

An ATMega328 microcontroller is an integrated circuit that gathers on a chip several complex

elements in a small space at the time of the pioneers of electronics. Today, by welding a large
number of bulky components; such as transistors; all the resistors and capacitors can be
housed in a small black plastic case with a number of pins whose programming can be done in
 21

C language. Figure below shows an ATmega 328 microcontroller, found on the Arduino UNO
board.

The ATMega328 microcontroller consists of a set of elements that each have a specific
function. It is actually made of the same elements as on the motherboard of a computer.
Overall, the internal architecture of this programmable circuit consists essentially of:[51]

 Flash memory: This is the one that will contain the program to execute. This memory
is erasable and rewritable program memory of 32K (including boot loader of 0.5 KB).
 RAM: it is the memory called "alive", it will contain the variables of the program. It is
called "volatile" because it disappears if you cut the power of the microcontroller. Its
capacity is 2 kb.
 EEPROM: This is the hard disk of the microcontroller. It records information that
needs to survive in time, even if the card is stopped.

Figure II.3: ATMega328 microcontroller.[51]

II.2.3 The GRBL.

The GRBL is a firmware for Arduino boards that controls the stepper motors and spindles or
laser. The GRBL uses Gcode as its input and outputs signals via the Arduino pins. I used the
ATmega328 based Arduino board because it is compatible with the GRBL and the GRBL is
mounted on the Arduino board. The stepper motor receives the Gcode signals and then
translates to the microcontroller. The GRBL has 4 standard stepper board pinout carriers, the
ability to select clone axis for multiple motor use, the is also the noise suppression limit switch
connections but in our design it is not used because we are not using limit switches. Some
connector for easy hookup like the screw terminal and JST connectors for easy hookup, the
reset select helps to select either GRBL reset or Arduino reset. Finally when we look at the
board we realize it has for slots for stepper drivers.
 22

Figure II.4: The GRBL Board. [43]

II.2.4 The stepper motor driver.

The stepper motor driver is an important circuit in this project as it has to do with the
controlling of the stepper motors. This small circuit board is being mounted on the GRBL and
the stepper motor strongly depends on the driving circuit. This drives have been specifically
designed to drive stepper motors, which are capable of continues rotation with precise position
control, even without feedback system. The drive offers adjustable current control and
multiple step resolutions. Also the driver circuit has built-translator that allow a stepper motor
to be controlled with simple step and direction inputs. This our some of the reasons I have
choose to use this drivers because my system can do without a feedback because it can work
on the principle of Open-loop system with precision. Finally many of the GRBL boards come
with the stepper drivers mounted on it already. The drivers can take a maximum of 45v,it six
different step resolutions: full-step, half-step, 1/4-step, 1/8-step, 1/16-step and 1/32-step, the
current linit is adjustable with a potentiometer, it has an under-voltage lockout, over-current
shutdown, over-temperature thermal shutdown.[43]
 23

Table II.1: stepper motor driver characteristics.[43]

Specification
Minimum operating voltage 8.2v
Maximum operating voltage 45v
Continuous current per phase 1.5amps
Maximum current per phase 2.2amps
Current limit adjustment Analog Trim pot
Microstep resolution Full, 1/2, 1/4, 1/8, 1/16, and 1/32
Connectors Screw terminal and JST PH connectors
Operating Temperature 0 to 40 0C
Storage Temperature -40 to 700C
Dimensions 3.25’’ x 2.25’’

Figure II.5: Shows the drivers mounted on the GRBL board. [43]
 24

II.2.3 The stepper motor

Stepper motors are special type of electric motors that move in precisely defined increments of
rotor position (Steps).The size of the increment is measured in degrees and can vary
depending on the application. This brushless DC electric motor divides a full rotation into a
number of equal steps. The motor's position can then be commanded to move and hold at one
of these steps without any position sensor for feedback (an open-loop controller), as long as
the motor is carefully sized to the application in respect to torque and speed.

Due to precise control, stepper motors are commonly used robotic and control applications.
There are several features common to all stepper motors that make them ideally suited for
these types of applications. They are as under
 High accuracy: Operate under open loop.
 Reliability: Stepper motors are brushless. Load independent: Stepper motors rotateat a
set speed under different load, provided the rated torque is maintained.
 Holding torque: For each and every step, the motor holds its position without brakes

In our system we shall use the NEMA 17 stepper motors to control the X and Y axis of the
system. The stepper motor will satisfy need of controlling the various axes with no feedbacks.
This 4-wire, 12v rated voltage bipolar stepper motor has an angle of 1.8° per step and 200
steps per revolution for smooth motion and a nice holding torque. The motor was specified to
have a max current of 350mA so that it could be driven easily with an Arduino UNO.[44]

Figure II.6: stepper motor NEMA17.[44]

 25

II.2.4 The Servomotor.

As the name recommends, a servomotor is a servomechanism. Particularly, it is a

servomechanism that uses position input to control its movement and last position. The servo
motor works on PWM (Pulse width modulation) principle, means its angle of rotation is
controlled by the duration of applied pulse to its Control PIN. Basically servo motor is made
up of DC motor which is controlled by a variable resistor (potentiometer) and some gears. The
servo circuitry is built right inside the motor unit and has a positionable shaft, which usually is
fitted with a gear. Servo motors have been around for a long time and are utilized in many
applications. They are small in size but pack a big punch and are very energy-
efficient.[45][46]
In this system I will use the MG996R high torque metal gear dual ball bearing servo. This
high-torque standard servo can rotate approximately 1200 degrees (60 in each direction).it has
a stall torque of 9.4kgfcm (4.8v), operating speed of 0.17s/60 0, operating voltage 4.8v to 7.2v,
a running current of 500mA to 900Ma, and a band width of 5μs.
This servomotor in this system will be to control the plotter movement either up or down.[46]

Figure II.7: The servomotor[46]

II.2.5 The mechanical system of the CNC machine.

The mechanical part of the system is the frame work in which all electronic components are
mounted and it also consist of some mechanical components. In a CNC machine, the
mechanical system has a major rule to play on the quality of the output. If the mechanical part
is not well designed and structured the system output can’t be admirable. The framework of
 26

this system has been produced out of wood and it is assembled in such a way, there was
provision for the X axis, the Y axis, and the Z axis which carries the plotter. The X and Y axis
movement is achieved by using the linear rails assempled with the linear bearings. The stepper
are mounted on the X and Y axis to control the movements of the system, while servomotor
controls the plotter movement. To each motor is coupled the shaft coupler of the motor
together with the lead screws of each axis which is responsible for converting the rotational
motion of the stepper motor to linear motion. The linear motion of each axis is done smoothly
by the linear rail assembly connected to each axis, which is capable of load carriers and allow
linear motion in each axis. The controlled motion in each axis is achieved directly by
controlling the rotation of the stepper motor. The speed of the motion in each axis can also be
controlled by direct control of the speed of the stepper motor by giving required control
signals.

The design from below was gotten from [20] but the dimensions have been modified.

Figure II.8: System design[20]

 27

II.2.6 The lead screw.

The lead screw turns rotary motion into linear motion combining a srew and a nut where the
screw threads is in direct contact with the thread. The lead screw together with the stepper
motor will enable the linear motion of the system. The lead screw is a threaded silver piece of
material. In the system I have used an 8mm lead screw.

Figure II.9: Lead screw. [47]

II.2.7 Ball bearing.

A ball bearing is a type of rolling-element bearing that uses balls to maintain the separation
between the bearing races. The purpose of a ball bearing is to reduce rotational friction and
support radial and axial loads. This is achieved by using at least three races to contain the balls
and transmit the loads through the balls. One race is stationary and the other is attached to the
rotating lead screw.

Figure II.10: Ball bearing

 28

II.2.8 The Linear rail.

A linear bearing is to provide free motion in linear direction. The load is carried away by the
linear bearing and reduces frictional slides over linear rods. A linear-motion bearing or linear
slide is a bearing designed to provide free motion in one direction.

Figure II.11: The Linear rail

II.3 The principle of motion for the mechanism.

The CNC Machine operates on three axes, the X axis runs left to right and back with the
servomotor on it carring the plotter. The Y axis moves front and back with the base placement.
In the process of the movement while operating to produce an object, a system either operates
on Point-to-Point system of operation or the continues part system of operation.

II.3.1 The point-to-point system.

Point-to-point control systems cause the tool or work piece to move from one point to another
on the part and execute an operation at that point only. The tool is not in continuous contact
with the part while it is being moved to a working location. Some point-to-point operations are
drilling, reaming, boring, tapping, and punching. [49][50]
 29

Figure II.12: Point-to-point tool movement.[49]

II.3.2 Continuous path system (Straight cut and contouring systems).

These system provide continuous path such that the tool can perform while the axes are
moving, enabling the system to generate angular surfaces, two-dimensional curves, or three-
dimensional designs. It should be noted that continuous path controllers output motion by
interpolating each position of the tool. Interpolation is a mathematical method of
approximating the true or exact positions required to follow a precalculated path. The
interpolated positions are determined such that they differ from the exact positions within an
acceptable tolerance. Many continuous pathcontrollers interpolate curves as a series of
straight-line segments. Very high accuracy can be achieved by making the line segments
smaller and smaller. Example is a milling machine where such tasks are accomplished. Each
axis might move continuously at a different velocity. These concepts are illustrated in the
figure below.[49][50]

Figure. II.13: Continuous path tool movement[49]

 30

II.4 The servo- motor system.

II.4.1 The simulation of the experimental test of DCM based servo-motor.

The experimental workbench used is to test the realistic nature of the proposed DCM-based
servo system. The system consists of a PC with the installed inkspace and G-code sender
compiler, an Arduino development board, a servo-motor and a digital storage oscilloscope.
The servo system studied in this paper, is founded on the digital duty-cycle modulation
principle. It consists of a simple digital duty-cycle modulation program loaded in the flash
memory of an Arduino. Referring to the whole controlling system, the servo controller
receives position commands through a serial connection which is provided by using one
output input (I/O) pin of the Arduino. This pulse signal will course the shaft of the servo-
motor to locate itself at a particular angle. The shaft rotation on a servo motor is limited to
approximately 1800.

Figure II.14: The simulation of the experimental test of DCM based servo-motor
 31

II.5 Conclusion.

In this chapter, the methods and materials for the designing of a CNC Machine with a DCM
based servo-motor for plotter movement was studied. The general block diagram of the sytem
was given and also detailed study of each block. In the next chapter we shall focus on the
realization of the system through the idea of some components.
 32

CHAPTER III
METHODS AND MATERIALS FOR THE REALIZATION

III.0 Introduction

In chapter II, we studied the materials and methods for the system design. We studied details
of section of the system by understand the various components. In this chapter we shall focus
on the realization of the system. The realization of this system was done by sub dividing the
the system into three subsystem; the program of instructions susbsystem, the electrical and
electronic subsystem and the mechanical subsystem. In the process of realizing I started with
the building of the framework.

III.1 Mechanical system

The mechanical system is a major part that has to be done with much care, because if care is
not taking in building a good and solid framework, the will not be a proper functioning of the
mechanical system. To that effect the output results will not be the best. In realizing the
mechanical system, the first thing I did was to go get my material: the bolds and nuts, the 1cm
thick plywood which I took to a sawmill for designing. The framework was built out of
plywood and consist of the linear rails, the ball bearing, the stepper motor attached to the lead
screw. The table below are the dimensions of the systems

Table III.1: machine dimensions

24
X axis travel
24
Y axis travel
Consist of the router
Z axis travel
38cm
CNC height
47cm
CNC length
38cm
CNC width
 33

Table III.1 represents the dimensions of our CNC machine framework, the axial travel
dimension is very a precious information used during the programming process of the control
unit and needs to be kept in mind so as to recall the borders, so it will not be exceeded, also for
g-code programming where it is an obligatory information.

III.1.1 The design calculation

 X axis lead screw.

The movement required is =24cm

For safer side selecting length of scew is =40cm

Size = M8 x 1; pitch,

P = 1mm, Major diameter, d0 = 8mm, Mean diameter, d = (d0 – p/2) = 7.5mm

 Y axis lead screw

The movement required is = 24cm

For safer side selecting length of screw as = 40cm

Size = M8 x 1; pitch,

P = 1mm, Major diameter, d0 = 12mm, Mean diameter, d = (d0 – p/2) = 7.5mm

 Power calculation

The load on the Y axis is maximum; hence the power required at Y axis sub assembly will be
maximum. Hence the power required at Y axis lead screw is considered for selecting the
motor.

 The power required is calculated as:

Co-efficient of friction, µ=0.0015

tan = p/(pd) = 1/(px10) = 0.0318

tan Ф= µ =0.0015

 Mass on lead screw in Y-direction, my = 5 kg

 34

 External force,

Fey= my x g = 5 x 9.81 = 49.05 N

 Frictional force,

Ffy= µ x my x 9.81 (selecting µ=0.0015) = 0.0015 x 5 x 9.81 = 0.0736 N

 Total force,

Fty = Fey + Ffy = 49.05 + 0.0736 =49.1236 N

 Tangential force required at the circumference of screw is:

Fy = Fty × [tana x tanF]/[1-tana× tanF]

= 49.1236 x [0.0318+ 0.0015] / [1-0.0318x0.0015]

= 1.636 N

On the basis of tangential force torque required for screw rotation is,

TY = FY × d/2 + µ× FTY × R

= 1.636 x 10/2 + 0.0015 x 49.1236 x (10/2)

= 8.5484 N-mm = 0.0854 Kgf-cm

 Speed of lead screw,

Ny = 30 rpm.

 Angular speed,

ωY = 2πN/60 = 3.14 rad/sec

 35

 Power, PY = TY × ωY = 0.0854 x 3.14 = 0.2681 W

III.1.2 The realized basement.

The picture below presents the base structure of the system; where we can see the linear rails,
and the lead screw. The machine is designed in such a way it can draw on a flat surface which
is made of glass material. The basement plate is 24cm x 24cm. The linear rails that where
mounted on frame is to enable linear movement along the Y-axis so that it can travel freely for
forward movement and backward moevement. The rails are of 50cm long, made of silver
material and passes through the frame. As the stepper motor rotates, the lead screw together
witih the linear rail ensure linear motion which causes the plate to travel smoothly.

Figure III.1: The base of the machine.

III.2 The Electrical and electronic system

The electrical and electronic system consist of the; stepper motor, the Arduino UNO board
which carries the GRBL and the stepper drivers and also a power source. The electrical system
receives the streamed Gcode signals, then converts to electrical signals or pulses which will
are sent to the stepper motor which will convert to mechanical signals.
 36

Figure III.2: Electrical and electronic system.

 37

III.2.1 The algorithm of the DCM servo-system

Figure III.3: The algorithm of the DCM servo-system

III.2.2 The X-axis and Y-axis movement using the Brensenham algorithm.

The bresenham algorithm is another incremental scan conversion algorithm. The big
advantage of this algorithm is that, it uses only integer calculations. Moving across the x-axis
in unit intervals and at each step choose between two different y coordinates. This is the
algorithm I used in programming the axial movements of the system.
 38

Figure III.4: The X-axis and Y-axis movement using the Brensenham algorithm.
 39

III.3 The realization steps.

To realize this work piece, I laid down some short steps I followed to help me accomplish my
goal.

 Have the conceived design.

 Draw up the list of materials.
 Shaped the plywood as desired design.
 Bore the holds for bolds and lead screw.
 Build the framework.
 Mount the linear rails.
 Mount the step motors.
 Mount the lead screw and ball bearing.
 Mount the plotter.
 Install the electrical and electronic system.

Figure III.5: The realized frame

 40

III.4 Programme of instruction

The tool chain of CNC-based manufacturing is represented in the figure below. The part to be
machined is designed in a computer-aided design (CAD) software, whose output is a drawing
in one of many acceptable formats most preferable format is .stl format. This drawing is then
fed to the computer-aided manufacturing (CAM) software, whose output is the machine
readable code used for numerical control of the machine. Since implementation of the G code
is machine dependent, it is necessary to test out different choices for an open source G code
interpreter for the Arduino, so that the correct motions are obtained for the machine axes
through the stepper motor driver. I have used GRBL, an open source G-code interpreter or
milling controller for the Arduino development board.

CAD/ Drawing Software

Create the parts to be machined

CAM Software
Convert the part file to G-code

CNC Control Software

Turn the G-code file into motion

Figure III.6: Programme of instruction

 CAD software

The Computer-aided design (CAD) is used by the help of a computer for the creation,
modification, analysis, or optimization of a design 3D parts for the CNC engraver machine.
CAD tools in the truest sense are designed to allow you to easily change and manipulate parts
based on parameters. The most widely used interchangeable mesh file format is .STL files,
and are important because, they are used by CAM tools to generate Gcode. OpenSCAD,
FreeCAD, HeeksCAD PTC Creo (formerly PTC Pro/Engineer), Dassault Solidworks,
Autodesk Inventor, Auto CAD are some examples of CAD packages.
 41

 CAM software

The Computer Aided Manufacturing, or CAM, tools handled the intermediate step of
translating the CAD files into a machine-friendly format used by the Microcontroller board.
The CAM software receives the .STL file format from CAD software and generates machine
friendly GCODE. The software programme used for the CAD/CAM was F-Engrave. After the
image is generated, this image is put in the UNIVERSAL G-CODE SENDER software which
acts like the link between the software and the aduino

Figure III.7: the F-Engrave interface

 CNC control software (G-code Sender)

The Universal Gcode sender was used to send the G-code files to an integrated hardware
interpreter(Atmega 328). G-code Sender will take a G-code program in file and send it line by-
line to the Atmega 328 microcontroller. The G-codes will send over the signals through
wireless communication by the Bluetooth module between the computer and microcontroller.
GRBL Controller is software that is designed to send G-code to CNC machines is, such as 3D
milling machines. It isn‟t super smart, it just needs to give the user a nice way to get
commands down to whatever controller they are using.
 42

Figure III.8: Universal G-Sender

III.4.1 Steps for machine operation.

 Power on the CNC machine.

 Connecting to the machine with the USB cable.
 Launch the inkSpace installed software in laptop.
 Import image.
 Check if it vector image.
 Size the image.
 Generate Gcode.
 Launch the Universal Gcode sender.
 Import Gcode.
 Test machine movement or set to zero position by using X+,X-,Y+ and Y-
 Send Gcode for exwcution.
 43

CHAPTER IV
RESULTS OBTAINED, DISCUSSIONS AND OUTLOOK

IV.0 Introduction.

From the previous chapters we have been talking on materials and methods used for the
design, simulation and realization of the system. In this chapter we shall discusses the obtained
results from the realization of the system and also the outlooks.

IV.1 The results of the DCM servo-system.

The figure below shows the experimental workbench used to test the realistic nature of the
proposed DCM-based servo system. The system consist of a PC with the installed inkspace
and Gcode sender compiler, an Arduino development board, a servo-motor and a digital
storage oscilloscope. The servo system studied in this paper, is founded on the digital duty-
cycle modulation principle. It consists of a simple digital duty-cycle modulation program
loaded in the flash memory of an Arduino. Referring to the whole controlling system, the
servo controller receives position commands through a serial connection which is provided by
using one output input (I/O) pin of the Arduino. This pulse signal will course the shaft of the
servo-motor to locate itself at a particular angle. The shaft rotation on a servo motor is limited
to approximately 1800.

Figure IV.1: The experimental simulation

 44

Figure IV.2: Results of the simulated DCM servomotor system.

 The figures above show the switching periodic output waves coming from the Arduino
with a simple digital duty-cycle modulation programme loaded in the flash memory
 45

which evolves according to a known angle to control the servo-motor at a desired

instant.

IV.2 The implemented low cost CNC machine with a DCM based servo-
motor for plotter movement.

Figure IV.3: The realized work piece.

IV.2.1 The advantages of the prototype.

The low cost CNC machine offers the following advantages in manufacturing:

 It is cheap.
 Higher flexibility.
 Increased productivity.
 Reliable operation.
 Automatic material handling.
 Lesser floor space.
 Reduced manpower.
 Consistency in quantity and quality.
 46

 Just-in-time manufacture.
 Reduced non-productive time.
 Shorter cycle time.
 Higher accuracy.
 Machining of modern electronic materials

IV.2.2 The list of materials for the realization of the machine.

Table IV.1: The list of materials for the realization of the machine.

S/N Name of Materials Characteristics Quantity

1 Plywood 1.5cm thickness ½ sheet
2 Bolds ///////// 100
3 Bold nuts //////// 100
4 Linear rails. Sliding 2 of 1m
5 Ball bearings //////// 2
6 Stepper motors NEMA17 2
7 Servomotor MG699 1
8 Arduino board. Arduino UNO 1
9 GRBL shield Arduino compactiple 1
10 Stepper motor drivers Polulu drivers 2
11 Power supply 12v 1 adapter
12 USB cable ////////// 1
13 Lead screw (M8) 8mm ½ meter

IV.3 Conclusion

The feasibility and quality of the DCM technique for the servomotor control presented in this
report, have been shown through a practical experimental by using real components and
Oscilloscop .The realized prototype has been presented, its advantage and the list of materials.
The realized low cost CNC machine works well as required, but for the absence of a good
plotting machine which was represented by a pen.
 47

General conclusion

This research work has been of great challenge to me but in course of it I have gotten more
knowledge on machine control. The thesis has helped to get familiar with one of the famous
industrial technology which is Computer Numerical Control which previously I had little or no
idea about it. After my hard work in the research for realizing a working CNC prototype I
have gained skills in electronics and software development as well as carpentry and a little
mechanical skill too since I built the mechanical part by myself. In the electrical and electronic
part, I was elated and encouraged to push on with research when I realized the upcoming
DCM scheme was mostly studied and published by my own teachers.

I found out that the DCM is much cheaper and easy to work with than the PWM. I have
studied the stepper motor mechanism, and its control theory, the servo-motor mechanism
working on the DCM pulses switching pulses for a CNC Machine which is new to science.
Also, I used the big easy stepper motor drivers. These motors were very helpful in the project
since they are easy to use because they are controlled with open loop control system. In this
work, I have enhanced my skills in the microcontroller programming with the C language
using the IDE. Also, how to communicate the microcontroller to a servo-motor with the DCM
switching pulses, which had a great impact on me on this project. Thanks to this small single
mechanism I have discovered the need for DCM electronic systems which seems very useful
and helpful for engineers and programmers since it offers a handy implementation.

The results produced by the CNC machine are satisfactory after such a hard work; I finally got
good result with a huge treasure of knowledge and skills in electronics and software
development.
With increasing demand for small scale high precision parts in various industries, the market
for small scale machine tools has grown substantially. Using small machine tools to fabricate
small scale parts can provide both flexibility and efficiency in manufacturing approaches and
reduce capital cost, which is beneficial for small business owners. In this thesis, a small scale
three axis CNC machine is designed and realized under very limited budget.

This project is about building a mechanical prototype of a CNC plotter which is able to draw a
PCB layout and Wood engraving. This setup of hardware with a combination of G-code gives
better accuracy and reduces the work load. G code make easy to find the information of
locations of all stepper motor moving, as the status of our moving motor are directly seen on
computer, hence we can start or stop the machine whenever we want. Making a small machine
brings flexibility to do work. It will be very fruitful to extend the use of DCM techniques
using arduino for pulse generation to the control of other electronic systems. It will be
 48

interesting also to developed DCM devices and drivers using Rasberry Pi technology. These
aforementioned issues appear to be a potential opportunities for future research works.
 49

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