Robotics and Computer Integrated Manufacturing 63 (2020) 101927

Contents lists available at ScienceDirect

Robotics and Computer Integrated Manufacturing

journal homepage: www.elsevier.com/locate/rcim

Full length Article

From classic CNC systems to cloud-based technology and back T

⁎
Georgi M. Martinov , Aleksandr B. Ljubimov, Lilija I. Martinova
Department of Computer-Architecture Control Systems, Moscow State Technological University “STANKIN”, Vadkovsky per. 1, Moscow 127994, Russia

A R T I C LE I N FO A B S T R A C T

Keywords: The transition to cloud-based technology in the field of CNC systems requires significant changes to the archi-
CNC tecture of the control system, which is associated with a partial loss of funds already invested in its development.
SoftPLC The paper suggests an approach to the architectural organization of the CNC system modules, which allows
External interpolator reconfiguring the control system on-the-fly in order to form any of the possible solutions: the classical layout of
Cloud layout of the CNC system
the CNC system, the extended layout (using an external interpolator), or the cloud layout of the CNC system.
Experimental studies were carried using the 3-axis machining of parts on a milling machine with the cloud
layout of the CNC system.

1. Introduction
The inevitability of the transition to cloud-based technologies in the
segment of real-time control of industrial equipment has already be-
come obvious [1]. This promises a reduction in the cost of maintenance
and operation of machine tools, expansion of the functionality of the
CNC system and a decrease in the time required to commission tech-
nological equipment.
A wave of new trends - Industry 4.0, industrial Internet of things,
virtual and augmented reality [2], Big Data, remote monitoring and
diagnostics of machine tools, service-oriented architecture – has not
spared the control systems of technological equipment [3]. Today, new
types of CNC architecture suggest the transferability of their key
modules to the cloud. The research of Internet channel bandwidth is
performed to substantiate the efficiency of the above-mentioned ideas.
The main results of architectural changes include the reconfigurability
of CNC systems, the ability to scale and use them within digital pro-
duction. Some researchers in the field of computer and network tech-
nologies [4–7], seeing an inherent development lag in control systems
(explained by a conservative perception of the latest computer trends),
are trying to force the transition to the cloud. The examples, they de-
monstrate, are mostly academic and focused on small pilot machine
tools in which neither complex 5-axis machining [8,9] nor precision
machining [10] is required. Moreover, sometimes these examples are
limited to CNC emulator experiments.
The manufacturers of traditional CNC setting the objective of
moving to cloud technologies have certain reservations: if they follow
the proposed path, would they not be forced to come back? The ques-
tion at stake is whether it is possible to find a solution in the
development of CNC systems that would be equally suitable for both the
traditional and the cloud-based approach. It would be rational to find
an architectural solution for the CNC system, where the transition from
the traditional to the cloud-based approach or back would be reduced
to reconfiguring the CNC system without changing the modules them-
selves.
This research is based on the works and scientific results obtained
and published previously by the authors [8,9], and aims to support the
manufacturing processes using Internet-based technology. The con-
tribution of this research to the development of CNC systems is sum-
marized below.
1 A new scientific idea has been proposed - architecture of the CNC
system, enabling the reconfiguration of the CNC system on-the-fly to
form any of the possible solutions: classic layout, layout using an
external interpolator or cloud layout of the CNC system without
changing the modules themselves.
2 A new concept of a “controller of external devices” has been pro-
posed, which allows, based on an open communication protocol, to
transfer out of CNC kernel the actuator control specifics, for ex-
ample: the work with field buses, the control of servo drives ac-
cording to the “master/slave” scheme, etc.
3 The concept of an “external interpolator”, which allows connecting
proprietary devices issued by third-party manufacturers to the CNC
system, is adjusted to Internet-based technology.
4 The technology of layout and reconfiguration of the cloud-based
CNC system on-the-fly, based on the proposed set of commands of
the control system kernel interface, is presented.

⁎
Corresponding author.
E-mail address: martinov@ncsystems.ru (G.M. Martinov).

https://doi.org/10.1016/j.rcim.2019.101927
Received 4 May 2019; Received in revised form 16 November 2019; Accepted 11 December 2019
0736-5845/ © 2019 Elsevier Ltd. All rights reserved.
G.M. Martinov, et al.
The remainder of this paper is organized as follows: Section 2
analyzes architectural solutions in the field of web-based CNC systems;
Section 3 builds a cloud-based model of the CNC system. Section 4
presents the architecture of a configurable CNC system. Section 5 de-
scribes the layout and reconfiguration technology of a cloud-based CNC
system and Section 6 describes experimental studies that confirm the
validity of the proposed approach. Conclusions and ways of further
development of the study are presented in Section 7.
2. Analysis of new architectural solutions in the field of web-
based CNC systems
The architectures of CNC systems presented in publications [4–7,
11–15] are focused on solving specific problems, but they do not allow
sufficiently eliminating the existing contradictions and simultaneously
achieving flexibility and maximum computing power.
Formally, we can distinguish two main areas of research of archi-
tectural solutions in the field of web-based CNC systems:
• the first is the simplification of the CNC system on the machine tool
up to the motion controller for the implementation of interpolation.
In this case the main functions of the control system are moved to
the cloud;
• the second is the intellectualization of the CNC system using cloud
services and the transition to the STEP-NC standard.
• In particular, solutions [4,5,7] using some form of compilation of a
part program into a set of low-level CNC commands (motion, I/O
control and information commands) will require re-generation of
low-level commands in such situations as:
• correction for the wear of the cutting tool;
• compensation of temperature deformations;
• displacement correction based on the results of measuring cycles,
etc.
Transferring fine interpolation to the cloud will inevitably reduce
the performance of the look-ahead algorithm due to the rapidly chan-
ging operational environment, since bandwidth through the cloud will
always be inferior to a direct connection.
The research works within the second area are focused on the
transition to the STEP-NC standard for part programs and the sub-
sequent planning of the processing in the cloud [11–13]. In this case,
the information about the workpiece, cutting tool, geometric toler-
ances, etc. is set before machining. Processing planning is carried out
using the knowledge base in the cloud created with the help of On-
tology Web Language (OWL). Communication with the NC system is
carried out through file exchange [14,15]. The development of CNC
systems in accordance with the STEP-NC standard is an interesting di-
rection, but unfortunately the control of PLC in the STEP-NC standard
has not been developed yet. Therefore, many manufacturers of control
systems are waiting for the next standard based on STEP-NC, where this
problem will be solved.
Such architectural solutions suggest the rejection of the traditional
scheme of machine tool functioning, turning it into a set of equipment
that only works with the cloud. The considered approaches do not
support the reconfiguration of the CNC system that would depend on
the specific type of the cloud, its computational capabilities and
bandwidth of the channel. This does not mean, however, that we should
abandon the search for new solutions and should not take into account
new ideas embedded in the types of architecture discussed.
3. Building a cloud-based model of CNC system
The cloud-based model should be considered from the perspective
of three stakeholders linked by the production chain: CNC manu-
facturers, machine tool builders and end users.
Historically, end users have amassed a very diverse fleet of CNC
2
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
equipment to reach production goals, and this equipment requires
timely servicing. It is common to have machine tools from different
vendors with different CNC systems on the shop floors; machine tools of
the same make may also be available, but they could be equipped with
CNC systems from different manufacturers. Even machine tools with
CNC systems of the same model, but purchased at intervals of one and a
half to two years will be different - their CNC systems will have dif-
ferent versions of firmware, i.e., different kernel versions of the CNC,
which ensures only backward compatibility of part programs, but
nothing more [16].
The machine tool builder is not able to employ a staff of specialists
for a wide variety of CNC systems, and thus is forced to look for private
solutions. As a result, it can turn out that the machine tool is equipped
with a CNC system, whose machine parameters do not correspond to
the initial order of the end user. Another problem arises when a par-
ticular machine tool model is produced with different CNC systems, and
the problem concerns the means of transferring the PLC program [17]
to another control system.
Manufacturers of CNC systems face other types of problems: when
buying the control system as a ready-made device, machine builders
believe that all software should be built inside the control system, while
utilities and software tools are purchased as separate products. As a
result, a scheme has emerged in the market, where the CNC system is
sold in a basic configuration, and a list of advanced solutions is offered
in the form of software, or hardware and software modules for an extra
fee. For example, a control system in its base configuration is equipped
with a standard HMI, and advanced HMI is another product that is
purchased separately. Besides, spline interpolation functions [18],
compressions, etc. may be available for an extra fee.
The problems outlined above can be solved by means of transition
to cloud-based technologies [19] and the use of services via a pay-per-
use pattern. For example, cloud-based services provide automatic
firmware updates from the repository, rental of software utilities and
advanced HMIs, rental of development and debugging tools of para-
metric part programs in the workpiece coordinate system, etc.
It is, however, advisable to place only non-real-time functions in the
cloud: remote terminal functions for monitoring the process [20] and
setting up the control system [21], diagnostic utility for machine tool
actuators [22], Web and OPC UA clients, advanced HMI, tools for
configuring machine parameters, machine tool start-up utilities (digital
oscilloscope, circle test, logical analyzer, etc.) [23]. Alongside those, it
is advisable to place in the cloud the CAD/CAM system [24], including
shop floor level CAM system [25], Big Data services for logging ma-
chine operation protocols and tracking machine tool working hours
[26], services for process modeling and collision control, [27] etc.
If a cloud-based real-time operating system [5] is developed on the
Intranet, then the kernel of the CNC system can also be placed in the
cloud, which will be demonstrated below.
3.1. Introduction to the concepts of "external interpolator" and "controller of
external devices"
The terms "external interpolator" and "controller of external devices"
are non-trivial for traditional CNC systems. Each of them is focused on
its area of tasks.
3.2. External interpolator
The external interpolator is a forced solution for connecting pro-
prietary devices of third-party manufacturers with a closed solution to
the CNC system. For example, the implementation of hybrid or multi-
functional machining on machine tools entails a number of require-
ments. One of them is the integration of a laser scanner controlled from
a PCI or PCIe board autonomous controller with its own interpolator
[28]. It is necessary to synchronize the tool path, interpolated by the
CNC system, with the power of the laser and with the path of its beam
G.M. Martinov, et al.
movement, interpolated by an autonomous controller [29]. The ex-
ternal interpolator mechanism synchronizes both interpolators, the
regular one of the CNC system and the autonomous one on a PCI or PCIe
board, according to the interval of execution of tasks [30].
3.3. External device
Modern industrial networks use different, but close in capabilities,
fieldbus standards for connecting equipment (Sercos III [31], EtherCAT
[32], PROFINET [33], Ethernet PowerLink [34], Ethernet/IP, Devi-
ceNet, CANopen, PROFIBUS, Modbus, etc.). It is unlikely that in the
near future one of these standards will displace the rest (as it happened
in information networks, where twisted pair and WiFi as transmission
medium and TCP/IP as protocol have long been predominant) [35].
The reason for this is simple - different fieldbuses are supported by
different companies or communities that compete with each other. It is
unlikely that in the near future they will be able to agree on the support
of a common standard for connecting industrial automation devices and
electric drives, especially if there is a huge heterogeneous fleet of
equipment manufactured by them. As a rule, the support of an in-house
standard includes the release of the appropriate set of devices, and the
licensing of the application. At present, compatibility between field-
buses is realized through gateways or switching actuators to another
fieldbus, if the manufacturer has provided such a possibility.
The use of external device controllers allows solving the following
key tasks:
• connecting actuators of various kinds (electric drives, I/O devices,
sensors, automation controllers, etc.);
• connecting actuators of various fieldbuses (Sercos III, EtherCAT,
Ethernet PowerLink, Ethernet / IP, etc.);
• ensuring the independence of the online data exchange cycle time
from a particular work cycle time of the actuator.
External devices can be implemented by one or more controllers
that are functionally close to the following solutions: MotorController
[6], MachineBox [5], Controller + Motor / Drives [4], Hardware [7],
Controller [24].
An external device controller is an Ethernet controller of peripheral
devices, most importantly, servo drives and input-output devices, which
exercises the specifics of control over one or several field buses.
The concept of an external device controller makes it possible to
transfer out of CNC kernel the fine interpolation functions, the specifics
of working with field buses, drive control according to the master/slave
and gantry schemes [36]; the handling of probe signal [37], the refer-
encing of axes with incremental encoders, the zero mark signal pro-
cessing, etc.
The structure of the external device is illustrated in Fig. 1.
The external device controller implements the specifics of working
with drives, I/O devices and with sensors on field buses. The CNC
Fig. 1. The structure of the external device.
3
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
kernel provides information about the current state of the actuators. In
hard real-time only external device controller and actuators are oper-
ating.
3.4. Connecting external devices to the CNC kernel
The CNC kernel contains a software module for connecting external
devices, which allows the use of several external devices, including
PLC.
The mechanism of connecting external devices is based on an open
communication protocol and standard Ethernet TCP/IP data transport.
The block diagram of the connection the CNC kernel and industrial
equipment is shown in Fig. 2.
The CNC kernel controls external device controllers using an open
protocol. If a PLC implements the open communication protocol, then it
can be used without an additional controller of external devices, as
shown in Fig. 2.
Key features of the use of an external device controller:
• open communication protocol in combination with standard
Ethernet TCP/IP protocol;
• implementation on almost any hardware-software platform with no
restrictions on supported field buses for communication with ac-
tuators (drives, i/o devices, sensors);
• real-time solution of time-critical tasks: closing the loop of servo
drive feedbacks, handling end switches, capturing a position when a
touch probe sensor is triggered, etc.
3.5. Open communication protocol
An open interaction protocol assumes that each drive or I/O device
in the real time network is mapped to a data block and to a unique
logical address. The device address range starts from 1. The zero ad-
dress is used for broadcasting commands.
Fig. 3 shows the logical addressing of external devices for the soft-
ware module of connecting these external devices, for example issued
by third-party manufacturers.
3.6. Basic principles and state machine of the open communication protocol
The CNC kernel is always mastering the equipment. This means that
the CNC kernel is a master initializing the information exchange, and
controlling the change in the communication phases. In different phases
of communication, different sets of commands are available for re-
ceiving by slave devices. For example, the command for switching to
the cyclic data exchange mode is available only in the parameterization
phase. The recording-reading of external device parameters, as well as
commands for changing the phases of communication, always follows
the request-response scheme, where the kernel performs the request
and the drive or I/O device responds to this request during a certain
G.M. Martinov, et al.
Fig. 2. Block diagram of the external devices connection.
time interval (request time-out).
The phases of communication and possible transitions between
them are shown in Fig. 4.
The following scheme displays tree phases of communication (in-
itialization, parameterization and cyclic exchange) and two corre-
sponding transitions. The state machine of communication is illustrated
in Fig.5.
The initial state corresponds to turning the system on, hardware reset
of the system, as well as recovery from critical errors (for example, after
disconnection). In this state, the master device checks for the presence
of slaves in accordance with its own machine parameters and waits for
the slaves to be ready for information exchange (for receiving com-
mands).
The transition to parameterization state is initialized by the master
device. Master sends to the slaves a command to switch to the para-
meterization state. In future, the master device waits for the con-
firmation of the transition of all slave devices to the parameterization
state and enters the parameterization state, or, in case of errors or a
timeout, returns to the initial state.
In the state of parameterization the following tasks are carried out:
• setting parameters for drives or I/O devices;
• starting the drives in easy startup mode (if this functionality is im-
plemented by the manufacturer), for example, to select the optimal
parameter value set;
• control of input and output status of I/O devices (if this functionality
Fig. 3. Logical addressing of external devices.
4
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
is implemented by the manufacturer).
In the parameterization state, the actions of the master device de-
pend on the mode in which the CNC kernel operates. In particular:
• if the CNC kernel is in the equipment configuration mode, then the
operator may change the machine parameters;
• if the CNC kernel starts up in regular mode, it automatically sets the
parameters of the slaves in accordance with the current set of ma-
chine parameters and initiates the transition to cyclic exchange;
• if the CNC kernel shuts down, then it immediately goes out of the
parameterization state.
The master initializes the transition to the cyclic exchange state by
sending the corresponding command to the slaves. Following that, the
master device waits for confirmation that all slave devices are ready for
cyclic exchange. In case of an error or after a timeout, it returns to the
parameterization state.
The cyclic exchange state implements the main working mode. The
cyclic exchange with devices consists of receiving input data and
sending output data. The initiator of cyclic exchange can be either a
master device or a slave one (the initiator is defined at the stage of
parameterization). The master device, after entering the cyclic ex-
change state, sends to the slaves a command to switch to the cyclic
exchange state. The structure of the cyclic data is defined in the para-
meterization phase.
G.M. Martinov, et al. Robotics and Computer Integrated Manufacturing 63 (2020) 101927

Fig. 4. Communication phases.

The transition from the cyclic exchange state is initialized by the

master, which sends the corresponding command to the slaves.
Following that, the master device waits for confirmation of the transi-
tion of all slave devices to the parameterization state.
The transition from parameterization state is initialized by the master
by means of sending the appropriate command to the slaves. Following
that, the master device waits for confirmation of the transition of all
slave devices to the initial state.

4. Architecture of configurable CNC system

The basis of a configurable CNC system is the use of common

hardware and software platforms, standard communication channels
and open communication protocols. The proposed architecture of the
configurable CNC system expands the capabilities of the “classic”
(traditional) CNC systems and provides the reconfigurability and scal-
ability of the control system depending on the specific process equip-
ment.

4.1. General structure of configurable CNC

A simplified structure of a configurable CNC system without buffers

of the processed code and commands is illustrated in Fig. 6.
The structure of the configurable system includes the following
elements: a СNC kernel, external devices and terminal devices (HMI,
control panels, monitoring and diagnostics panels, as well as cloud
tools). The number of control channels, number of axes, kinematic
scheme and other parameters are set in the machine parameters of the
control system. The machine parameters are available for outside cor-
rection, for example through a remote terminal. The CNC kernel im-
plements open communication protocols with terminal devices and
with external devices via Ethernet TCP/IP.
The open communication protocol with terminal devices ensures
Fig. 6. The structure of the configurable CNC system.
their connection to the kernel of the control system by type of terminal
clients [38].
The task is to provide, on the basis of the configuration (without 4.2. Control channel and the particularities of its interpolator
changing the hardware and software modules), architectural solutions
for: the “classical” CNC system, the “extended” CNC system using an The architecture of the control channel is similar to the described
external interpolator, and the “cloud” CNC system. structure of the data processing pipeline [39], so we are going to con-
sider only its key features. Channel data processing pipeline is shown in

Fig. 5. Communication protocol state machine.

5
G.M. Martinov, et al.
Fig. 7. Channel data processing pipeline.
Fig. 7.
The part program in the high-level language and in the G-code is
loaded into the preprocessor; its task is to deploy all the instructions in
the high-level language into a sequence of G-code blocs [40]. The in-
terpreter converts the variety of G- and M-functions of the part program
blocks into the internal format with a minimum sufficient command set.
In this case, the interpreter recalculates the movement trajectory taking
into account the compensations of the radius and the length of the
cutting tool. The translator creates the task for the interpolator from the
internal command format. The task of the interpolator is to form a
buffered flow of microinstructions from relatively large commands re-
ceived from the NC block. In particular, for one input of the information
command (for example, modifying the active G-functions) there will be
one corresponding output microinstruction. The number of output
movement microinstructions (setpoints with positions, velocities and
execution times calculated during the interpolation) corresponding to
one input interpolation command, will depend on the required accu-
racy of movement. The higher the accuracy required, the higher the
frequency of the generated movement microinstructions.
An input command can be represented as a structural object with
fields sufficient for its processing by the interpolator:
• type of command (G-function, M-function, information command,
etc.);
• subcommand (kind of interpolation);
• command data (for example, start and end points, feedrate, etc.
comprise the data for interpolation commands);
• IP address of an external device controller (optional, in case of using
several external device controllers);
• execution time relative to the last command (optional, in case of
external interpolator);
• etc.
6
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
The key feature of the channel interpolator is the fact that it can
receive commands from the cloud via an open protocol (see Fig. 8).
The local resources displayed in Fig. 8 correspond to the CNC
kernel. The interpolator has an input command buffer. It allows loading
a sufficient number of commands for the operation of the look-ahead
algorithm [41] and real time is not required for the input of commands.
The position feedback, limit switches and the probe are connected
to the drive controller. This scheme frees up the computational re-
sources of the control system expended on closure position feedback
and provides a faster response when hitting the limit switches or when
the touch of the probe is activated. It is necessary to reset the buffer of
prepared NC blocks and to recalculate them if a tool wear correction or
compensation of temperature deformations is required during proces-
sing. The mechanism is identical to the mechanism used in classical
CNC systems.
Using the Ethernet TCP/IP protocol limits response time and data
rate speed in a multiuser environment. The first limitation is solved by
using modern data transmission facilities and buffering the data be-
tween the CNC modules. Modern facilities of data transmission [42,43]
increase the actual network performance, reduce delays and packet
losses and ensure the fulfillment of security requirements. The second
limitation is solved by the organization of a multi-layer cloud [44],
which combines multiuser access and network performance of the
production layer.
Operation in autonomous mode corresponds to the classical scheme
of building a CNC system, and in this mode the control system can be
effectively used in digital manufacturing. It is worth mentioning that
due to the presence of an open communication protocol in the CNC
system, cloud-based services can monitor the CNC system (for example,
with the aim of timely detecting the possible destruction of the cutting
tool [45,46]).
Operation in the external interpolation mode or cloud mode
G.M. Martinov, et al.
Fig. 8. Different modes of Interpolator operation.
involves using the CNC interpolator. In this case, the cloud is not re-
quired to provide a real-time environment. The same modules of the
CNC kernel are present in the external interpolation mode and in the
cloud mode, but with a difference. The cloud can work with the CNC
kernel in two ways.
In the first option, the NC blocks of the part program are transmitted
to the input of the data processing pipeline in the kernel. In this case,
the entire data processing pipeline is used. For example, it is possible to
pause processing, correct a part program and restart processing, taking
into account the new corrections.
The second way uses only the last part of the data processing pi-
peline in the kernel, and the commands are transmitted directly to the
interpolator and SoftPLC. In this case, the cloud performs the functions
of preprocessor, interpreter and translator, and if necessary, adjusts the
part program without interrupting the process of machining.
7
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
The proposed solution uses the cloud mode (the second way) to load
relatively large commands (for example, circular interpolation com-
mands, tool change commands, etc.) into the control channel, which
allows getting maximum performance in the cloud version of the con-
figurable CNC system, and does not require a real-time environment.
5. Layout and reconfiguration of CNC system
5.1. Layout options for configurable CNC system
The reconfiguration of the CNC system does not require changing
the control system modules. The layout options of the configurable CNC
system do not require changes to the control system modules. Layout
options for configurable CNC system are presented in Fig. 9.
The reconfiguration of the CNC system is performed on-the-fly by
G.M. Martinov, et al.
Fig. 9. Layout options of configurable CNC system.
using the CNC kernel interface commands intended for interacting with
terminal clients or similar commands received through the part pro-
gram. These commands enable or disable certain parts of the data
processing pipeline. At the same time, the CNC system itself does not
change, but the composition of the modules that it uses does.
Due to the open protocol of interaction between the CNC kernel and
terminal clients, it is possible, in any layout option, to monitor and
diagnose the CNC system in general and its specific modules. In parti-
cular, in any layout option, it is possible to monitor the actual move-
ment of the axes, the current energy consumption of drives, operating
hours, etc. [47,48].
A classic layout of CNC system can be converted to an extended one
if it is required to use equipment that is not part of the classic layout.
The use of the modules of the CNC data processing pipeline in the
“cloud” version of its layout is ensured by the presence of sufficiently
capacious data buffers in the system, which allows independence from
the Real-Time cloud environment.
There is an option where the cloud can control external devices
directly, which becomes possible if a real-time cloud operating system
is organized. Then the cloud completely fulfills the functions of the CNC
kernel using its external devices (drives, sensors, I/O devices).
8
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
A layout option is also possible where the kernel of the CNC system
implements the movement of the drives and the control of the PLC
functions is fully or partially performed by cloud-based services. If
necessary, it is possible to implement other combinations of the de-
scribed layout options.
5.2. CNC reconfiguration mechanisms
CNC reconfiguration is implemented on three levels.
At the level of machine parameters, the CNC implements the widest
possible reconfiguration that allows, for example, changing the number
of control channels of the CNC system, redistributing the axes between
the channels, changing the composition of the involved external de-
vices, etc. However, this level does not always allow for quick inter-
vention, especially by the part program during its execution.
Commands on the machine parameters level may come from terminal
clients (if they have the appropriate rights), from SoftPLC, or from the
external interpolator.
At the level of the PLC, as a rule the CNC uses partial reconfigura-
tion on-the-fly. For example, when executing determined commands,
the PLC may connect or temporarily use additional external devices.
G.M. Martinov, et al.
Fig. 10. Experiment of machining parts on milling machine tool.
Commands on the PLC level can come from the SoftPLC of the CNC
kernel and from the external interpolator.
The level of the part program is similar to the level of the PLC. The
CNC system implements a set of special high-level language commands,
which are available from the part program. These commands can
manage layout changes (Fig. 9), for example, to connect/disconnect an
external interpolator.
6. Experimental studies
The experiment with 3-axis machining of the part (Fig. 10) was
carried out at the 5-axis planing and milling machining center
E7106MF4 with the specialized AxiOMA Control CNC system that
controls the servo drives using the SERCOS III protocol. Technical
parameters, kinematic scheme and design features of the machining
center were published in [49]. The structure, hardware implementation
and interaction mechanism of the components of the CNC system are
presented in publications [12,50]. The file of the part program was
generated using a CAD/CAM system and stored in the cloud storage.
The part program has a size of 1147 KB and contains about 41,900 NC
blocks. The workpiece was machined from model plastic with the fol-
lowing parameters: feed - 1200 mm/min, spindle speed - 14,000 rpm,
cutting tool - spherical cutter with a diameter of 3 mm; the processing
time was 52 min.
The prototype of the CNC system was configured for a cloud layout
(Fig. 11). A private cloud-based Ubuntu server on the OpenStack plat-
form was used. Cloud storage of part programs was implemented by the
Swift service, and virtual machine management by the Nova service.
HMI was run on a Windows virtual machine and a virtual CNC kernel
(VNC) was run on a Linux virtual machine in the private cloud. The
HMI device was a client of the HMI service running in the cloud. The
part program on the HMI device was selected and executed from the
cloud storage. The virtual NC kernel performed the functions of a
preprocessor, an interpreter and a translator.
During the execution of the NC blocks, the virtual NC kernel gen-
erated and transmitted via TCP/IP commands for the interpolator and
SoftPLC of CNC kernel. The CNC kernel sent the microinstructions
calculated during the interpolation process to an external device con-
troller in order to control the drives and I/Os of the machine tool. The
HMI device using the information commands from the interpolator,
displayed the interpolated NC block, the current coordinates of the
servo drives, and the state of the control system.
The interpolation cycle in the cloud configuration of the NC system
was 1 ms, which corresponds to the interpolation cycle in the classical
layout of the NC system. This also defined the SERCOS cycle settings of
1 ms.
9
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
The parameters of the CNC system with a cloud layout, obtained as
a result of the experiment of executing the part program are represented
in Table 1.
The maximum size of a microinstruction is 1.15 KB. The calculation
shows that the microinstruction buffer size for an external interpolator
of 250 KB parries the local network delay up to 500 ms.
7. Conclusions and future work
The proposed architecture of a configurable CNC system allows, on
the one hand, configuring and reconfiguring the CNC system (if ne-
cessary on-the-fly) in different ways, from “classical” to “cloud”, and on
the other hand, providing maximum computing power. This does not
require any changes in the hardware and software of the CNC system.
The possibility of using both the built-in and external interpolators and
the proposed open TCP/IP communication protocols is of key im-
portance.
Incorporated into the CNC system, the kernel interface commands
and commands that come through the part program, allow laying out
(reconfiguring) the control system on-the-fly, depending on the specific
type of the cloud, its computational capabilities, and the bandwidth of
the channel. The use of cloud services of the CNC system provides the
updating of firmware from the repository, the rental of software utilities
as they are needed, the storage of part programs and the history of their
modification. Cloud services, updating the software of CNC systems,
organize the versions of firmware, software updates, corresponding
documentation and the accumulated knowledge base in this area.
The parameters of the investigated cloud layout of the CNC system
with an external interpolator (Fig. 11), such as the interpolation cycle,
the PLC cycle, the number of interpreted NC blocks per second, etc., are
comparable with the parameters of the classical layout of the CNC
system and are sufficient for a conventional 3-axis milling processing. A
research is planned in the future to determine the parameters of the
remaining options for the cloud layout of the NC system.
Service issues, assessing the reliability of the proposed CNC cloud
system architecture, fault prediction, creating a set of automatic func-
tional tests, certifying software and hardware components, are beyond
the scope of this article and will be investigated in the future.
CRediT authorship contribution statement
Georgi M. Martinov: Conceptualization, Funding acquisition,
Methodology, Formal analysis, Software. Aleksandr B. Ljubimov:
Conceptualization, Data curation, Methodology, Resources, Software,
Writing - review & editing. Lilija I. Martinova: Conceptualization,
Data curation, Formal analysis, Supervision, Methodology, Writing -
G.M. Martinov, et al. Robotics and Computer Integrated Manufacturing 63 (2020) 101927

Fig. 11. Experimental platform for processing the workpiece on a milling machine tool with a prototype of cloud layout of the CNC system.

Table. 1 augmented reality technology, MATEC Web Conf. Volume 224, 2018, Proceedings
The parameters of the CNC system with a cloud layout obtained as a result of of the International Conference on Modern Trends in Manufacturing Technologies
the experiment. and Equipment (ICMTMTE 2018), Sevastopol, Russia, 2018, pp. 1–7, , https://doi.
org/10.1051/matecconf/201822402093 September 10-14, 2018.
Measured parameters Comment [3] L. Martinova, G. Martinov, Automation of machine-building production according
to industry 4.0, Proceedings of the 3rd Russian-Pacific Conference on Computer
Number of microinstructions 1 300 000 designation – N_mcin Technology and Applications, Vladivostok, 2018, pp. 1–4, , https://doi.org/10.
The total size of microinstructions 1 350 MB designation – Sz_mcin 1109/RPC.2018.8482165.
[4] Z. Sang, X. Xu, The framework of a cloud-based CNC system, Procedia CIRP 63
Executing time of part program 52 min (3 120 s) designation – T
(2017) 82–88, https://doi.org/10.1016/j.procir.2017.03.152.
Number of NC blocks interpreted 505 NC blocks /s
[5] A. Verl, A. Lechler, S. Wesner, A. Kirstädter, J. Schlechtendahl, L. Schubert, S Meier,
per second
An approach for a cloud-based machine tool control, Procedia CIRP (2013)
Calculated parameters 682–687, https://doi.org/10.1016/j.procir.2013.06.053.
Microinstructions traffic 420 [micro- N_mcin / T = 420 [6] Y. Yingxue, L. Miao, D. Jianjun, Z. Liang, Design of a machine tool control system
instructions/s] [micro-instructions/s] for function reconfiguration and reuse in network environment, Robot. Comput.
Size of microinstructions traffic 4.5 Mb/s Sz_mcin / T /10 = 4.5 Integr. Manuf. 56 (2019) 117–126, https://doi.org/10.1016/j.rcim.2018.09.005.
Mb/s [7] N.D.O. Pacheco, E. Harbs, R.S. Rosso Jr, M.D.S. Hounsell, J.C.E. Feneira,
Application of the step-NC standard in a computer numerical controlled machining
device, Proceedings of the ABCM Symposium Series in Mechatronics, 5 2012, pp.
713–723.
original draft, Writing - review & editing. [8] S.N. Grigoriev, G.M. Martinov, Research and development of a cross-platform
CNCkernel for multi-axis machine tool, Procedia CIRP 14 (2014) 517–522, https://
Declaration of Competing Interest doi.org/10.1016/j.procir.2014.03.051.
[9] S.N. Grigoriev, G.M. Martinov, The control platform for decomposition and
synthesis of specialized CNC systems, Procedia CIRP 41 (2016) 858–863, https://
The authors declare that they have no known competing financial doi.org/10.1016/j.procir.2015.08.031.
interests or personal relationships that could have appeared to influ- [10] J.C. Wu, H.C. Zhou, X.Q. Tang, J.H. Chen, A NURBS interpolation algorithm with
continuous federate, Int. J. Adv. Manuf. Technol. 59 (2012) 623–632, https://doi.
ence the work reported in this paper.
org/10.1007/s00170-011-3520-2.
[11] W. Gao, C. Zhang, T. Hu, Y. Ye, An intelligent CNC controller using cloud knowl-
Acknowledgements edge base, Int. J. Adv. Manuf. Technol. 102 (2019) 213–223, https://doi.org/10.
1007/s00170-018-03222-8.
[12] F. Tao, J. Cheng, Y. Cheng, S. Gu, T. Zheng, H. Yang, SDMSim: a manufacturing
This research was supported by the Ministry of Education and service supply–demand matching simulator under cloud environment, Robot.
Science of the Russian Federation as a public program in the sphere of Comput. Integr. Manuf. 45 (6) (2017) 34–46, https://doi.org/10.1016/j.rcim.2016.
scientific activity (N 2.1237.2017/4.6) and was carried out using 07.001.
[13] F. Tao, Y. Zuo, L.D. Xu, L. Zhang, IoT-Based intelligent perception and access of
equipment provided by the Center of Collective Use of MSUT manufacturing resource toward cloud manufacturing, IEEE Trans. Ind. Inf. 10 (2)
“STANKIN”. (2014) 1547–1557, https://doi.org/10.1109/TII.2014.2306397.
[14] Y. Ye, T. Hu, C. Zhang, W. Luo, Design and development of a CNC machining
process knowledge base using cloud technology, Int. J. Adv. Manuf. Technol. 94
Supplementary materials (1–13) (2016) 3413–3425, https://doi.org/10.1007/s00170-016-9338-1.
[15] Y. Ye, T. Hu, C. Zhang, W Luo, Design and development of a CNC machining process
Supplementary material associated with this article can be found, in knowledge base using cloud technology, Int. J. Adv. Manuf. Technol. 94 (2018)
3413–3425, https://doi.org/10.1007/s00170-016-9338-1.
the online version, at doi:10.1016/j.rcim.2019.101927. [16] S.N. Grigoriev, G.M. Martinov, An ARM-based multi-channel CNC solution for
multi-tasking turning and milling machines, Procedia CIRP 46 (2016) 525–528,
References https://doi.org/10.1016/j.procir.2016.04.036.
[17] L. Martinova, N. Kozak, R. Nezhmetdinov, R. Pushkov, A. Obukhov, The Russian
multi-functional CNC system Axioma control: practical aspects of application,
[1] X Xu, From cloud computing to cloud manufacturing, Robot Comput. Integr. Manuf. Autom. Remote Control 76 (1) (2015) 179–186, https://doi.org/10.1134/
28 (2012) 75–86, https://doi.org/10.1016/j.rcim.2011.07.002. S000511791501018X.
[2] Viktor Chekryzhov, Ilya A.Kovalev, Anton S.Grigoriev, An approach to technolo- [18] G. Martinov, N. Kozak, R. Nezhmetdinov, A. Grigoriev, A. Obukhov, L. Martinova,
gical equipment performance information visualization system construction using Method of decomposition and synthesis of the custom CNC systems, Autom. Remote

10
G.M. Martinov, et al.
Control 78 (3) (2017) 525–536, https://doi.org/10.1134/S0005117917030122.
[19] Y. Ye, T. Hu, C. Zhang, W. Luo, Design and development of a CNC machining
process knowledge base using cloud technology, Int. J. Adv. Manuf. Technol. 94
(2016) 3413–3425, https://doi.org/10.1007/s00170-016-9338-1.
[20] Petr Nikishechkin, Nadezhda Chervonnova, Anatoly Nikich, Approach to the con-
struction of specialized portable terminals for monitoring and controlling techno-
logical equipment, MATEC Web Conf. Volume 224, 2018, Proceedings of the
International Conference on Modern Trends in Manufacturing Technologies and
Equipment (ICMTMTE 2018), Sevastopol, Russia, 2018, pp. 1–9, , https://doi.org/
10.1051/matecconf/201822401089 September 10-14, 2018.
[21] I. Kovalev, P. Nikishechkin, A. Grigoriev, Approach to programmable controller
building by its main modules synthesizing based on requirements specification for
industrial automation, Proceedings of the International Conference on Industrial
Engineering, Applications and Manufacturing (ICIEAM), 2017, pp. 1–4, , https://
doi.org/10.1109/ICIEAM.2017.8076121.
[22] P. Nikishechkin, I. Kovalev, A. Nikich, An approach to building a cross-platform
system for the collection and processing of diagnostic information about working
technological equipment for industrial enterprises, Proceedings of the MATEC Web
of Conferences, 129 2017, p. 03012, , https://doi.org/10.1051/matecconf/
201712903012.
[23] G. Martinov, S. Sokolov, L. Martinova, A. Grigoryev, P. Nikishechkin, Approach to
the diagnosis and configuration of servo drives in heterogeneous machine control
systems, Proceedings of the 8th International Conference, ICSI, Fukuoka, Japan,
2017, pp. 586–594, , https://doi.org/10.1007/978-3-319-61833-3_62.
[24] A. Epureanu, F.B. Marin, V. Marinescu, M. Banu, I. Constantin, Reconfigurable
machine tool Programing- A New approach, WSEAS Trans. Syst. Control 5 (2008)
463–472.
[25] Liliya I. Martinova, Nikolay N. Fokin, An approach to creation of a unified system of
programming CNC machines in the dialog mode, MATEC Web Conf. Volume 224,
2018, Proceedings of the International Conference on Modern Trends in
Manufacturing Technologies and Equipment (ICMTMTE 2018), Sevastopol, Russia,
2018, pp. 1–5, , https://doi.org/10.1051/matecconf/201822401101 September 10-
14, 2018.
[26] L.D. Xu, L. Duan, Big data for cyber physical systems in industry 4.0: a survey,
Enterp. Inf. Syst. (2018) 1–22, https://doi.org/10.1080/17517575.2018.1442934.
[27] L. Qiu, C. Yin, X.B. Li, Information composition analysis and adaptation access of
CNC lathes in cloud manufacturing environment, Proceedings of the Monterey
Workshop, 2016 2016, pp. 66–76, , https://doi.org/10.1007/978-3-319-61994-1_7.
[28] G.M. Martinov, A.B. Ljubimov, A.S. Grigoriev, L.I Martinova, Multifunction nu-
merical control solution for hybrid mechanic and laser machine tool, Procedia CIRP
1 (2012) 260–264, https://doi.org/10.1016/j.procir.2012.04.047.
[29] G.M. Martinov, A.I. Obuhov, L.I. Martinova, A.S Grigoriev, An approach to building
specialized CNC systems for non-traditional processes, Procedia CIRP 14 (2014)
511–516, https://doi.org/10.1016/j.procir.2014.03.049.
[30] R. Nezhmetdinov, S. Sokolov, A. Obukhov, A. Grigor'ev, Extending the functional
capabilities of NC systems for control over mechano-laser processing, Autom.
Remote Control 75 (5) (2014) 945–952, https://doi.org/10.1134/
S0005117914050129.
[31] W. Elmar, M. Marcel, R. Marc, Integration of real-time Ethernet in Linux CNC, Int. J.
Adv. Manuf. Technol. 78 (2015) 1837–1846, https://doi.org/10.1007/s00170-015-
6786-y.
[32] K. Langlois, T.van der Hoeven, D.R. Cianca, T. Verstraten, T. Bacek, B. Convens,
C. Rodriguez-Guerrero, V. Grosu, D. Lefeber, B. Vanderborght, Ethercat tutorial: an
introduction for real-time hardware communication on windows [Tutorial], IEEE
Robot. Autom. Mag. 25 (1) (2018) 22–122, https://doi.org/10.1109/MRA.2017.
2787224.
[33] R. Schlesinger, T. Sauter, A. Springer, Automatic packing mechanism for simplifi-
cation of the scheduling in Profinet IRT, IEEE Trans. Ind. Informat. 12 (5) (2016)
1822–1831, https://doi.org/10.1109/TII.2015.2509450.
[34] J.A. Maestro, P. Reviriego, Energy efficiency in industrial ethernet: the case of
powerlink, IEEE Trans. Ind. Electron. 57 (8) (2010) 2896–2903, https://doi.org/10.
11
Robotics and Computer Integrated Manufacturing 63 (2020) 101927
1109/TIE.2009.2036640.
[35] N.I. Aristova, Ethernet in industrial automation: overcoming obstacles, Autom.
Remote Control 77 (5) (2016) 881–894, https://doi.org/10.1134/
S0005117916050118.
[36] Georgi M.Martinov, Akram Al Khoury, Ahed Issa, An approach of developing low
cost ARM based CNC systems by controlling CAN drives, MATEC Web Conf. Volume
224, 2018, Proceedings of the International Conference on Modern Trends in
Manufacturing Technologies and Equipment (ICMTMTE 2018), Sevastopol, Russia,
2018, pp. 1–6, , https://doi.org/10.1051/matecconf/201822401020 September 10-
14, 2018.
[37] M. Holub, R. Jankovych, O. Andrs, Z. Kolibal, Capability assessment of CNC ma-
chining centres as measuring devices, Measur. J. Int. Measur. Confed 118 (2018)
52–60, https://doi.org/10.1016/j.measurement.2018.01.007.
[38] S. Grigoriev, G. Martinov, An approach to creation of terminal clients in cnc system,
Proceedings of the 3rd Russian-Pacific Conference on Computer Technology and
Applications, Vladivostok, 2018, pp. 1–4, , https://doi.org/10.1109/RPC.2018.
8482153.
[39] S.N. Grigoriev, G.M. Martinov, Scalable open cross-platform kernel of PCNC system
for multi-axis machine tool, Procedia CIRP 1 (2012) 238–243, https://doi.org/10.
1016/j.procir.2012.04.043.
[40] Roman Pushkov, Evgeniy Salamatin, Svetlana Evstafieva, Method of developing
parametric machine cycles for modern CNC systems using high-level language, In:
MATEC Web Conf. Volume 224, 2018, Proceedings of the International Conference
on Modern Trends in Manufacturing Technologies and Equipment (ICMTMTE
2018), Sevastopol, Russia, 2018, pp. 1–7, , https://doi.org/10.1051/matecconf/
201822401116 September 10-14, 2018.
[41] W. Zhong, X. Luo, W. Chang, F. Ding, Y. Cai, A real-time interpolator for parametric
curves, Int. J. Mach. Tools Manuf. 125 (2017) 133–145, https://doi.org/10.1016/j.
ijmachtools.2017.11.010.
[42] K. Yamanaka, H. Nakanishi, T. Ozeki, N. Nakajima, J. Farthing, G. Manduchi,
S. Urushidani, High-performance data transfer for full data replication between iter
and the remote experimentation centre, Fusion Eng. Des. 138 (2019) 202–209,
https://doi.org/10.1016/j.fusengdes.2018.10.030.
[43] S. Larsen, P. Sarangam, R. Huggahalli, S. Kulkarni, Architectural breakdown of end-
to-end latency in a TCP/IP network, Int. J. Parallel Program. 37 (6) (2009)
556–571, https://doi.org/10.1007/s10766-009-0109-6.
[44] W. Su, W. Liu, C. Chen, T. Chen, Cloud access control in multi-layer cloud networks,
Proceedings of the IEEE International Conference on Consumer Electronics, Taiwan,
Taipei, 2015, pp. 364–365, , https://doi.org/10.1109/ICCE-TW.2015.7216945.
[45] L. Martinova, A. Grigoryev, S. Sokolov, Diagnostics and forecasting of cutting tool
wear at CNC machines, Autom. Remote Control 73 (4) (2012) 742–749, https://doi.
org/10.1134/S0005117912040133.
[46] X.F. Liu, M.R. Shahriar, S.M.N. Al Sunny, M.C. Leu, L Hu, Cyber-physical manu-
facturing cloud: architecture, virtualization, communication, and testbed, J. Manuf.
Syst. 43 (2017) 352–364, https://doi.org/10.1016/j.jmsy.2017.04.004.
[47] K. Xing, S. Achiche, J.R.R. Mayer, Five-axis machine tools accuracy condition
monitoring based on volumetric errors and vector similarity measures, Int. J. Mach.
Tools Manuf. 138 (2018) 80–83, https://doi.org/10.1016/j.ijmachtools.2018.12.
002.
[48] M. Soori, B. Arezoo, M. Habibi, Tool deflection error of three-axis computer nu-
merical control milling machines, monitoring and minimizing by a virtual ma-
chining system, J. Manuf. Sci. Eng. 138 (8) (2016) 081005, , https://doi.org/10.
1115/1.4032393.
[49] G. Martinov, N. Kozak, Specialized numerical control system for five-axis planing
and milling center, Russian Eng. Res. 36 (3) (2016) 218–222, https://doi.org/10.
3103/S1068798X16030126.
[50] G.M. Martinov, P.A. Nikishechkin, A.S. Grigoriev, N. Yu, Chervonnova organizing
interaction of basic components in the CNC system Axioma control for integrating
new technologies and solutions, Autom. Remote Control, 80 (3) (2019) 584–591,
doi:10.1134/S0005117919030159.