Student: Dimache Cornel Dumitru Grupa 1628

Wood printing command

CNC Router Systems

The CNC Wood Router Basics

How it works A CNC wood router works almost the same as any other CNC machine. A CNC machine or a Computer Numerically Controlled system which uses computer software and CNC controller electronics to drive a mechanical system. Using this setup, it is possible to achieve far better accuracy and precision than a human operator. A traditional CNC router can move and cut in three directions which are usually referred to at the X, Y, and Z directions. The X-axis is usually the longest of the three running front to back. The Y-axis runs from left to right while the Z-axis runs up and down. Below you can see each axis labeled respectively. These machines are very efficient in that they work in all three directions in near perfect unison, giving this machine the capability of carving complex shapes.

The Components Lets identify the major components of these machines and see how they come together to make it all work. Below you can see a picture labeling the major components on a generic CNC wood router. There are many other components and additions available but most all routers have these components in common.

The CNC Controller and Computer System The CNC controller and computer system work together as the brain for these machines, telling the motors and drive system which direction to move and how far. Of course the computer must be given a design. Most designs start in a digital format such as a dxf drawing or some other similar format. The user would then use a CAM software package along with the CNC controller software provided. These types of software convert a 3D or 2D digital image into a tool path code such as G-code. The computer then converts these commands into a digital signal which it relays to the CNC controller which converts the digital signal to varying voltages and currents that control the mechanical drive systems. Most of this is far more than anyone operating a CNC wood router would need to know. It is usually plug and play. The user interface varies depending on the type or manufacturer, but the overall process is the same. You begin with a digital design and then use additional software to make tool paths for the machine to follow. The Spindle The spindle is the part of the machine doing the cutting. Think of it as the actual router, such as a standard wood router. The router spindle is classified by its power rating, horse power in English units and Watts in SI units. The spindle works bye rotating a cutting tool, such as router bits, at varying speeds. A typical spindle designed to cut wood plastics and other soft materials usually have a range of 8000 to 30,000 revolutions per minute. Spindles designed to cut metals operate between 2000 and 10,000 RPMs.

Most CNC wood routers are capable of cutting metals as well. However, it is usually limited to non ferrous metals such as aluminum. When cutting metals or carbon based composites at high spindle speeds, a coolant system that cools the material being cut and the tool itself is usually necessary. Some spindles are controlled via the CNC controller which regulates the RPM based on material and the feed rate of the machine. There are other options that may be installed as well, some of which include an automatic tool changer, tool sensor, and touch probe. The Cutting Bed The cutting bed is where all the action happens. The cutting bed may come in several different types but the function remains the same. The cutting bed is designed to support and secure the piece of material being cut. There are several different designs that do this effectively. Some of the most common cutting bed designs cutting bed designs are the T-slot, pictured above, and the vacuum table. The T-slot style table works well for most any part as it uses bolts and clamps to secure the piece to the bed. The vacuum table is found on many high end models and works well for companies cutting the same design several times a day. However, it is limited to relatively flat pieces such as wood and sheet material. The T-slot is more versatile in that is can hold virtually any piece but lacks in efficiency and speed of setup. There are many other types available, some are a hybrid mix employing both a Tslot and the vacuum design. However, these are the two primary types of cutting beds.

The Linear Drive Systems Each axis employs a linear drive system that moves the spindles in that axis. TheCNC linear drive system includes a motor, a linear bearing system, and some sort of lead screw assembly. The motor is the link between the mechanics and the electronics of the system. The motor receives its power via the CNC controller providing rotational power when needed to the lead screw assembly. There are two types of motors found on CNC wood router machines, which are stepper motors and servo motors. Steppers motors are the cheaper alternative and offer good performance and reliability but are usually not a closed loop system. Servo motors offer a closed loop system, which

means after receiving their directions from the CNC controller, they send a signal back to the controller that verifies they have completed the task. Closed loop systems are usually found on high end models. The type of controller depends on the type of motor. The controller for a stepper motor or a servo motor is not the same. The motor offers the power in the form of rotational motion which needs to be converted to linear motion. This is where the lead screw assembly takes over. Combined with a linear bearing assembly , the lead screw assembly moves the gantry or spindle along its axis. Different designs employ varying methods of converting rotational motion to linear motion and some are better than others. The most common are a lead screw and nut assembly, a ball screw and nut assembly, or a rack and pinion assembly. Each system has its own advantages and disadvantages but that information is too detailed for this section.

(1)The Linear Motion System Overview

A complete linear motion system is a combination of a drive system and linear bearing system. However in this section, this term is referring to the linear bearing assemblies and the associated parts. There is an entire section devoted to the CNC drive system. The term linear motion system will be called the LM system for simplicity. As stated before, the LM system is responsible for three primary tasks. 1) Support Machine Components 2) Guide the machine in a precise linear motion with minimal friction 3) Support secondary loads (Torque, Lateral Loads, etc)

Supporting Machine Components

The LM system must be able to handle the weight of the components while transporting it along a linear distance and maintaining linearity. For example, thegantry on a CNC router is supported on a LM system and is able to move along the X-axis. The LM system must support the weight of the gantry and still provide a low friction motion.

Providing Precise Linear Motion While supporting a load, the LM system must also provide a precise linear motion with minimal friction. This is the primary task of a LM system. The type of LM system directly related to the accuracy or a CNC router. A sloppy linear motion system leads to a sloppy CNC machine. That is why it is important to have the correct LM system installed on each axis. Supporting secondary Loads Aside from supporting the weight of the machine, LM systems must also be able to support secondary loads such as torque or lateral loads, depending on the setup. Some applications of LM systems require only one dimensional load ratings, such as supporting a vertical load like weight. Other applications require multi-dimensional load ratings. For example, the LM system of the Y-axis on a CNC router router is required to support the vertical loads caused by the weight of the Z-axis assemble, and also support torsion forces cause by the cutting action. We will cover more on load ratings in later sections. Every LM system is rated for certain loads and certain applications. Choosing or identifying the right system for your CNC router is a vital ability to have when buying or building. Categories of LM systems If you could categorize linear motion systems into 2 categories it would be: 1.) Fully Supported Systems 2.) Partially/End Supported Systems Fully supported LM systems are supported throughout the entire length of the system. This type of system can usually support more load without sacrificing linear precision due to deflection. A quality CNC router will have fully supported LM systems on all axes. Some mid or low range machines use fully supported systems on the X and Yaxis while using end supported systems on the Z-axis. As the length of an axis increases the more vital it is to have a fully supported system. Examples of these systems include linear rails and guide blocks as well as track rollers. Partially or end supported LM systems are just what they seam. These systems are supported on their ends. These systems are due to flex and deformation because of the machine weight or the forces applied. However, these systems are more suitable in some applications. The most common type of end supported LM system is the linear rod and bushing setup.

(2)CNC Motors
CNC motors are the heart of any CNC machine. The size and type of motor can define a CNC routers precision, speed, and accuracy. There are two primary classes of motors used on CNC machines, stepper motors and servo motors. Within these two classes there are several types. Stepper motors and servo motors both have their advantages and disadvantages which will be discussed in greater detail in later sections. The following sections will attempt to cover all aspects of the types of motors associated with CNC routers and other types of CNC machines. This section goes hand in hand with the CNC controller and Drive Components sections.

(2.a)CNC Motor Terminology

When reviewing specifications for CNC motors, there are a few terms that should be known to understand the information thoroughly. Most will have a sufficient understanding of these terms to cope but it never hurts to review.

RPM Probably the most recognizable term associated with motors is RPM or revolutions per minute. Simply enough, this term describes the rotational speed of a motor in revolutions per minute. Torque Torque describes the rotational strength of a motor. Torque is force times unit length such as oz-in., ft-lb., and N-m. When choosing a motor be sure to check the unites. Torque Speed Curves A torque-speed curve is a graphical chart representing the relation between a motors torque and RPM. This information is very helpful in judging the motors performance. Many sellers will quote a specific torque which is the maximum torque. With a torque curve you can estimate the torque at a given RPM. This is very helpful when designing your own machine as you can choose you gear ratio to get the best performance from your motor.

NEMA standards NEMA is an acronym for the National Electrical Manufacturers Association. Most of the time when reviewing the motor specifications, there will be a NEMA standard rating. This standard represents the motor frame size and shaft dimensions. The frame size defines the mounting face width and height and the size and position of the mounting holes. The shape and appearance may vary depending on manufacturer, even between motors with the same NEMA rating. The most common NEMA sizes for router tables are 8, 11, 14, 17, 23, 34, and 42. Lower NEMA ratings define smaller frame sizes. For more on NEMA standards such as charts, drawings, and suffixes; visit the NEMA standards page. The NEMA rating will give you general range of torque but has no direct relation to the motors performance. CNC motors with the same NEMA rating may have very different performance. Power rating A motors power rating refers to the voltage rating of the motor and the current per phase. Power which is measures in watts, is equal to the voltage multiplied by the current. The higher the power rating the higher the work output of a motor. It is important to know the power rating of a motor so a proper power supply can be used.

(2.b)Stepper vs Servo Motors

The following will attempt to justly compare stepper vs servo motors assuming the following: -The motors are of equal rated power -Both motors we are comparing are of same quality -Servo is equipped with an encoder -Stepper is not equipped with an encoder -The driver is assumed to provide the same features excluding feedback options -The Servo motors are of DC Brushed type

Stepper Vs. Servo Motors

Characteristi cs

Servo Motor (DC Brushed

Stepper (Hybrid)

Cost

This feature would have to go to The cost for a servo motor and stepper motors. Steppers are servo motor system is higher generally cheaper than servo than that of a stepper motor motors that have the same power system with equal power rating. rating. Stepper motors are also very versatile in their use for Servo motors are very versatile automation and CNC applications. in their use for automation and Because of their simplicity CNC applications. stepper motors may be found on anything from printers to clocks. This is a toss up because it depends on the environment and how well the motor is protected. Servo motors are availible in a wide variety of frame sizes, from small to large motors capable of running huge machines. Many of the motors come in NEMA standard sized. Servo motors require tuning of the (PID) closed loop variable circuit to obtain correct motor function. The brushes on servo motors must be replaced every 2000 hours of operation. Also encoders may need replacing. The stepper takes this category only because it does not require an encoder which may fail. Stepper motors do not have as many size selections as servo motors in the large sizes. However stepper motors may still be found in a variety of NEMA frame sizes. Stepper motors are almost plugand-play. They require only the motor wires to be wired to the stepper motor driver. The bearing on stepper motors are the only wearing parts. That gives stepper motors a slight edge on life.

Versatility

Reliability

Frame Sizes

Setup Complexity

Motor Life

Low Speed High Torque

Servo motors will do fine with low speed applications given Stepper motors provide most low friction and the correct gear torque at low speed (RPM). ratio Servo motors maintain their Stepper motors lose up to 80% of

High speed

High Torque

rated torque to about 90% of their no load RPM.

their maximum torque at 90% of their maximum RPM.

Because of the way stepper Servo motors can have very motors are constructed and good repeatability if setup Repeatability operate they have very good correctly. The encoder quality repeatability with little or no can also play into repeatability. tuning required. Overload Safety Servo motors may malfunction if overloaded mechanically. Stepper motors are unlikely to be damages by mechanical overload.

Power to Weight/Size ratio

Stepper motors are less efficient Servo motors have an excellent than servo motors which usually power to weight ratio given means a smaller power to their efficiency. weight/size ratio. Stepper motors consume a lot of power given their output, much of Servo motors are very efficient. which is converted to heat. Yielding 80-90% efficiency Stepper motors are usually about given light loads. 70% efficient but this has some to do with the stepper driver. Stepper motors usually have 1.8 or 0.9 degree resolution. However thanks to micro-stepping steppers can obtain higher resolutions. This is up to the driver and not the motor. Stepper motors are also capable of accelerating loads but not as well as servo motors. Stepper motors may stall and skip steps if the motor is not powerful enough. Stepper motors draw excess current regardless of load. The excess power is dissipated as heat.

Efficiency

Flexibility in motor resolution

Since the encoder on a servo motor determines the motor resolution servos have a wide range of resolutions available.

Torque to Servo motors are very capable Inertia Ratio of accelerating loads.

Least Heat production

Since the current draw of a servo motor is proportional to the load applied, heat production is very low.

Reserve

A servo motor can supply about Stepper motors do not have

Power and Torque

200% of the continuous power for short periods.

reserve power. However stepper motors can brake very well.

Noise

Stepper motors produce a slight Servo motors produce very little hum due to the control process. noise. However a high quality driver will decrease the noise level. Stepper motors vibrate slightly and have some resonance issues because of how the stepper motor operates.

Resonance and Vibration

Servo motors do not vibrate or have resonance issues.

Availability

Servo motors are not as readily Stepper motors are far easier to available to the masses as are find than quality servo motors. stepper motors. Servo motors are more mechanically complex due to their internal parts and the external encoders. Servo motors usually require more gearing ratios due to their high RPM. It is very rare to see a direct drive servo motor setup. Stepper motors are very simple in design with no designed consumable parts. Stepper motors will work fine in direct drive mode. Many people simple use a motor couple and attach the motor shaft directly to the leadscrew or ballscrew.

Motor Simplicity

Direct Drive Capability

Because servo motors are The power availability range for available in DC and AC servo Power Range stepper motors is not that of motors have a very wide power servo motors. availability range.

(3)The CNC Router Table Top

The CNC router table top is where the cutting magic happens. The table top, also called the cutting bed, can make the life of a CNC router operator enjoyable or a nightmare.

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For example, if you are in the prototyping business, you will probably be working with all kinds of materials and shapes. This would probably push you towards a T-slot style, which offers numerous clamping options. On the other hand, you might produce the same type of product on a daily basis which would push you towards a different style. On higher end CNC router router tables now days, you may find a combination of different types of cutting table tops. However, it is best to be knowledgeable about what kind of CNC router table will be best for you. If you are building your own CNC router , your options are limited unless your budget allows. However, there is still a lot of material to be covered regarding the cutting board. This information should be very helpful to your design. The T-Slot table top The T-slot table is often seen on traditional CNC milling machines. However, these are usually made of tooling steel and are extremely heavy. The T-slot tables found on CNC routers are usually made of extruded aluminum. There are many advantages to the Tslot type table. The Vacuum table top The vacuum style CNC router table top is often found on higher end models. They can be very useful for many applications. However, there are drawbacks. The Perforated table top Similar to the vacuum table in appearance, the perforated table top is simple yet affective. Much cheaper than a T-slot style bed, yet offers similar performance. The "Disposable" table top The "The "Disposable" table top is actually one of my favorites. Especially if you are new to operating a CNC router. This table style, usually composed of one or two sheets of high density MDF board, are very useful even if you have some other table top installed. I can't tell you how awful it makes you feel when you cut into your brand new t-slot or vacuum table. Yes I know there are limit switches, touch off pad and sensors to prevent that type of mistake. However, you would be surprised at how often we "bypass" those features.

(4)The CNC Controller

The CNC controller is the brain of a CNC system. A controller completes the all important link between a computer system and the mechanical components of a CNC machine. The controller's primary task is to receive conditioned signals from a computer or indexer and interpret those signals into mechanical motion through motor output. There are several components that make up a controller and each component works in unison to produce the desired motor movement.

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The word controller is a generic term that may refer to one of several devices, but usually refers to the complete machine control system. This system may include the protection circuitry, stepper or servo motor drivers, power source, limit switch interfaces, power controls, and other peripherals. Owners, operators, designers, and builders of CNC devices should understand the tasks performed by these components and how they affect machine performance. The following sections will discuss the primary task of each component in the controller and how they work together to create a complete CNC system.

(4.a)The CNC controller History Past to Present

CNC controller History

Numerically Controlled (NC) machines were introduced in the late 1940s and early 1950s and were used for all machine control and data processing before the advent of microprocessors or computers. Computerized Numerically Controlled (CNC) controllers are sometimes still refereed to as NC controllers. An NC controller receives a set of sequenced instructions, the program, consisting of alphanumeric characters. The controller then uses this set of instructions to direct the motions of a machine tool such as a milling machine, lathe, plasma cutter and of course router, much like the controllers today. In the past the program was edited and programmed with the very basic computers of the time. The program would then be transported to the controller via a tape. This permitted the program instructions to be read by the controller's tape reader only once and then stored in the controller's memory. Magnetic tape recorders and floppy disk drives were also being used for program recording and storage. There were no direct links between the computer and controller on early systems.

In the past the program was edited and programmed with the very basic computers of the time. The program would then be transported to the controller via a tape. This permitted the program instructions to be read by the controller's tape reader only once and then stored in the controller's memory. Magnetic tape recorders and floppy disk drives were also being used for program recording and storage. There were no direct links between the computer and controller on early systems.

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Debugging an N/C program before the advent of the computerized NC required making a new tape, trying out the new tape, finding the next error, making another tape, and so on. The process of debugging a new program could require making a dozen or more punched tapes until an error free program was achieved. Engineering changes required a new tape to be made and debugged. Modern Controllers Today, with the use of powerful microprocessors and computer systems, the NC controller now communicated directly to a computer system with a real time link. This is the CNC controller that is standard today. The controllers today do far more than drive motors. Some controller systems have the capabilities to control spindle speeds, coolant flow, and other peripherals. Modern controllers still require operators to create a program for the controller to follow. Operators today receive help from Software such as Computer-Aided Design (CAD) packages and Computer-Aided Manufacturing (CAM) software along with the controller software to create the necessary numerical code such as G-code. The CNC controllers today range from professional standalone systems, with their own keyboard and user interface, to hobby CNC controllers that require a personal computer. In the next section, CNC Controller Components, the breakdown of the CNC controller components and their function will be discussed.

(4.b)The CNC Controller Components

The CNC controller components work together to interpret positioning signals created by a computer and NC software into precise motor control. This page will explain the function of each of the controller components and how they work together to make a controller system. The Components There are three primary CNC controller components that make up a CNC controller, the power supply unit, the circuitry protection system, and the motor driver. The Power Supply Unit When you plug a small flash drive up to your USB port, the computer powers the device through the port. When you plug a larger device, say a printer for example, you have to use an external power source because the computer is not capable of supplying sufficient power. This condition means that you have to plug that device into the computer as usual, but you also have to plug a second line to an auxiliary power source, such as the 110V outlet on your wall.

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The same conditions are true for CNC devices. They require a low-voltage communication line, through which the computer tells the machine what to do, and a power source that provides the power for moving, cutting, and other such operations. A power converter, usually referred to as the power supply unit (PSU), is often used to change the form of the supplied power from alternating current (AC) from the power grid, to direct current (DC) that is more easily used by the machines drive motors. The power supply handles large voltages and currents that could be harmful to the NC circuitry. Therefore, the power source, motor drivers, and motors are often separated from the computer with a circuitry protection system that isolates surges in electrical power.

The Circuitry Protection System The circuitry protection system contains a breakout board to isolate signals from the computer, distribute the signals to the desired drivers, and also allows easy hook up of peripherals such as limit switches that feed information back to the computer. Fuses are also part of the circuitry protection system. Fuses could save the equipment in case of electrical spikes, shorts, or faulty wiring. A low-voltage communication signal passes from the computer through the breakout board unchanged to the motor drivers. This isolated your computer from the CNC controller circuit but allows the signals to carry through to your motor drivers. The motor drivers The motor drivers receives the communication signal and and then coordinates pulses of the desired current and voltage to elicit the movement in the drive motors. The motor drivers may communicate position information one way to the motor (open loop system), or send and receive position information(closed loop system), depending on the users choice of drive system. More on these systems may be found in the drivers sections. CNC Controller Components Setup The figure below shows the typical setup of the CNC controller components, such as that for a 3 axis CNC router. The system is composed of a computer with NC control software, the controller box, and the drive motors. The controller box includes a breakout board, power source (not shown), and motor drivers. The breakout board provides the circuitry protection and signal distribution inside the controller box.

In the figure above, you can see the computer is connected to the breakout board,

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usually through the printer port (DB25). There are many types of breakout boards; some of very high quality and great protection, and lower budget options that do not offer much protection. The best models employ opto-isolators, which use a light signals to transmit data across an air gap. These devices provide complete conductive isolation between the controller circuit and your computer. As a note, the computer is fully capable of connecting directly to the drivers and driving the motors, but this setup puts your computer at risk. The first figure is an idealized block diagram of your CNC electrical system. A little more detail has been added in the figure below to show the conceptual layout of signal wires (light black) and power wires (heavy black).

Although your computer will run on 110VAC, the CNC machine may run on 110VAC, or 220VAC, or 480VAC, and may be single phase, three phase, etc This power enters the controller box and will be distributed by the power supply. For most machines, the power supply will convert the incoming power from alternating current (AC) to direct current (DC). This DC supply will be of a lower voltage, such as 12V, 24V, 36V, or higher. The power supplied depends on you CNC controller components, specifically the motor drivers.

The "Signals" The signal lines coming from the computer operate on 5V DC supplied by the computer communication port, and is a square wave form called a Transistor-to-Transistor Logic (TTL) signal. This signal is essentially a series of small pulses from 0V to +5V that

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represent 0s and 1s in a binary computer language. This signal is a form of a PulseWidth Modulated (PWM) signal where the length of the pulse is varied to indicate information. The width of the pulse determines the binary code sent; either a 0 or a 1 as communicated by the computer and interpreted by the motor driver. More on the signals may be found in the signals page. The signal from the computer to the breakout board is the same as that from the breakout board to the motor driver. Remember, the breakout board provides circuit protection and signal distribution. Therefore, the signal coming out of the breakout board is also a 5V TTL signal of the same form. However, as discussed previously, the signal after the driver has been conditioned as needed to provide the large move voltage and current needed to drive the machine

Summary of CNC Controller Components The computer generates the signal which passes through the breakout board. The motor drivers and limits switches hook up to the breakout board. The power supply unit provides the correct voltage and current required by the motor drivers and the motors. The motor drivers receive the position signals from the breakout board and supplies the correct power to the motors to make them rotate to the correct positions.

(5)Calculators and Charts

http://www.cncroutersource.com/calculators-and-charts.html#
Critical Angular Speed Calculator Linear Speed Calculator

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Pitch and Lead Calculator Lead Screw Efficiency Estimator Total Lead Accuracy (Inch) Lead Screw Life Estimator(Metric) Lead Screw Life Estimator (Inch) Column Stregnth Calculator (lb) Linear Force Calculator (lb) Linear Resolution (inch) Forces of Acceleration, Friction, and, External (inch) Find the minimum recomended lead screw diameter (compression) (inch)

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