COMPUTER AIDED MANUFACTURING

COMPUTER AIDED MANUFACTURING

MANUFACTURING PLANNING MANUFACTURING CONTROL
PLANNING & MANAGEMENT MANAGING & CONTROLLING PHYSICAL OPERATIONS IN
THE FACTORY

 COST ESTIMATION
 PROCESS CONTROL
 CAPP
 QUALITY CONTROL
 COMPUTERISED MACHINABILITY
 SHOP FLOOR CONTROL
DATA SYSTEMS

 COMPUTER ASSISTED NC PART  PROCESS MONITORING

PROGRAMMING

 COMPUTER AIDED LINE BALANCING

 PRODUCTION AND INVENTORY

PLANNING

DEVELOPMENT OF WORK STANDARDS

 WHEN TO GO FOR NC?

 FLEXIBILITY IN DESIGN AND PRODUCTION – HIGH

 PRODUCTIVITY – HIGH – 50%-75% CUTTING TIME(NC)

15% CUTTING TIME(CONV.)

 REPRODUCIBILITY - HIGH

 ACCURACY - HIGH

 INVENTORY INSPECTION - LESS

 BETTER MANAGEMENT CONTROL

 WHY TO GO FOR NC?

 COMPLEX JOBS AND GREATER VARIETY OF DESIGNS

 SMALL TO MEDIUM BATCH PRODUCTION

 100% INSPECTION JOBS

 SET UP TIME - HIGH

 HIGHER OPERATOR SKILLS

 BASIC COMPONENTS OF NC/CNC SYSTEM

Part program

Machine Control Unit

Machine Tool
 MACHINE CONTROL UNIT

DATA PROCESSING UNIT(DPU)

CONTROL LOOPS UNIT (CLU)

 HISTORICAL DEVELOPMENTS
NUMERICAL CONTROL

1950s – I GENERATION NC VACCUM TUBES, EM RELAYS,

HYDRAULIC SERVO SYSTEMS

CONTROL SYSTEMS UNRELIABLE,INACCURATE

1960s - II & III GENERATION NCs DIGITAL CKTs,TRANSISTORS,ICs

CONTROL SYSTEMS MORE COSTLY, LESS

SOPHISTICATED FUNCTIONS

LATE 1960s - IV GENERATION SYSTEMS

COMPUTER TECHNOLOGY, MICROPROCESSOR BASED

1970s DEDICATED COMPUTER AS CONTROLLER

1980s OPEN ARCHITECTURE CONTROLLERS

1990s FOR SENSOR BASED MACHINING,RAPID PROTOTYPING,

MFG.OVER INTERNET, AGILE MFG
 DATA PROCESSING UNIT(DPU)

FUNCTIONS

 READING & DECODING THE PART PROGRAM

 PROVIDING THE DECODED INSTRUCTIONS TO THE CONTROL LOOPS OF

THE MACHINE AXES OF MOTION

 ADVANCING THE TAPE/CONTROL EACH TIME THE PREVIOUS

INSTRUCTIONS WERE FULFILLED i.e. AT THE END OF EACH SEGMENT OF
THE PROGRAM.
 CONTROL LOOPS UNIT (CLU)

FUNCTIONS

 CONTROLLING THE DRIVES ATTACHED TO THE MACHINE LEAD SCREWS, AND

 RECEVING FEEDBACK SIGNALS ON THE ACTUAL POSITION, VELOCITY OF EACH

ONE OF THE AXES

 SENDING A SIGNAL BACK TO DPU THAT PREVIOUS SEGMENT IS COMPLETED

AND THAT DPU CAN READ A NEW SEGMENT OF THE PROGRAM
 CLASSIFICATIONS OF NC SYSTEMS

BASED ON TYPE OF TRAJECTORY CONTROL

 POINT TO POINT (PTP) CONTROL SYSTEMS

 STRAIGHT LINE CONTROL SYSTEMS
 CONTOURING CONTROL SYSTEMS
2D,2½ D, 3D OR MULTI-AXES CONTROL

BASED ON STRUCTURE OF CONTROLLER

 HARDWIRED (NC)
 SOFTWIRED (CNC)

BASED ON METHOD OF PROGRAMMING

 ABSOLUTE
 INCREMENTAL

BASED ON TYPE OF MOTION CONTROL

 OPEN LOOP
 CLOSED LOOP
 NC VERSUS CNC

NC CNC

HARDWIRED CONTROLLER SOFTWIRED CONTROLLER

RIGID & LIMITED FUNCTIONS FLEXIBLE & UPGRADABLE

ADVANTAGES OF CNC

– IMPROVED RELIABILITY IN PROGRAM ENTRY

– GREATER FLEXIBILITY – EASY TO UPGRADE WITH NEW SOFTWARE

– STORAGE OF MACROS, CUTTING SPEED, FEED DATA

– EASY TO MODIFY PART PROGRAMS

 FUNCTIONS OF CNC

1. MACHINE TOOL CONTRIOL

2. IN PROCESS COMPENSATION

3. IMPROVED PROGRAMMING & OPERATING FEATURE

• MDI OPERATION
• CONVERSATIONAL PROGRAMMING FEATURE

4. DIAGNOSTICS
• EASY MAINTENANCE
• FAIL SAFE OPERATION
 COMPUTER NUMERICAL CONTROL
CNC
SINGLE PROCESSOR MULTIPROCESSOR
(MULTI AXES CNCs)
DNC
NC CNC CNC WITH DNC
(TAPE CONTROL) W/O DNCPROTOCOL PROTOCOL
PARALLEL INTERFACE SERIAL INTERFACE SERIAL INTERFACE
(NC) (CNC)
 CNC SYSTEMS

BASIC TASKS PERFORMED BY MICRO-COMPUTER

- SYSTEM MANAGEMENT

- DATA INPUT/OUTPUT

- DATA CORRECTION

- CONTROL FOR NC PROGRAM EXECUTION

- PROCESSING OF OPERATOR COMMANDS

- OUTPUT OF NC PROCESS VARIABLES TO THE DISPLAY.

 TYPES OF CNC SYSTEMS

1. CNC with interpolator completely implemented in software

(Fast computational support for tool path calculation-

Multi-axis CNC machine tools with multi processor
architecture with dedicated CPU’s for calculation

2. CNC with software interpolator for coarse interpolation, fine interpolation by

software

3. CNC with no software interpolator. Interpolation completely by hardware. Little

flexibility. No real time speed problems (single CPU architecture)
 Software structure of a CNC system

Level I - Interpolator executes stepwise the CNC part

program (PSC) for each block, FP models are
referenced (path control).

Level II - Activates basic functional programs in a defined

sequence (BPF) (Axis control)

Level III - Post processor

Logic & Arithematic programs – Acquires the
process data & generates information for the
operator (or) DNC computer.
PART PROGRAMMING