Evaluation of CNC Controllers in MillingMachines-Relationship Between Dynamic

Capability, Productivity and Cost-Edición Única

Title Evaluation of CNC Controllers in Milling Machines-RelationshipBetween Dynamic Capability, Productivity and Cost-Edición Única

Issue Date 2005-12-01

Publisher Instituto Tecnológico y de Estudios Superiores de Monterrey

Item Type Tesis de maestría

Downloaded 25/05/2018 11:33:37

Link to Item http://hdl.handle.net/11285/567191

INSTITUTO TECNOLÓGICO Y DE ESTUDIOSSUPERIORES DE MONTERREY

CAMPUS MONTERREY

DIVISIÓN DE INGENIERÍA Y ARQUITECTURAPROGRAMA DE GRADUADOS EN INGENIERÍA

ff TECNOLÓGICO

DE MONTERREY

EVALUATION OF CNC CONTROLLERS IN MILLINGMACHINES - RELATIONSHIP BETWEEN DYNAMIC

CAPABILITY, PRODUCTIVITY AND COST

TESIS

PRESENTADA COMO REQUISITO PARCIALPARA OBTENER EL GRADO ACADÉMICO DE:

MAESTRO EN CIENCIASCON ESPECIALIDAD EN SISTEMAS DE MANUFACTURA

POR:FERNANDO DAVID REYES LUNA

MONTERREY, N.L. JUNIO DE 2005

INSTITUTO TECNOLÓGICO Y DE ESTUDIOSSUPERIORES DE MONTERREY

CAMPUS MONTERREY

DIVISIÓN DE INGENIERÍA Y ARQUITECTURAPROGRAMA DE GRADUADOS EN INGENIERÍA

Los miembros del Comité de tesis recomendamos que la presente Tesis del Ing.

Fernando David Reyes Luna sea aceptada como requisito parcial para obtener el grado

académico de Maestro en Ciencias con especialidad en:

SISTEMAS DE MANUFACTURA

COMITÉ DE TESIS

Dr. Ciro A. Rodríguez GonzálezASESOR

Dr. Horacio Ahuett Garza Dr. Nicolás Hendrichs TroeglenSINODAL SINODAL

APROBADO

Dr. Federico Viramontes BrownDirector del Programa de Graduados en Ingeniería

Junio de 2005

DEDICATORIA

A mis padres Claudio y Aracely,

por su apoyo incondicional, confianza y cariño

pero sobre todo por ser el ejemplo de mi vida.

A mis hermanas Claudia y Pochi,

a mi familia y amigos

por siempre creer en mi.

ni

AGRADECIMIENTOS

A mi asesor, el Dr. Ciro A. Rodríguez González, por su guía, buenos consejos y

sobre todo paciencia durante la realización de esta tesis.

A mis sinodales, el Dr. Horacio Ahuett Garza y el Dr. Nicoás Hendrichs Troeglen

por su participación en el comité de tesis y por sus atinados comentarios y sugerencias.

Al Ing. Miguel de Jesús Ramírez por su apoyo, motivación y confianza, pero

sobre todo su amistad.

Al Departamento de Ingeniería Mecánica del ITESM, por el apoyo de beca

brindado para la realización de mi maestría.

A la Cátedra de Investigación en Mecatrónica del ITESM, por financiar parte de

mi colegiatura.

A mis compañeros de estudio y trabajo: Eva Delgadillo, Victor Flores, Alejandro

Martínez, Francisco Jasso, Esteban Suárez, y Gabriel Soto, por su amistad y apoyo.

IV

LIST OF FIGURES

Figure 1. Example of machine tools with different price ranges and their cost drivers 1

Figure 2. Machine tool cost tends for productivity and capability [Adapted form Amone; 1998]. 2

Figure 3. Controller architectures for different markets 6

Figure 4. Three level classification scheme for controllers, actuators and mechanism 7

Figure 5. Block processing times and prices of different controllers 8

Figure 6. Different motor types with their corresponding drives 9

Figure 7. Balls Screws accuracy performance for three levéis 10

Figure 8. Different bearing systems with their corresponding friction valúes 11

Figure 9. Taxonomy of VKM3 and VM16 machines 11

Figure 10. Application requirement comparison between VKM3 and VM 16 12

Figure 11. Method summary ,evaluation procedures for different performance indexes 14

Figure 12. Method Summary, relative valué evaluation 15

Figure 13. Controller productivity and quality based on certain application requirement 16

Figure 14. General evaluation procedures for productivity and capability quantification 17

Figure 15. Ishikawa diagrams for productivity and dynamic capability 17

Figure 16. Block definition 18

Figure 17. Block processing time capability experiment of three different total length lines 19

Figure 18. Heidenhain KGM-181 grid encoder Set Up 21

Figure 19. Contour error graph of Milltronics VKM3 at 4000mm/min 22

Figure 20. Velocity profile at4000mm/min of Milltronics VM16 machine 23

Figure 21. Acceleration profile at 4000mm/min of Milltronics VM16 machine 23

Figure 22. Percentage representation for productivity and dynamic capability 24

Figure 23. CNC controllers technologies architecture 25

Figure 24. Relationship between controller cost and machine attributes (performance index) 26

Figure 25. Application of Hurón KX-10 with a Siemens 840D controller 27

Figure 26. 3-D straight line processing times 28

Figure 27. Block per second for a 3-D straight line 28

Figure 28. 2-D straight line processing times 29

Figure 29. Bocks per seconds for a 2-D straight line 29

Figure 30. 1-D straight line processing time 30

Figure 31. Blocks per second for a 1-D straight line 30

Vil

Figure 32. Average feedrates for different Siemens controllers 31

Figure 33. Processing times for Siemens 802C, 802D, and 840D and their corresponding cost.. 32

Figure 34. Relative valué of different Siemens controllers technologies 32

Figure 35. Application of Milltronics VM16 with centurión VII controller 33

Figure 36. Average contour error comparison on VM16 for different programmed feedrates.... 34

Figure 37. Average feedrate comparison on VM16 for different programmed feedrates 34

Figure 38. Dynamic capability and productivity representation for DNC control option 35

Figure 39. UNC reference architecture 39

vin

CONTENTS

CONTENTS v

LIST OF FIGURES vii

LISTOFTABLES ix

LISTOFSIMBOLS x

GLOSSARY xi

SUMMARY xii

1. INTRODUCTION 1

1.1. Related Work 2

1.2 Motivation 5

2. TAXONOMY OF MACHINES 7

2.1 Controllers 8

2.2 Actuators 9

2.3 Mechanisms 9

3. METHODOLOGY 14

3.1 STEP I. APPLICATION 15

3.2 STEP ü. PERFORMANCE EVALUATION PROCEDURES 16

3.3 STEP El. TAXONOMY OF MACHINES 25

3.4 STEP IV. RELATIVE VALUÉ EVALUATION 25

4. EXPERIMENTAL RESULTS 27

4.1 CASE STUDY 1 27

4.2 CASE STUDY II 33

5. DISCUSSION 37

5.1 Machine tool selection and configuration 37

5.2 Machine tool development 38

6. CONCLUSIONS 40

6.1. Contributions 41

6.2 Future work 41

7.REFERENCES 42

APPENDIX A.- CNC Design 45

APPENDIX B.- Literature Review 48

APPENDIX C- Controller Specifications 53

APPENDIX D.- Actuator Specifications 79

APPENDIX E.- Drive Train Mechanisms Specifications 90

APPENDIX F.- Case Study I Results 101

APPENDIX G. - Case Study II Results 104

APPENDIX H.- UNC proposed scheme for connecting to Milltronics VKM3 118

VI

LIST OF TABLES

Table 1. Literature review of related work 4

Table 2. VKM3 and VM16 general comparison 13

Table 3. Software implemented algorithm classification 21

Table 4. Relative Valué of DNC control options 36

IX

LIST OF SIMBOLS

am (mm/s2) Axis Acceleration

c ($ USD) Controller Cost

Cs ( % ) Static Capability

Cd ( % ) Dynamic Capability

e (mm) Contour Error

ea (mm) Average Contour Error

d (mm) Cumulative Distance

Is (mm) Programmed Line Segment

P ( % ) Productivity

Pt (s) Processing Time

Ptv ($ USD/ms) Processing Time Relative Valué

t (s) Cumulative time

ta (s) Actual Cycle time

Vfp (mm/min) Programmed Feedrate

Vfa (mm/min) Actual Average Feedrate

GLOSSARY

ASME.- American Society of Mechanical Engineers

BPS.- Blocks per second.

CAM.- Computer Aided Manufacturing

CNC- Computer numerical control.

CL.- Control law

DSP.- Digital Signal Processor.

Feedforward.- Feedforward tracking control algorithm.

H.- High cost level

ISO.- International Standards Organization.

JIS.- Japanese Industrial Standard.

L.- Low cost level

Look-Ahead.- Look-Ahead control option for high speed milling.

M.- Médium cost level

PCI.- Peripheral Component Interconnect

PG.- Profile generation.

TG.- Trajectory generation.

UNC- Universal numerical control.

XI

SUMMARY

CNC controllers play a key role in the selection and configuration of a specific

milling machine tool. CNC controller technologies understanding and evaluation is

important in order to take reliable decisions for a required application selection or

configuration. This thesis presents a structured methodology for evaluating CNC

controllers in terms of dynamic capability, productivity, and a relative cost valué for

different performance indexes. Performance evaluation procedures are presented to

quantify different performance indexes for CNC technologies or CNC controllers

characteristics based on dynamic measurements. A qualitative scheme for different

machine tool taxonomies associated with each CNC technology is classified for three

markets to establish a technology cost reference. Experimental results using the proposed

methodology are presented for two case studies.

Xll

1. INTRODUCTION

Modern machine tools such as milling machines and machining centers are

complex mechatronic systems that intégrate mechanical components (structure, columns,

linear bearing systems, etc), electromechanical actuators (spindle, servomotors, servo

amplifiers, etc), and computer numerical controllers (CNC). The complete mechatronic

system has an overall performance that directly depends on the individual component

performance and interaction among components. Based on this integration, there are

many types of milling machines and machining centers that provide a wide range of

performance and prices (see Figure 1). Specifically, the computer numerical control,

whose principal function is to control the feed drive mechanism (see APPENDIX A for

more information), can be considered as the "brain" of the entire system and plays a key

role in the selection or configuration of a specific machine tool.

$ "0KUSD

S20KUSD

MANUFACTURENPRODUCT

MACHINE TOOLCOST DRIVERS•Spindle type andorientation•Number of axis•Size•Accuracy andrepeatability•Control type

S200KUSD

Figure 1. Example of machine tools with different price ranges and their cost drivers.

Machine tool selection is a complicated task due to the wide range of

characteristics to be considered. Previous studies [Bacre;2005] show that spindle type

and orientation, number of axis, size, static capability, and control type are the main cost

drivers on machine tool selection. Based on the product or the application, final users

seek attributes such as capabilities, productivity and most important cost, in order to

select an appropriate machine [Arslan; 2004]. Figure 2, shows how the cost increases for

higher productivity and capabilities demands for a given set of machine tool driver. In a

general scheme, capability can be measured with two performance indexes: quasi static

or dynamic performance [Amone; 1998], and productivity with cycle time, or average

feedrate [Shuett; 1996]. From the cost drivers, the focus of this work is concentrated on

controller technology, where the required performance index is dynamic capability.

Productivity.

/ \Production \

\

Molds

• = machines

MACHINE TOOLCOST DRIVERS

•Spindle type andorientation•Number of axis•Size•Accuracy andrepeatability•Control type

Capability

/ \Quasi *Static Dynamic

Figure 2. Machine tool cost tends for productivity and capability [Adapted form Arnone; 1998].

1.1. Related Work

In order to increase dynamic capability of milling machines, much research has

been done in developing new controls algorithms, for reducing contour errors at high

speed interpolation speeds [Altintas; 2001a], [Tomizuka; 2001], [Koren;1997]. In recent

years significant amount of effort has been put into developing more efficient profile

generation and trajectory planning algorithms that provide smooth feed motion to

increase productivity [Lambretchs; 2005] [Yang; 2004] [Altintas; 2001]. These

investigations focus just on the design of the CNC controller algorithms, and have been

tested with dynamic measurements on specific machine hardware.

Productivity of CNC machines integrating the complete machining process has

been widely studied by several authors [Rodríguez; 2003] [Monreal; 2003]. Other studies

and publications evaluated both dynamic capability and productivity comparing several

machines. These studies evaluated the productivity in terms of cycle time and dynamic

capability in terms of contour error for different machines, with different CNC controls,

changing control parameters [Ortega; 2004] [Hascoét; 2003]. The controller was not

considered as the main element of the overall dynamic performance. For more

information about some reference articles mentioned abo ve see APPENDIX B.

These related work (see Table 1) evaluated machine tool attributes like

productivity, capability or both, from different points of view. From the controller design

point of view, capability and productivity attributes are evaluated by imposing new

control and profile generation algorithms respectively. From machine tool comparison

point of view, capability and productivity attributes are evaluated for different machine

tools taxonomies.

From all the points of views the controller plays a key role in the evaluation of

machine tools. The controller can not be evaluated alone without considering the whole

mechatronic system and the whole machining processes, because productivity and

capability depends on other mechatronic components and also on the required application

(product) respectively.

[Altintas; 2001]

[Amone; 1998]

[Hascoét; 2003]

[Lambrechts;2005]

[Ortega; 2004]

[Schuett, 1996]

[Tomizuka;2001]

[Yang; 2004]

[Reyes; 2005]

PRODUCTIVITY

Model/Evaluation

s

s

AlgorithmDesign

s

s

CAPABILITY

Model/Evaluation

s

s

AlgorithmDesign

COST ANALYSIS

Jerk limitedtrajectorygeneration.Contouringcontrol of feeddrives.MachineEvaluation, Staticaccuracy,Dynamicperformance.Qualification ofparallelkinematicsmachines.Trajectoryplanning, andfeedforwarddesign.Contour errorevaluation,relationshipbetweenaccuracy andproductivity.Look-ahead,accurate control,processortechnology.Contouringcontrol ofmachine toolfeed drivesystems.Parametricinterpolator witha real timejerk-limitedaccelerationEvaluation ofCNC controllersconsidering costrelationship

Table 1. Literature review of related work.

Based on the reviewed related work there is not a specific methodology or

standard for CNC controller evaluation. Table 1 also shows that [Amone; 1998] is the

only one that considered cost, but none of the presented related work considered the term

cost in relationship with the evaluated attributes which is what the final user seeks for

The information provided by most manufacturers in their brochures only qualifies

positional accuracy, CNC block processing rates, and axis feedrates [Amone; 1998]. On

the other hand the standards ISO 230-2 and JIS B6201, evalúate positioning accuracy and

repeatability to qualify the entire machine tool by quasi static measurements. This study

aims at complementing the related work by developing a standard methodology that

integrates all the required elements for a consistent and reliable CNC controller

technology evaluation.

1.2 Motivation

CNC controller type represents an important cost driver in the selection of a specific

machine. There is an industrial need for adequate tools to configure and selected the

optimal machine tool for a specific application. Performance indexes such as average

feedrate or dynamic capability are directly related with the CNC controller design and

need to be tested to evalúate the real valué of different CNC controller technologies. Also

there is a need to clearly define some performance indexes that are commonly used in

industry.

1.3 Objective

The objective of this work is to evalúate the impact of different CNC technologies

in terms of productivity, dynamic capability, and cost. Three different markets have be

taken in consideration (see Figure 3):

• Low cost controller.- Motion control is performed in software by a personal

computer. A PCI board is the main communication hardware.

• Médium cost controller.- Motion control is performed by a Digital Signal

Processor (DSP).

• High cost controller.- Specialized hardware for each component of motion

control.

Controller ArchitectureSOFTWARE

Computer - > CNC. TG, PG,CL.

PCI, I/O Board

(a) HARDWARE

SOFTWAREReal Time Master procesingUnit, TG. PG, CL. TG, PG, CL

PCI. DSP CPU

(b) HARDWARE

SOFTWAREDNC, PLC's

Computer - > CNC. TG. PG, CL.communication task PLC's.

(c) HARDWARE

Figure 3. Controller architectures for different markets

2. TAXONOMY OF MACHINES

Machine tool configuration becomes a more difficult task because of the great

variety of components of the mechatronic system. Based on commercially available

machines and preliminary testing, a three level classification scheme (see Figure 4) is

proposed in order to group machines with similar cost, performance and capabilities:

• Low cost level.- low cost retrofitted machines were cost ís the most important

factor to consider is an example of this level. The controller and actuators are

from different brands.

• Médium cost level.- Milling machines and machine centers, where the machine

and the control are from the same brand.

• High cost level.- Machine center have a specialized controller, where the

controller and actuators are from the same brand.

Controllers

Conventionalmachine

CNU ] ^ n =A/IWA i ^ ^ P i ^~~~

Siemens: ^ ^ B L____

Actuators

£> ^ ^ k i L"

Mechanisms

—^ rV)

— • V

> 1 MI |

Figure 4. Three level classification scheme for controllers, actuators and mechanism.

Taxonomy of machines was proposed to distinguish controllers, actuators and

mechanism elements in order to establish a technology cost reference. This taxonomy

also establishes a reference of some performance indexes of different controllers,

actuators and mechanism elements in the proposed three level classification scheme. A

configuration scheme can be build from the cost and performance index reference.

2.1 Controllers

Many controller manufactures specify hardware capabilities in terms of CPU

speeds, other in terms of block processing time as shown in Figure 5. Unfortunately, like

positional accuracy, interpreting published blocks per second (BPS) valúes is not

straightforward and some manufactures do not necessary refer to the same thing when

they refer to this metric [Amone; 1998]. Valúes in parenthesis correspond to published

BPS valúes. For example 600 BPS, correspond to a block processing time of 1.6 ms, and

that processing time can be achieved by a high cost controller (for more information of

controller brochures and prices see appendix C.

•

•

•System

architecture

PCI Board

32 Bit-processor<256 Kb

32 Bit Processor16-32 Mb

32 Bit processor>128Mb

Blockproccesingtime(ms)

40-24-12**(600 bps)

6 ms-4ms**(1200bsp)

3.6 ms-0.5 ms**(>1200 bps)

PRICE($ USD)

<4000

4000 - 6000

6000- 9000

>10000

Figure 5. Block processing times and prices of different controllers.

2.2 Actuators

Low cost actuators (in this work the actuators are referred as the motors and

motors drives) such as stepper motors are generally used in low cost retrofitted machines,

for a point to point control scheme. DC motors are also used for low cost retrofitted

machines when speed control is required. In such systems an encoder and tachometer are

required for contouring applications. The big difference between pnces can be seen on

drives technologies (see Figure 6). In a médium to high range cost of actuators, the servo

motor drive generally is from the same brand of the motor. AC servo motors are

commonly used in most machine tools. In a high level cost, the controller, AC servo

motor and the drive are generally from the same brand (quotations and specifications for

some brands are presented in APPENDIX D).

Motors

Stepper motorsmDC Servomotors

AC Servomotors

AC Servomotors

Price

($ USD)

300 - 700

1000-1200

900 - 2000

900 - 2000

Drives

I

Description

PWM 20 KHz

PWM 20 - 30KHz

Microprocessorcontroller PWM400Hz speedloop frequency

>1000Hz speedloop frequency

Price($ USD)

<500

700-1000

1500-4000

>10000

Figure 6. Different motor types with their corresponding drives.

2.3 Mechanisms

The influence of the drive train mechanism over the CNC controller performance

is very difficult to quantify. As shown in Figure 7 ball screw accuracy vanes for

different cost levéis. Grounded ball screws are commonly used in mid-seized vertical

machines with C5 accuracy grade [Amone; 1998]. Nut technology is important factor for

high speed performance (ball screws producís and accuracy grades are presented in

APPENDIX E).

M )

Ball Screw Description

Acmé screw

Balls screw O.OO1in/ft {25um/300mm)

Ground ball screw 0.0005 ¡n/ft(12.5um/300mrn)C5=18um/300mm (0.00072¡n/ft)

C1= 5um/300mm (0.0002 ¡n/ft)C3 = 8um/300mm (0.00032in/ft)C5=18um/300mm (0.00072¡n/ft)

Nut / yoke

ftí35»

<

^V. Bal tae* fat H&

i.i*H« bJl " * - . * ) : rOOM

<Í..*5 *> te sí< »

Figure 7. Balls Screws accuracy performance for three levéis

The linear bearing system is one of the more critical aspects of machine tools

design. Solid ways, (commonly referred as hardened ground ways) are used in low to

médium cost machines range. Low friction pads, made from Diamant, or Turcite are

commonly used [Amone; 1998]. Rolling element bearings have about 80% less friction

resistance than solid ways (see Figure 8). Roller element bearings are constructed with

balls or rollers. Rollers have higher load capacities than balls. (Linear bearing systems

brochures are presented in APPENDIX E).

10

Linear Bearingsystems

Description

Solid ways. (Turcite)Friction (0.2-0.02)

Ball type wayFriction(0.002-0.003)

Roller type wayFriction (0.001 -0.0025)

Figure 8. Different bearing systems with their corresponding friction valúes.

This taxonomy does not include spindle technology. Its consideration is

important not only for taxonomy but for CNC control technology evaluation because

CNC controller technology towards better control of spindle torque and speed is under

constant development by several authors in order to increase productivity.

Example of different machine tools taxonomies

An example of two machines with the same controller and actuators is presented

in Figure 9. The objective of this example is to show two different machine tools

taxonomies and the effect of the drive train mechanisms over quasi static measurements.

Controller Actuators Mechanisms

3O

VKM3

M VM16

Figure 9. Taxonomy of VKM3 and VM16 machines.

11

The application of Milltronics VKM3 and VM16 are very different (see Figure

10). Milltronics VKM3 is a small vertical knee machine that is used for production. The

price of this machine is around US$ 25,000. Milltronics VM16 is a linear way machine

center that is designed for molds manufacturing. The price of VM16 is around US$

70,000. Both machines have the same controller, but for VM16 a software package can

be purchase for feedforward and look-ahead for high speed machining.

CONTROLLER

«TUATORS

MECHAIIISMS

PtoJu

#

•trvrty

• |

SBfl f iProdu ¿1 rvrf y

Figure 10. Application requirement comparison between VKM3 and VM16.

Milltronics VKM3 and VM16 are compared in Table 2. VKM3 (30"xl5"x5.35")

and VM16 (30"xl6"x20") have very different volumes valúes but the table travel área of

both machines is similar. Notice that both machines have the same Yaskawa motors and

servo amplifiers, but VM16 can raise higher feedrates. Higher feedrates valúes

(máximum feedrate and rapid movements) for VM16 are almost twice from VKM 3

because of the Balls Screw pitch lead. Both balls screws have the same diameters, but

VM16 has a damped coupling.

12

The significant difference in drive train technologies can be seen on the linear

bearing system. VKM3 uses a solid way bearing system and VM 16 used a ball type way

bearing system. The performance valúes given by the manufacturer are performed with a

Reinshaw láser and ballbar system. VM16 has twice of capability considering position

accuracy as a performance index. This performance valué corresponds to quasi static

measurements, where the controller does not play a key role as the mechanisms.

Controller

Actuator

Mechanism

Performance

VKM3 (V= 0.04 m3>Centurión Vil

•Yaskawa Ac servomotors:SGMGH-05AC A61•Servo Amplifier:SGDH 05 AE•Feedback Resolution: 0.001 mm400 ipm rapids XY 200 ¡pm (5080mm/min) feedrates

•Heavily Ribbed Cast I ronConstruction•Precisión Ground Double AnchoredBall Screws•Ball Screw grade C5.•Ball Screw Pitch lead 0.2 " (5.08mm)•Fully Ground Solid Ways with TurciteSurfaces

•Position Accuracy: 0.01 mm•Repeatability: 0.005 mm

VM16(V =0.156 m3)Centurión Vil

Feed Forward and Look-Ahead for HighSpeed Machining or 3-D Milling

•Yaskawa Ac servomotors:SGMGH-05AC A61•Servo Amplifier:SGDH 05 AE Y220•Feedback Resolution: 0.001 mm1000 ipm rapids XY300 ipm(7620mm/min) feedrates

•Massive Heavily Ribbed MachineTool Grade Cast I ron Construction•Precisión Ground Double AnchoredBall Screws With DampeningCoupling

•Ball Screw grade C5.• Ball Screw Pitch lead 10mm.•Ball type ways

•Position Accuracy: 0.005 mm•Repeatability: 0.0038 mm

Table 2. VKM3 and VM16 general comparison.

13

3. METHODOLOGY

The correct evaluation of CNC controller technology for a specific selection or

configuration has to consider the application or requirement that the user wants to

manufacture. The evaluation is based on the dynamic performance of the CNC controller

under certain evaluation procedures measurements for different performance indexes (see

Figure 11). A relative valué between different performance indexes are quantify in

relationship with their actual cost (see Figure 12). The proposed methodology is divided

into four steps:

• I. Application,

• II. Performance evaluation procedures,

• III. Taxonomies of machines,

• IV. Relative valué evaluation.

PERFORMANCE INDEX

I.APPLICATION EVALUATION

PROCEDURES

TAXONOMY

III.

PERFORMANCE INDEX

Figure 11. Method summary ,evaluation procedures for different performance indexes.

14

111o! * •S uiceaO zu. —ceuia.

IV.RELATIVE

VALUÉEVALUATION

Controller C |Characteristic

C1.C2

UI> UJ

_ l <UJ >

Controller B

CharacteristicB1.B2

Controller A

CharacteristicA1.A2

COST$ B/A C/B

Figure 12. Method Summary, relative valué evaluation.

3.1 STEPI. APPLICATION

As mentioned before the application for selecting or configuring a specific

machine tool is the starting point. Figure 13 show that certain performance indexes are

required for productivity and capability attributes quantification. For CNC controller

technology dynamic performance, in terms of contour error, is a critical factor to consider

for certain capability and product requirement. Thus for contouring applications such as

mold manufacturing the selected performance index for dynamic capability will be

contouring error. On the other hand if the application is production of manufactured

parts, the selected performance index for static capability will be repeatability and

aecuracy. Average feedrate and block per second processing are examples of

performance indexes to evalúate productivity attribute.

Actuators and mechanisms are important to consider in mold manufacturing, but

for production their consideration is more important to evalúate correctly the effect of the

controller. This thesis only considers dynamic performance evaluation for contouring

15

applications. It is important to notice that dynamic performance not only depends on the

controller performance, but also on the actuators and mechanisms.

Productivity Capability

CONTROLLER

ACTUATORS

MECHANISMS

Production Molds Static Dynamic

) VERY IMPORTANT

) IMPORTANT

Figure 13. Controller productivity and quality based on certain application requirement.

3.2 STEPII. PERFORMANCE EVALUATION PROCEDURES.

As mentioned before there is not a specific methodology for evaluating CNC

controllers. Different evaluation procedures are considered to evalúate dynamic

capability of CNC controller technology. Standards and machine specifications are based

on quasi static measurements for prismatic parts (see Figure 14). For dynamic capability

sculptured surfaces are considered to evalúate contour performance.

16

gQ O

¡I

CAPABILITY(CQNTOUR PERFORMANCE)

PRISMATIC PARTSSTATIC CAPABILITY

CONSIDEREDINEVALUATION

[Momeal;2003]

NOTCONSIDERED IN

EVALUATION

SPEC

[Amone; 1998]

SCULPTURED SURFACESDYNAMIC CAPABILITY

CONSIDERED INEVALUATION

ÁBPS

NOTCONSIDERED

IN EVALUATION

HEIDENHAIN

Figure 14. General evaluation procedures for productivity and capability quantification.

The proposed methodology evaluates productivity and capability attributes of

different elements that intégrate the controller architecture (see Figure 15). Two mayor

aspects that consider the controller hardware and software architecture are proposed to

evalúate a specific controller technology: Data processing performance (blocks per

second) and software implemented algorithms evaluation.

BPS \

\

/

/ f

ACRiATORS

CONTROLLERS

OONTROL\OPTION: \

LOOK-AHEAD\

\ \/ /

MOTOR / 1

MECHANISM

V E U X m .ACCELERATION

'BAIXSC:REW

DRIVE/

ACTUATl.

CONTROLLERS

\ \ < (INTROL U W :\ \ <ONTOVR

\ \

/ / / /

/ / / BEARDMU/ / / Si-STEM

RS MECRW1SMS

DYNAMICC.\PABnJTY

Figure 15. Ishikawa diagrams for productivity and dynamic capability

17

3.2.1 Data processing performance (BPS) Test

One of the more popular ways to measure CNC performance is block processing

time. Block per second (BPS) or block processing time (inverse valué of BPS) can be

considered as the performance indexes to evaluated productivity. As mentioned before

not all manufactures refer to the same thing when they refer to BPS. Some manufacturera

define a block as a single CNC "word" such as XI or Yl. Other manufacturers have

defined a block as whatever will fit on a line up to the carriage return. This definition is

important, because the block definition reveáis the actual processing speed of the control.

For this reason is necessary to defined a block. Some recommendations proposed

by [Amone; 1998] like stripping the program of all superfluous characters, including line

numbers are considered. Also is important to not include tool length or radius

compensation or any other features that might consume additional processing time.

From preliminary testing and reviewed related work one block for data processing

performance evaluation purposes is defined as a three word line (X,Y,Z coordinates)

without: line numbers, linefeeds ,character spaces, tool length and radius

compensations (see Figure 16).

g646546l?G90721G01X0YOZ0F500XO.01443Y0.01443Z0.01443XO.02886Y0.02886Z0.02886XO.04329Y0.04329Z0.04329l|(Pií¡^pl?2¥O.OS7?2Z0.05772 I

XO*. 08658Y0*. 08658Z0*. 08658XO. 10101 YO. ÍOIOIZO. 10101|XO.11544Y0.11544Z0.11544

~ ~ ^ _ _ _

Figure 16. Block definition.

To evalúate the block processing capability a simple straight line divided in

small segments is proposed. Three experiments were conducted using a 1-D straight line,

18

2-D straight line and 3-D straight line to evalúate the effect of using different block

words. All of the three lines have a total length size of 700 mm. Different line segments

(see Figure 17) were considered and tested under different feedrates with the look-ahead

control option. This length lines and segments were selected because first experiments for

a lOOmm total length line and a 200mm total length line show that for big segments (

>0.2mm) the effect of acceleration of the servo motors, affect the experimented obtained

valúes. For a correct block processing time measurement the acceleration effect must be

decoupled. This decoupled is obtained by making longer lines, with smaller segments.

¥> •

X(mm)

? '£>-

/

X(mm)

£

1^ yS. V X (mm)

1-D STRAIGHT LINE

•Total length: 700mm

•Line segments: 0.1 mm, 0.05mm, 0.025mm

2-D STRAIGHT LINE

•Total length: 700mm

•Une segments: 0.05mm , 0.025mm

3-D STRAIGHT LINE

•Total length: 700mm

•Line segments: 0.05mm, 0.025mm

Figure 17. Block processing time capability experiment of three different total length lines.

To determine the required block per second capability for different line segments

formula [l]can be used. For example for a 0.1 mm segment at 3000 mm/min a

processing time of 2 ms (500 BPS) is required.

19

L = length of a typical programmed segment [mm]

F = programmed feedrate [mm/min]

T = 6 0 X ( L H - F ) [seconds] [1]

^ [1/second]

The real BPS is obtained using a chronometer and measuring the time from when the

program begins until it ends. The actual average feedrate can be calculated for several

line segments experiments just knowing the processing time or the BPS valué (dividing

the total line length by the processing time for certain number of blocks). This valué

represents the máximum feedrate that the controller can achieve for a specific line

segment, and it is important because the final user can notice that for small program

segments (longer line segments might easily permit high feedrates [Shuett; 1996]), the

programmed feedrate can not be achieved. For contouring applications, a "bunching" of

data points are generated by CAM systems in many detail áreas for precisión cutterpaths

[Shuett; 1996], and the controller can not achieve the programmed feedrate.

Productivity in terms of processing time or BPS as performance indexes can be

compared for different controllers of the same or different brands knowing the real

processing time. Notice that valúes of BPS provided by the manufacturer should be taken

carefully [Amone; 1998], and not all manufacturers provide this valué in their brochures.

3.2.2 Software implemented algorithms evaluation

As block processing evaluation there is not a specific methodology to evalúate

software implemented algorithms. Software implemented algorithms are evaluated by

dynamic measurements generally using ball bars and grid encoders. Grid encoder has the

advantage that is not limited to a circle path. Heidenhain KGM-181 grid encoder and the

ACCOM Software are used to evalúate software implemented algorithms (Figure 18).

With the ACCOM Software it is possible to have a graphical representation of the actual

and the ideal tool path for several measurements. For a detail explanation of dynamic

20

measurements using the KGM-181 grid encoder and the contour error algorithm see

[Ortega; 2004].

Figure 18. Heidenhain KGM-181 grid encoder Set Up.

Software options are classified considering what implemented algorithm affect

most dynamic capability and productivity (see Table 3). Classification is based on

preliminary testing and the reviewed related work. This thesis only considered the

control law and profile generation evaluation.

Dynamic capability

Productivity

Software implemented algorithmsControl Law (CL):PID, Feedforward.Trajectory Generation (TG):Interpolation, spline interpolaron, polynomialinterpolationProfile Generation (PG):Trapezoidal velocity description, Trapezoidalacceleration description (acceleration withjerk limitation)

Table 3. Software implemented algorithm classification.

Control law (contour performance)

To evalúate contour error as performance index is important to consider how

other authors evaluated their developed control algorithms. [Altintas; 2001a] used

circular and diamond shaped paths, [Tomizuka;2001] [Koren; 1997] used circular paths

21

to evalúate the contour error of their proposed control schemes. All of these authors

used different feedrates ranges and path sizes to test their control schemes.

A 20 mm hexagon size path is proposed [Ortega; 2004] for testing the dynamic

capability at different feedrate ranges. A contour error algorithm developed by same

author was used to quantify the average contour error as a performance index. Figure 19

shows and example of the contour error on a 20 mm hexagon. Notice that contour error

presents a máximum valué at the hexagon corners. The average contour error is the

average of all the contour errors at the cumulative distance. For a complete evaluation at

all the tested feedrate ranges, an average of all average contour error is considered.

0.11•p. o íE 0.09E 0.08

w 0.07« 0.06i- 0.05S 0.04fe 0.033 0.01

C -0.01O -0.02ü -0.03

-0.04

(

Contour error, magnitude and location /

''1

JiJE

1

— ? •

í

i' i

- . _

- -

,v

>

) 20 40 60 80 100 120

Cumulative distance d, (mm)

Figure 19. Contour error graph of Milltronics VKM3 at 4000mm/min.

Profile generation evaluation

Controllers specify several Ínterpolation and profiling generation techniques in

their brochures. Several authors suggest that smoother feed motions at high speed

machining will increase productivity and reduce mechanical shock imposed on the servo

system [Yang; 2004][Altintas; 2001]. To quantify productivity the average feedrate as

performance index is obtained from the velocity profíles in a 20mm side hexagon at

different feedrates. Figure 20 and Figure 21, shows an example of a velocity and

22

acceleration profile respectively at a tested feedrate. Notice that this graph has 8 line

segments. The average feedrate is obtained considering the time of 6 segments of the

hexagon (120mm distance). For a complete evaluation at all the tested feedrate ranges,

an average of all average feedrates is considered.

Ve locity Profile

eed

rate

Vfp

,m

in)

H

Pro

gra

m

4000-3500-30002500

15001000500 j

ol

II /i n A h n ri\ i\ i\ i\ iIXix 11 n i

rÍREBí T f —M

4fi- —

T0.5 1.5 2 2.5

Cumulative time t, (s)

3.5

Figure 20. Velocity profile at 4000mm/min of Milltronics VM16 machine.

Acceleration Profile o^ 1500

s innn

•atio

n a

m, (

mnr

0

O

O

C

£ i

| -1000

x -1500 -

-2000-

' «I

• J ; II*Ufe

I I .wni

"ti fe **"T

— T

—^ H f

1 i

0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75

Cumulative time t, (s)

Figure 21. Acceleration profile at 4000mm/min of Milltronics VM16 machine.

23

Dynamic capability and productivity is represented in a percentage X-Y plañe

scheme as in Figure 22 for visualization of several controller options. To use this

representation same programmed feedrates have to be considered between control

options.

Dynamic capability e

%(Average Contouring error)

! • • =

i •-.i i

:

íi; :

| Í

4^

«a

í: : 111111

i : : : : :

S "1**r*r

I [ [ 11 ¡141 F ^

II: a

m

DYNAMIC MEASURMENTSCONSIDERATIONS

•Same Shape•Equal segment size•Same Feedrates

Figure 22. Percentage representation for productivity and dynamic capability .

The abscissa corresponds to the average contour error (better control option is

localized to the left of the plañe), and the ordinate corresponds to the productivity in

terms of the actual average feedrate, both of them expressed as a percentage. To deploy

several machines in the same graph, an average valué of productivity and its

corresponding average contour error valué can be calculated considering the same

programmed feedrates.

24

3.3 STEPIII. TAXONOMY OF MACHINES

Based on the proposed taxonomy of machines it is possible to determine an

approximate level of cost and performance of an specific controller and a machine tool.

From the controller point of view is important to consider the controller architecture in

order to take decisión for selecting or configuring a CNC controller technology. Figure

23, shows a schematic representation of the controller architecture and it relationship

between software and hardware for the three proposed markets.

Low Cost Controller CNU

Software

M ) Médium Cost Controller

High Cost ControllerSoftware

Hardware

Hardware

Hardware

Figure 23. CNC controllers technologies architecture.

3.4 STEP IV. RELATIVE VALUÉ EVALUATION

Relative valué evaluation was proposed in order to establish a cost reference

between different controllers or controller characteristics, to quantify the machine

attributes the final user seeks for (see Figure 24).

25

3.4.1 Relative valué cost between performance indexes.

After the performance indexes have been quantified, they are plotted in a X-Y

plañe (see Figure 24). The abscissa corresponds to the real cost (provided by the

manufacturer) and the ordinate correspond to the consider performance index. Relative

valué can be calculated using formula [2].

Relative Valué of B/A=Cost B - Cost A

ABS(ControllerB-ControllerA)[2]

The relative valué comparisons between software options or controller

characteristics have to consider the following aspects (see Figure 24): Controller's

comparison between machines in terms of dynamic capability performance can be

executed if the machine has the same volume, same application purpose and similar

actuators and mechanism taxonomies. Different controllers comparison can also be

executed if data processing time is taken as performance index and assuming that they are

tested on the same machine. To evalúate the relative cost of software implemented

algorithms of the same controller the cost of the control options is required.

UI

o< Xi

2 ui£°2^te.UJQ.

^ ^ ^ i Controller C j^ ^ ^ Characteristic

C1.C2

•

Controller B

CharacteristicB1,B2

^ ^ ^ | Controller A |

^ ^ ^ CharacteristicA1,A2

eosT$

ÍELA

TWE

VA

LUÉ

J\>

V /

B/A

*

///

C/B

Figure 24. Relationship between controller cost and machine attributes (performance index).

26

4. EXPERIMENTAL RESULTS

4.1 CASE STUDY I

Case study I was conducted on a Hurón KX-10 machine center. Hurón KX-10

main application is for molds manufacturing where dynamic capability in terms of

contour performance is the main factor to consider (see Figure 25). It has a Siemens 840

D controller, which can be considered as a medium-high cost controller. The objective of

this case study is to compare Siemens 840D controller with different Siemens (802C and

802D) controllers in terms of processing time capability. Siemens 802D and 802C best

processing time are of 24 and 12 ms respectively. (processing time data was provided by

the controller manufacturer. See appendix C for more information).

CONTROLLER

ACTUATORS

KECHANISMS

Productivity ifflSiJI

fMMtoi J « » « j | SU*

• » •

bWI)

O"

-

/ "

rme

Í

iI. II.

Machine: Hurón KX-10Controller: Siemens 840DWork Volume: 0.35 m3.

III.

f r

Figure 25. Application of Hurón KX-10 with a Siemens 840D controller.

The evaluation procedure is for data processing performance (BPS) of Siemens

840D controller. The selected performance index is BPS and processing time. The

results for the block processing times and blocks per second are illustrated in Figure 26

27

and Figure 27 respectively for a 3-D straight line. The processing time of 4.6 ms is within

expected valué for a médium high-cost controller (see Figure 5). The 0.025 mm line

segment has a saturation of 4.6 ms (218 BPS) at all programmed feedrate valúes. There is

an insignificant difference (measurement errors) between the 0.025mm programmed line

segment (Pt) and the 0.05mm line segment of 4 BPS at saturation. The graphs also show

the actual average feedrate when saturation occurs for the programmed feedrates (see

APPENDIX F for more details).

Siemens 840D

Control Option G64: ON

7.000

£ 6.000

3-D STRAIGHT UNE

5.000

4.000

3.000

--<1*

1 1

—

[• — • - — -

Vfa= 668.3 mm/mlnVfa= 327.3 mm/mln

4

—

ls= 0.05 mmls= 0.025 mm

)

O

•/

1 -

Measured Valué

Data Sheet

Models—•

t

1000 2000 3000

Programmed feedrate Vfp, (mm/min)

4000

• • - 0.05mm -0.025mm

Figure 26.3-D straight line processing times

Siemens 840D

Control Option G64: ON

250.000

a.&W 225.000o.m

200.000

175.000

150.000

3-D STRAIGHT UNE

^

, t

, ' T>

9

1

1. Vfa= 668.3 mm/mlnVfa= 327.3 mm/mln

ls= 0.05 mmls= 0.025 mm

® Nleasured Valué

• Data Sheet

/ Models

1000 2000 3000

Programmed feedrate Vfp, (mm/min)

4000

- • - 0.05mm -0.025mm

Figure 27. Block per second for a 3-D straight line.

28

Figure 28 and Figure 29 show the processing time and BPS values for a 2-D straight line

respectively. Compared with the 3-D straight line, there is not a significant difference

between the obtained Pt, and BPS values. For the 0.025 programmed line segment the

difference in terms of actual average feedrate is of 3.4 BPS for programmed feedrates

superior to 1000 mm/min.

7.000

,§.6.000

<D

F 5.000

4.000

3.000

Siemens 840DControl Option G64: ON

2-D STRAIGHT

1000 2000 3000

Programmed feedrate Vfp, (mm/min)

- • - 0.05mm -0.025mm

<V

1 1i

— —

Vla= 668.2 mm/minVfa= 330.7

imrrvmln

— —

I© Measured Value

• Data Sheet

/ Models

ls= 0.05 mmls= 0.025 mrr

4 1 |

4000

Figure 28. 2-D straight line processing times.

250.000

m225.000

200.000

8m

175.000

150.000

Siemens 840DControl Option G64: ON

1000 2000 3000

Programmed feedrate Vfp, (mm/min)

- • - 0.05mm -0.025mm

2-D STRAIGHT

<

f

*

t

t

t

\

1Vfa= 668.2 mm/minVfa= 330.7 mm/min

ls= 0.05 mmls= 0.025 mm

© Measured Value

H Data Sheet

/ Models

4000

Figure 29. Bocks per seconds for a 2-D straight line.

29

In a 1-D straight line there is no difference between the programmed line

segments (see Figure 30 and Figure 31). This is because the time was calculated from the

actual average feedrate obtained from the machine display. For 2-D and 3-D lines, there

was not possible to obtain the actual average feedrate from the machine display because

there was not a constant value of the actual feedrate.

13.0 -i

t, (

ms) b

ess

ing T

ime (

~i

tob

b

2 5.0

3.0

(

1

I

I\\ \

\\\

I 1

) 1000

Siemens 840D

Control Option G64: ON

Vfa= 1350 mm/minVfa= 675 mm/mlnVfa= 337.5 mm/min

o•

1

•]

I-D STRAIGHT UNE

IMeasured Value

Data Sheet

Models

ls=0.1 mmls= 0.0S mmls= 0.025 mm

1T2000 3000

Programmed feedrate Vfp, (mm/min)

—•—0.1mm - • - 0.05mm —•—0.025mm

4000

Figure 30.1-D straight line processing time.

250.0

en" 200.0a.mT3

8 150.0 •

J2 100.0

ffl

50.0

Siemens 840D

Control Option G64: ON1-D STRAIGHT LINE

1

1

1

*

• ' )

/

<

\*^

Vfa=Vfa=Vfa=

1350 mm/min675 mm/min

337.5 mm/min

s=0.1 mms= 0.05 mms= 0.025 mm

—•

9 Measured Value

S Data Sheet

/ Models

1000 2000 3000

Programmed feedrate Vfp, (mm/min)

4000

0.1mm - 0.05mm 0.025mm

Figure 31. Blocks per second for a 1-D straight line.

30

The programmed line segment vs. actual average feedrate is illustrated in Figure

32. Notice programmed feedrates and the actual average feedrate difference when the

controller saturates. This comparison is important because for high speed contouring

applications, higher average feedrate values are required to mill accurately at high speeds

[Shuett;1996].

Siemens controllers comparison

1400

1200

1000

800

600

400

200

(3) Measured Value

Data Sheet

Models

1-D STRAIGHT UNE

I Vfp > 2000 mm/mln I

0.025 0.05 0.075

Programmed line segment Is, (mm)

0.125

-Siemens 8400 (4.4 ms) - • - Siemens802D(12 ms) - Siemens 802C(24 ms)

Figure 32. Average feedrates for different Siemens controllers.

The cost relationship of Siemens controllers with their processing time (3-D

straight line with a programmed line segment of 0.025mm) as a performance index is

illustrated on Figure 33. Siemens 840D processing time was obtained by the above

experimentations on a specific machine. For that reason this comparison can be consider

with the assumption that Siemens 802D and 802C were tested on the same machine. The

cost of Siemens 840D was provided by the manufactured but it was not given in a formal

quotation format as for Siemens 802C and 802D. The price of $USD 12,000 for Siemens

840D can vary depending on the selected processor speed.

31

Performance Index comparison for Siemens controllers X-^ 2 5

£ 2 0

Pro

cess

ing

Tim

eo

yi

o

en

3-D STRAIGHT LINE

© Measured Value

• Data Sheet

/ Models

-

4,000 6,000 8,000 10,000Controller Cost c,($USD)

12,000 14,000

Figure 33. Processing times for Siemens 802C, 802D, and 840D and their corresponding cost

The relative value of Siemens 802D vs. 802C, is of $USD 213.5 for each

millisecond of reduction in processing time. This relative value is important because

with this comparison the final user can have an idea of what is the cost of processing time

in milliseconds per dollar from one technology to another (see Figure 34). The relative

value of processing time for a high performance controller (840D), between a medium

performance controllers is of $USD 681.75 for each millisecond.

Relative Value of Siemens Controllers

700

X-3-D STRAIGHT UNE

5 ^ID CO

EDi

2a.

600

500

400 -

300

200

100

^ Measured Value

H Data Sheet

/ Models

802D vs. 802C 840D vs. 802D

CNC Siemens Technologies

Figure 34. Relative value of different Siemens controllers technologies.

32

4.2 CASE STUDY II

Case Study II was conducted on a Milltronics VM16 machine center. It has a

Centurion VII controller, and a work volume of 0.156 m3. Milltronics main application is

for molds manufacturing where dynamic capability is the main factor to consider (see

Figure 35). The objective of this case study is to compare the relative cost of the

purchased software upgrade of feedforward and look ahead option for high speed milling

operations. The published cost of this software upgrade is of $USD 1,500.

a n

:ONTROLLER HIACTUATORS ^ A

MECHANISMS • HIn u

•JX •

PRISH»T!C PMTS

I.

Machine: Milltronics VM16Controller: CENTURION VIIWork Volume: 0.156 m3.

Figure 35. Application of Milltronics VM16 with centurion VII controller.

To activate feedforward and look ahead (see APPENDIX A for more

information), the DNC software option has to be used in the Milltronics controller.

Feedforward control strategy for machine has tools been tested by several authors

[Tomizuka; 2001][Altintas;2001a][Koren;1997], that reduce the contour error. The

results from dynamic measurements for contour error and actual feedrate are in Figure 36

and Figure 37 respectively (for more information see APPENDIX H). Notice that the

look ahead option is not evaluated in this case because the hexagon has only 8 program

blocks.

33

~ 0.008 -I

£ 0.007 -

8 0.006 -

8 0.005

- 0.004 -

% 0.003

° 0.002

2 0.001

3 0 -I

VM16 Average Contour Error Comparison / \

\ /

... ...

- ^

1 ^

2000 4000 7620

Programmed feedrate Vfp, (mm/min)

ffl DNC OFF • DNC ON

Figure 36. Average contour error comparison on VM16 for different programmed feedrates.

VM16 Average Feedrate Comparison

3000

2000 4000 7620

Programmed feedrate Vfp, (mm/min)

DNC OFF • DNC ON

Figure 37. Average feedrate comparison on VM16 for different programmed feedrates.

34

The proposed method for relating productivity and dynamic capability on the

same X-Y plane is illustrated in Figure 38. Notice that the dynamic capability percentage

of DNC OFF is 114%. This means that the contour error increases 14% ( dynamic

capability reduces 14). Centurion VI has not dynamic look-ahead, for that reason the

programmed feedrate has an insignificant reduction (0.06%) with DNC ON control

option.

Dynamic Capability vs. Productivity / \

\ /1 nn m n/

100.00% -

99.99%

Ig, 99.98%

£ 99.97%

Z= 99.96%

°" 99.95%

99.94%

— ——

--

^ ^ -

r_. .._.

- — —

^ — — — —

p- - -—

_.. — ._

.._ —

— _

,

_.

98% 100% 102% 104% 106% 108% 110% 112% 114% 116%

Dynamic Capability Ca, (%Contouring Error) ••

DNC OFF

DNC ON

Figure 38. Dynamic capability and productivity representation for DNC control option.

Considering a standard cost of Milltronics Centurion VII of $USD 8,000 for DNC

OFF (See APPENDDC C for more information of Centurion VII price), with the software

upgrade package the cost of Centurion VII, will be of $USD 9,500. DNC OFF has an

average contour error for the three tested feedrates of 6.7 um. With DNC ON the average

contour error reduces to 5.904 um. The relative cost of DNC ON vs. DNC OFF is of

$USD 1,826 per micron (see Table 4). This value is important because the final user can

evaluate the relative cost of two characteristics of the same controller. Software options

35

or upgrade control options are commonly presented in controller brochures. It is

important to note that the results presented here are only valid for the hexagon test.

DNC OFF 1

COST SUSD

8,000

Average AverageError(mm) Error (urn) Relative value SUSD/urn

DNC ON 9,5000.0067296 6.7296301 DNC ON vs. DNC OFF 1826.60285610.0059084 5.9084335

Table 4. Relative Value of DNC control options.

36

5. DISCUSSION

This section presents a discussion based on the presented methodology and the

case study results. Application and relevance of the proposed methodology for the

industrial need of selecting and configuring a machine tool can be discussed considering

the reviewed related work, proposed cost reference taxonomy and experimental results in

the case studies. In addition, a general scheme for machine tool development can be

considered based on the experience acquired with the development of thesis.

5.1 Machine tool selection and configuration.

A typical investment project for aerospace or automotive industry, with a given

target product cost, quality and lot size, requires the selection or configuration of specific

machine tools. From the controller point of view, machine tool configuration and

selection can be done with experimental testing. In this regards, this thesis defines

evaluation procedures to quantify the controller performance (BPS) and the machine tool

dynamic performance (average contour error). The selection of an appropriated CNC

controller for a specific machine is based on the controller performance and cost. Some

procedures such as software implemented algorithms evaluation do not evaluate the CNC

controller performance by itself, but the dynamic performance of the CNC controller and

its interaction with the actuators and mechanisms (machine tool dynamic performance).

For example, comparing the Milltronics VKM3 and VM16, they have the same

controller, actuators and balls screws, but a different kind of linear bearing system.

Based on some dynamic evaluation of these machines, the VKM3 was found to have

approximately twice as much error compared to the VM16. A possible reason for this

performance difference could be the friction characteristics of the different linear

bearings used with these machines. Assuming this explanation, there could be an

opportunity to use a lower cost controller with the VKM3, better matching the controller

with actuators and mechanisms, and therefore lower the total cost of the machine.

37

In a lower cost scheme for configuring a retrofitted machine tool, the principal

attribute that final user seeks for is cost. In this context, the CNC controller and actuators

are the bottle necks in configuring a low cost retrofitted machine. An optimization of the

required actuators (and some mechanisms if they are going to be changed) for

configuring a retrofitted machine tool can be done knowing the controller performance

and its compatibility with actuators and mechanism. This discussion is extended in the

next point.

5.2 Machine tool development

The proposed methodology can also be used as a reference framework for

machine tool development. This discussion will focused on machine tool development

with a low cost controller denominated "Universal Numerical Control" (UNC) that is

under development at ITESM. A brief description of the Universal numerical control

will be presented for a better understanding of the controller proposed architecture.

The UNC is a PC-based and open system control architecture, that is focused on

providing a low cost CNC technology for Small and Medium-Sized Enterprises (SMEs)

[Ramirez; 1998]. The UNC reference architecture (see Figure 39) is a conceptual model

that establishes rules and methods of integration and standard interfaces between its

components [Ramirez; 2004].

The most important element of the hardware layer is the PC bus, which is a

universal interface which connects all components of a PC system. The selected interface

is a standard PCI bus to communicate the software modules with a PCI board. All the

controller basic tasks (PG, TG and CL) are processed in software by a real time operating

system. The limitations of using only a PC for doing all basic tasks is evident for block

processing time performance. Comparing UNC with a medium cost controller, it is

possible to see that the significant difference in hardware is a DSP board. For example,

popular board as the Delta-Tau PMAC DSP board (medium cost card), can execute a

multiply-accumulate (MAC) instruction, a fundamental operation, in a single clock cycle.

38

This same operation on a current Pentium processor chip takes 11 clock cycles [Shuett;

1996].

Programming ApplicationInterface

Real Jime Operating System

HardwarePC^

Figure 39. UNC reference architecture.

Machine tool development with the UNC control will be focused on configuring

low performance actuators and mechanism for production machine tools. Since the

controller is the "brain" of the entire system, and has a relative low performance, some

elements can be developed in the house. For example it is possible to develop the UNC's

own driver for a low cost step motor. Dynamic performance will not be as important as

quasi static performance, for this reason solid ways can be considered in developing the

machine tool structure. For static performance low lead ball screw are recommend to

ensure high degree of accuracy and repeatability. It is important to notice that these

recommendations are base on the review related work, proposed cost reference taxonomy

and case studies of this work.

39

6. CONCLUSIONS

Machine and product application has to be considered to evaluate a specific CNC

technology. Evaluation procedures to evaluate some performance indexes were validated

and proved on two case studies. Evaluation of different CNC technologies and their

relationship with their cost in terms of dynamic capability and productivity was possible

considering constant volumes, similar quasi static capabilities and same tested

parameters. Characteristics of the same controller and their relative value can be

evaluated using the proposed methodology.

Taxonomy of machines was established in order to have a technology cost and

performance reference. Comparing different machine tools taxonomies, with the same

controller and actuators, the effect of the linear bearing system on the static capability

was evident

It was possible to compare Siemens 840D with Siemens 802C and 802D

controllers in terms of processing times as performance index assuming that those

controllers were tested on the same machine. A relative value between Siemens

technologies was presented.

The effect of the feedforward control algorithm over the dynamic capability was

evident by using the DNC command on Milltronics Centurion VII controller. The

measured dynamic error varies in 18% from the quasi static error specified by the

manufactured. Considering a hexagon the dynamic error is higher than quasi static error

and is within expected results. A 14% of dynamic error was reduced using a feedforward

control in a hexagon. The relative value of contour error as performance index was

compared between DNC control options.

40

6.1. Contributions.

A Structured methodology oriented to an application, considering different

machine tools taxonomies with relative cost values comparison between selected

performance indexes.

• Definition of a Block for block processing time evaluation purposes.

• Cost relationship between different performance indexes.

• Relative cost of processing time between different controllers of the same brand

• Relative cost of dynamic capability for a feedforward control option.

• Taxonomy of machine tool with a technology cost reference between controllers

and actuators. Reference performance values of the mayor elements that

integrated the drive train mechanism of a machine tool.

• Machine tool test bed proposal for evaluating UNC dynamic capability on VKM3

vertical knee milling machine (see APPENDIX I).

6.2 Future work

This work provides a basis for future research and development on a methodology

for CNC technologies evaluation taking into account the following aspects:

• Implement the propose methodology using UNC developed controller on a

Milltronics VKM3 milling machine, to quantify the dynamic capability of a low

cost controller.

• Study different profiles for dynamic measurements, for contour error evaluation.

Circular paths are used and recommended by many authors.

• Evaluation procedures for dynamic measurements using sculptured surface

profiles for a more reliable comparison between look-ahead control option.

• Include a cost reference for drive train mechanisms on the proposed methodology

• Evaluation and taxonomy considerations of spindle technology.

41

7. REFERENCES

[Altintas; 2000] Altintas, Yusuf; Manufacturing Automation, Cambridge

University Press, Cambridge, 2000.

[Altintas; 2001] Altintas, Yusuf; Erkorkmaz, Kaan; "High Speed CNC System

Design. Part I: Jerk Limited Trajectory Generation and Quintic

Spline Interpolation", International Journal of Machine Tools and

Manufacture, Vol. 41, pp.1323-1345, 2001.

[Altintas; 2001a] Altintas, Yusuf; Erkorkmaz, Kaan; "High Speed CNC System

Design. Part III: High Speed Tracking and Contouring Control of

Feed Drives", International Journal of Machine Tools and

Manufacture, Vol. 41, pp.1637-1658, 2001.

[Arnone; 1998] Arnone, Miles; High Performance Machining, Hanser Gardner

Publications, Cincinnati,1998.

[Arslan; 2004] Arslan, £agdas M.; Catay, Biilent; Budak, Erhan: "A decision

support system for machine tool selection", Journal oj

Manufacturing Technology Management, Vol 15, N 1, pp. 101-

109, 2004.

[Fan; 2001] Fan, Chun; Dong, Chensong; Zhang Chun; H P Wang; "Detection

of Machine Tools Contouring Errors Using Wavelet Transforms

and Neural Networks", Journal of Manufacturing Systems, Vol 20

N 2, pp. 98, 2001.

42

[Hascoet; 2003] Hascoet, J-Y; Dugas, Arnaud; Terrier, Myriam; "Qualification of

parallel kinematics machines in high-speed milling on free form

surfaces", International Journal of Machine Tools and

Manufacture, Vol. 44, pp.865-877, 2004.

[Koren; 1983] Koren, Yoram; Computer Control of Manufacturing Systems,

McGraw Hill, New York, 1983.

[Koren; 1997] Koren, Yoram; "Control of Machine Tools", Journal oj

Manufacturing Science and Engineering, Vol. 119, November

1987.

[Lambrechts; 2005] Lambrechts, Paul; Boerlage, Matthijs; Steinbuch Maarten; "

Trajectory planning and feed forward design for

electromechanical motion systems", Control Engineering

Practice, Vol. 13, pp. 145-157,2005.

[Monreal; 2003] Monreal, Manuel; Rodriguez Ciro A.; "Influence of tool path

strategy on cycle time of high-speed milling", Computer-Aided

Design, Vol. 35, Issue 4, pp. 395-401, 2003.

[Ortega; 2004] Ortega, Carlos; Algorithm development for contour error

evaluation - analytical relation ship between accuracy and

productivity on high speed milling machining, Research modality

investigation thesis, CSIM, 2004.

[Ramirez; 1998] Ramirez, Miguel; Desarrollo de un control numerico Universal de

bajo costo basado en software y sistemas abiertos, Tesis de la

Maestria en Sistemas de Manufactura, Instituto Tecnologico y de

Estudios Superiores de Monterrey, Diciembre 1998.

43

[Ramirez; 2004] Ramirez Cadena, Miguel de Jesus; Jimenez Perez, Guillermo;

Molina Gutierrez, Arturo; Noriler , Maria A.. "Design

Methodology for CNC Applications Based on Open Systems". 7th

IFAC Symposium on Cost Oriented Automation COA 2004.

CANADA, pp: 153-158. June. 2004

[Rodriguez; 2001] Rodriguez, Guadalupe; Evaluacion de Tiempo en Operaciones de

Freasdo de Alta Velocidad - Impacto del Perfil de Aceleracion,

Tesis de la Maestria en Sistemas de Manufactura, Instituto

Tecnoldgico y de Estudios Superiores de Monterrey, Diciembre,

2001

[Shuett;1996] Shuett, Todd; Advance Controls for High Speed Milling, SME

Conference, Chicago Illinois, May, 1996.

[Tomizuka; 2001] Tomizuka, Masayoshi; Chiu, George; Contouring control of

machine tool feed drive systems: A task coordinate frame

approach", IEEE Transactions on control Systems Technology,

Vol. 9, No.l, pp. 130-139, January, 2001.

[Yang; 2004] Yang, Min-Yang; Nam, Sho-Ho; "A study on a generalized

parametric interpolator with real-time jerk-limited acceleration",

Computer-Aided Design, Vol. 36, Issue 1, pp. 27-36, 2004.

44

APPENDIX A.- CNC Design.

A very basic three axis CNC milling machine requires the fine coordinated

feeding velocity and position control of all three axis and the spindle speed

simultaneously. This type of control is known as control of contouring system, and

almost all milling machines are based on this scheme. In the market there are also

retrofitted milling machines with point to point control scheme, were only control of final

position is required. In both schemes the controller has to perform three basic tasks

(motion control): interpolation/trajectory generation (TG), profile generation (PG) and

control law (CL). Current CNC systems tend to employ multiple CPU's depending on the

number of computational tasks [Altintas; 2000] [Shuett;1996]. In such multiprocessor-

based CNC systems additional CPU can be added to extend CNC intelligence and

functions.

In this lower level there are three crucial times that depend on the hardware

capability of the CNC: the block transfer time, interpolation time and servo cycle time

[Shuett;1996]. Each of these times are distinctly different, and each has the potential of

limiting the CNC from meting its requirements.

Trajectory generation

Generate trajectories must not only describe the desired tool path accurately, but

must also have smooth kinematic profiles in order to maintain high tracking accuracy ,

and avoid exciting the natural modes of the mechanical structure or servo control system

[Altintas; 2001]. At high speeds, small discontinuities in reference path result in high

frequency harmonics in the reference trajectory which end up exciting natural modes. On

some complex shapes, employing only linear and circular interpolation techniques has

serious limitations in terms of achieving the desired part geometry and productivity

[Altintas; 2001]. To address these problems a lot of research has been done in recent

years in developing new trajectory generation algorithms that provide smooth feed

motion to high speed machining systems.

45

Velocity command generation

The acceleration (A), deceleration (D), and jerk (J) values are either set to default

values within the CNC or given by the NC programmer within the NC part program.

The acceleration and deceleration of the axis is controlled by imposing a trapezoidal

velocity profile on the position command generation algorithm.

The trapezoidal velocity profile is simple to implement, computationally advantageous,

and suitable for most low speed, low cost machines, however the trapezoidal velocity

profile employs constant acceleration, (the jerk or the derivate of acceleration is zero),

which leads to various oscillations and noise on the feed and acceleration when

interpolating along complex tool paths [Altintas; 2000].

Contour error

The contour error is defined as the orthogonal deviation from the desired toolpath,

arises due to the tracking errors in the individual axes [Korem; 1983]. The main reasons

behind the tracking errors are: The dynamics response of the feed drive system to the

reference trajectory; disturbances, such as friction and cutting forces; nonlinearities, such

as backlash and saturation in the actuator system; modeling errors and axis dynamics

mismatch [Altintas; 2000]. The existence of contour error definitely indicates the

existence of tracking errors, the opposite is not always true.

Two mayor approaches have emerged for reducing the contour error in high speed

drive systems, The first approach, known as the tracking control concentrates on only

reducing the tracking error in each axis (feedforward Control). The second approach

known as contouring control (Cross Coupling Control, and Optimal Control) aims at

estimating the control error in real time and using these estimates in the feedback control

law [Altintas; 2001a].

Feedforward

The principle of design of Feedforward control is simple to implement. A transfer

function G0~l(z) that is the exact inverse of the one of the real control loop G(z). For

46

example if Go~' (z)G(z) = 1 then the actual position becomes equal to the required position.

This Feedforward controller is the inverse of the feedback control loop, which consist of

the controller and the drive. However if Gox(z) includes unstable poles, it cannot be

implemented as a feedforward controller and must be modified To address this problem,

a feedforward controller entitled "Zero Phase Error Tracking Controller (ZPETC)" was

proposed by [Tomizuka; 2001].

Look-Ahead

Look-Ahead is control software option that medium and high cost controllers have.

This software option depends on the hardware capabilities of the CNC controller. Look-

ahead in now offered by some companies either as a pre-processing step or as a part of

the DNC system. The amount of look ahead varies based on contours, feedrates and

machine performance. Look-Ahead must evaluate data ahead in several different way.

The most obvious check is whether or not the next point deviates from the current path.

With today's dense data for 3-D forms, many blocks of CNC data must be checked to

foresee vector changes [Schuett; 1996].

47

APPENDIX B.- Literature Review

High Speed CNC Speed System Design. Part I: Jerk Limited Trajectory Generation

and Quintic Spline Interpolation [Altintas; 2001].

If the feed drive acceleration command produce by the trajectory generator is not

smooth, the resulting acceleration torque for ball screw and force for linear motor drives

contain high frequency components that excite the structural dynamics of feed drives an

cause undesired vibrations. To obtain smooth velocity and acceleration profiles as in

Figure B 1, jerk -limited trajectory generation algorithms are used .

T,

©

y©

time

time

Urns

(a)

Traptfzoktal Velocity ProWe

- TrApe'oical Acceteratnn Profte^.-^*r (Jork Umitod Traiectory)

0 0.02 O.W 0.06 006 0 1 0.12 O H 0.16 0.18

0 002 0.04 0.06 OOfl 0.1 0.12 014 0.16 0.18

0 0.02 0.04 0-06

- 2x10*; i Jerk

O 002 004 006 0.08 0 1 0.12 0.M tt16 CMSTime (sec)

I . I . ^ . - - , - , , - , - .0 SO 100 150 2 0 0 2 5 0 3 0 0 3 5 0 4 0 0 4 5 0 5 0 0

Frequency JHi]

(b)

Figure B 1. (a) Kinematic profiles for Jerk-limited feedrate generation, (b) Comparison between jerklimited and trapezoidal velocity profiles [Altintas; 2001].

Important considerations:

To impose this jerk-limited generation algorithm, the following parameters need to be

known:

48

• The control loop sampling period

• The total distance of travel

• Total number of interpolation steps

• Initial, desired and final federates

• Desired acceleration, deceleration magnitudes

• Desired Jerk magnitude.

Reference trajectories generated from the interpolator need to be resample at control

loop frequency. Is recommendable to have an interpolation without federate fluctuation,

to allow jerk limited federates profiles to be realized as they are planned, without

degradations arising from feedrate fluctuations (quintic spline interpolation).

Altintas introduce a new quintic spline interpolation technique to maintain constant

position increment at each step, and eliminate feedrate fluctuations.

The proposed curves are inappropriate as CAD models for designing complex shapes

[Yang; 2004].

High Speed CNC System Design. Part III: High Speed Tracking and Contouring

Control of Feed Drives [Altintas; 2001a].

High speed machining techniques required faster feed motion between the tool

and work piece, in proportion to increased spindle speed. However, due to the limited

bandwidth achievable by using only P, PD, or PID types of servo controllers, which are

the most common ones used in industrial CNC,s there will be tracking errors in each axis

as the closed loop control system is not able to follow the rapid varying position

commands. [Altintas; 2001a].

In this paper the authors, adapt a feed forward control scheme, with Cross

Coupling Control scheme, for minimization of tracking and contour errors

simultaneously. This scheme has a large computational complexity for designing a third

order Kalman filter, a second order state feedback gain, and a third order feedforward

49

filter (see Figure B 2). This required the axis controllers to be coupled among

themselves, in accordance with the kinematic configuration of the machine tool which

has to be very accurately known.

i t AzPETC ]Feedforward L*.

Axis Dynamics ,Compensation

1 z-1

rg T,z

FeedforwardFriction Compensation

O/> r 1 1— I """HI

State

>c

Gain

DACResolution

yy -*-

A t

A

0)

AJ:

FilterState and

DisturbanceEstimator

\ 1 d Axis Dynamics i

" • to

1'Ir'i

CO

5

X

Tachometer

Encoder

1

11

Figure B 2. Axis tracking control scheme [Altintas; 2001a].

This is not very practical because actual machine tool design is toward building standard

feed drive modules with digital motors which can easily be reconfigured and used in

different production arrangements [Altintas; 2001a].

A study on a generalized parametric interpolator with real-time jerk-limited

acceleration [Yang; 2004].

Parametric curves, are used together with the traditional linear/circular blocks in

modern CAD systems. Yang proposed a new interpolation algorithm that produces

smooth kinematic profiles for parametric curves that have no relationship between

parameter and arc-length. For this approach, each linear/circular block should be

defined as a pseudo-parametric curve by the simple parameterization. The results of

mixing linear/circular blocks and NURBS blocks as in Figure B 3,with the jerk limited

profile are shown in Figure B 4.

50

0 10 20 30

V' (CO, 0,0.1.2.3.4, 5,6. 6. 6. 6}

P- HI. 1».(IO, J 429). ([5. 1.8575).(20. 2.727). (25. 5), (28. 10),(29, 15). {29 5, 20), (30. 3O)|

50 60

Figure B 3. Toolpath example of mixed blocks [Yang; 2004].

«yo

h.

seE

I4O00-,12000-I0O00-8000-6000-4000-2000-

0-

ft = 10000 [mm/min]

/ \ // \ /

/ B> \ /

/ VCVB,

/ . = 12000 (mm/min]

\\

B \\

f * I *

0 4 0 S I 0

g J^-1000-< -2000H

0 0 04 0 6lime [sec]

0 8 1 0

Figure B 4. Jerk-limited profile for mixed blocks [Yang; 2004].

Important considerations:

• The simulation for jerk limited acceleration profile for a parametric curve was

using a third order NURBS parametric curve.

• The NC blocks are interpreted using a real time operating system, were each

block is interpreted and stored in a buffer with lower priority than the

interpolation thread.

51

Algorithm development for contour error evaluation - analytical relation ship

between accuracy and productivity on high speed milling machining [Ortega; 2004]

Dynamic measurement of the contouring accuracy of the machining centers with

the HEIDENHAIN KGM-181 Grid Encoder is presented. An algorithm for contour errors

estimation is developed based on vector theory for a hexagon. Experimental results for

dynamic measurements for different programmed feedrate on two machines are presented

with different control options. Is possible to compared velocity and acceleration profiles

for the two tested machines. Machine A have a jerk limited acceleration profile.

Important considerations

1. This study evaluates dynamic capability of two different machines with very

different taxonomies.

2. Both machines were tested at same programmed feedrates, but machine A

considered a programmed feedrate of 16m/min too.

3. Other prismatic parts and a sculptured surface contour error algorithms have to be

developed.

52

APPENDIX C- Controller Specifications

53

CENTROID M-39 CNC Control

All the Power and Economyof a True PC-Based CNC.

• 3 or 4 Axis CNC• Hand-Held Jog Pendant• Conversational Programming• Teach Mode• Engraving• Master cam Level 1 V 3.21**

Standard!• Tool Path Graphics

Jog Pendant with Optional MPG Handwheel

S»«ayl7,1998C5mroMCoip.

What You Get with an M-39*The M-39 is a 3 or 4 axis CNC designed for milling applications. It's ideal for CNC knee mills,bed mills, wood routers, and XYZ gantry machines. Includes:• Pre-wired enclosure with PC, powerful servo drive, power supply, and I/O• Hand-held jog pendant; E-stop; dedicated jog, rapid override, spindle and coolant buttons• 3 Powerful servo motors w/cables and encoders• Mounting arm with monitor stand and keyboard tray•Conversational, G-code, and Master cam. Level 1 version 3.21** CAD/CAM software installed• Ready to bolt on and run!

True PC Based. Open Architecture SystemThe M-39 is the easiest control to integrate into your system. It uses a standard PCwith off-the-shelf components. The software is installed and ready to go. Includes:

• ISA motherboard with powerful CPU• Connections for PC keyboard, VGA, and mouse• Large capacity hard drive, 3.5" floppy disk drive, and RS-232 port

•User supplies keyboard, mouse, and monitor"Limited time offer

ProgrammingConversational Programming: Our easy conversational lets you program lines, arcs, pockets,and drilling operations graphically. Canned cycles, mirror, rotate, repeat, copy, and Teach makeprogramming easy. With Math Help, solve for unknown intersections and tangent points.

G-Code Programming: FANUC style G-codes are standard. G-code text editor is included.

Mastercam, Level 1 version 3.21** comes standard on the M-39. Lay down toolpaths on existingZAD drawings, or draw your own. Generate irregular pocket-cleanout with island avoidance. Convert-\utoCAD*DXF to Centroid G-codes. Import DXF, CADL, IGES, ASCII, and other CAD files.

Engraving: Add Engraving to your M-39 for quick and easy engraving. Cut words, symbols, andlumbers. Engraving also includes 20 fonts. Also, you can easily create your own font library' from\utocad* DXF and HPGL files.

Tool Path Graphics: Check your work graphically. Plot the exact cutter path. View parts in 2D>r 3D. Zoom in/out. Scaled axes.'*Limited time offer

High Speed ContouringDentroid's CNC technology provides smooth, continuous movement with no hesitation or gouges.[Tie M-39 processes G-codes at high speed block throughput600 block/sec, speed with 2000 blockiccel/decel look-ahead. Even the largest files can be run without hesitation, thanks to the Unlimited'art Program Size feature (optional, standard program size is 640Kb). The M-39 comes equippedWth a large capacity hard drive to store all of your programs on the control.

Deluxe Automatic M-FunctionsOption #1: Pre-installed contactors for auto spindle CW/CCW, flood, mist, lube,and other extra I/O. Option #2." Auto spindle speed control, CW/CCW; pre-wiredcontactors for flood, mist, lube, and other I/O. Option#3: PLC Direct™ Interfacelet's you program your PLC Direct1" to control up to 64 I/O for automatic control ofmulti-spindle applications, tool changer, and other special functions.

M-39: Tool Path Graphics

M-39 Options'Engraving:•Digitizing:•4th Axis•Auto Tool Measure:• Unlimited Prog. Size:• Spindle Control:• Spindle S-Function:• Probing Cycles:• WCS:• Subs & Macros:• Mastercam, Level 2:• MPG Handwheel:

Comes complete with 20 fonts; generates G-codes automatically.Automatically copy any 3D surface and cut the 3D part on your M-39.Use as a linear or rotary axis.11-1 touch-off block automatically measures tool heights.Maximum part program size = available hard drive space.Automatically turn your spindle on/off and change direction CW/CCW.Control spindle speed automatically; specify speed in tool library.Automatically find part centers/corners of bosses, bores, webs, pockets.Multiple work coordinate systems for multiple fixtures [G28-30, 52-59].Cut one part using a family of part programs [M98, G65].Upgrade from Level 1.Manual Puke Generator makes touching off a breeze.

CENTROID159 Gates Rd.Howard, PA 16841(814) 353-9256 Sales(814) 353-9265 Faxwww.centroidcnc.oom

CMayi7.1998 Central Cop.

I h i n thaII««.* (lie 0 In a 1 iu tile i irs l o i l t imu (o t l n « i « opt ions dosii oil.

C0NTWX1ERCH0CE1 CertroidM39S Base Price (Keyboard Jogging)

0 Cenlroid M400S Base Price with 29 In. Lb. Motor UpgradeCENTROID OPTIONS

0 10703 M39S Jog Pendant (Sane buttons as M400 S but Hand Held)010770 DP4 Digitizing Package for all rigid surfaces and software010405 DP4 Probing package with probing software0 10015 MPG on the pendant010220 TT1 Tod touch off probe010730 Intercon Offline

4th axis rotary kit (Drive, Motor, Cable and 140mm or 220mm table) From

010450 CNC-151R 150mm, 5.9 h. Rotary Table0SC6CNC-151 Chuck0AP-1CNC-151AP.

010451 CNC-201R 200mm, 7.8 in. Rotary Table0SC-7CNC-201 Chuck0AP-1CNC-201AP.0 5CC-15C Manual chuck0TSA530Tai Stock010510 Linear 4th axis (Drive, Motor, Cable)010740 Mil write engraving software on the controler0 Software Pkg B (Mut V\CS, Subs and Macs, MnorfScaling)010620 Compression Tapping010630 Unlimited Fie Size Software Pkg C010264 SPhase option High power option

010711 AI"M" functions prewired at Centroid010711s Prog. SS analog output wired win (10711)

0 Installation0 TRAINING OPTION:

$550.00 Per Day plus travel and expenses

ELROD MACHNE RETRORT HARDWARE

1 ElrodZ Axis Qul Drive ModelQU2C4wih Quick Disconnect formanualZuse1 Ekod Smart Z on Qul Drive gives Z axis feed back manual Z use0 Elrod Smart Stop helps with precise Z axis depth control in manual Z use1 Elrod Machine X&Y Bracket Kit Model DOXLFT 2:1 Ratio1 Elrod Machine Ground Bal Screw K* for X&Y Axis1 Autoway Lube Pump1 Elrod Heavy Duty Bal Screw Mounting Yoke0 Elrod Limit Switch Kit (Optional)

ACCESSORES0 Kurt Vise D675

010100 HenchFcgBusterCoolant SprayerPower Draw Bar

0 TorqueRte Power Draw BarCat 40 Tooing Package

0R8tcoing PackageR8 Collet Rack on the Quil Drive

0R8CT-O90 AL-250Z Power Feed for Knee

CADCAM OPTION0 Order Code "F+4" Vero VisHSeries 2M2D Sold Machining with Solid Operations

Order Code "G1 Vero VishSeries 2D/3D Solid Machining with CAD $14,220.00

$ 8,060.00$ 9,550.00

$762.00$4200.00$1,825.00

$490.00$695.00

$600.00

$5,091.00$295.00$159.00

$6,055.00$436.00$159.00

$365.00$825.00$1,910.00$665.00$1,850.00$350.00$1,699.00$850.00

$635.00$635.00

$1,000.00$550.00

Sub Total

$1,624.00$550.00$250.00$1,106.25$1,450.00$192.00

$295.00$550.00

Sub Total

$440.00

$355.00

$575.00

$625.00

$69.40$460.00Sub Total

$6,700.00Price w/o Options

Total OptionsQhinrJnn

•60

$

•60

$

•60

$

$

•60

$

$

$

$

$

$

$

$

$

$

•60

•60

$

$

•60

•60

$

$

$

$

$

$

$

$

•60

$

$

•60

•60

•60

•60

•60

$

$

•60

$

$

$

8,060.00-

_-----

_-----------

-----

-

1,624.00650.00

-1,106251,450.00

192.00

295.00-

5,31725

-

-

-

_--

13,37725-

The Milltronics Centurion Control

Centurion VI Control

•Memory - Data Storage•3-1/2" 1.44 MB - Standard

100 MB Zip ® Drive - OptionalHard Disk 2 + Gig - OptionalRAM Memory - Volatile 16 MB - Standard32 MB - OptionalRAM Memory - Program Storage 6 MB - Standard

140 MB-OptionalRAM Memory - Operating System 2 MB

•Dual Processor Control Utilizes Latest Computer Technology•I t is estimated that 90% of all computer related engineering efforts are directed

towards the rapidly advancing PC arena. Centurion controls take advantage of theseadvances by utilizing a PC based Pentium processor to handle the operator interfaceand a robust 32 bit Motorola processor to handle the motion control. These combinedprocessors provide data throughput and features unsurpassed in the industry.

Because Centurion controls are based on a PC platform, expandable data storage,memory and communications are possible. You can also rest assured that the open PCarchitecture of the Centurion CNC controls will allow service and upgrades to beperformed well into the future and at substantially less cost than other dedicatedsystems. Additionally, all Centurion controls are five axis standard - allowing quickand inexpensive installation of an additional axis.

•Flexible Communications•Anyone who has struggled transferring programs with a CNC in the past will

appreciate the IBM format 1.44 MB floppy disk drive and RS232 communicationsport, both standard on the Centurion controls. Networking and Iomega Zip® are alsooffered as options to further enhance the file transfer ability of the control.

•Networking•Due to the Centurion control's PC architecture it is possible to connect to a Local

Area Network. Networking offers numerous advantages over RS232 communicationsas it provides transparent transfer of data at speeds of up to 100 MB/sec - more than50 times faster than typical RS232 communications. Features built into the softwarealso enhance the network connectivity by allowing the user to easily save and loadfiles to and from the network.

•Zip® Drive

•Fully compatible with Iomega Zip® Drives, which allow the user to transfer up to 100MB files via Zip disk to and from the machine seamlessly.

• A Front Panel Designed For The Operator•An operator will spend thousands of hours working with the front panel of any CNC,

this is why we have designed our front panel around an oversized high resolutionactive matrix LCD color screen rather than the tiny monochrome monitor often foundon other CNC's.

But we did not stop with the screen either. We listened to operators frustrated withinsensitive flat keypads and added a sealed full travel keypad. Machine functionbuttons such as flood, mist and spindle illuminate when selected. In fact buttons thatrequire operator response, such as Cycle Start, flash as needed to prompt the operatorthrough the task at hand.

•Conversational Programming

• A menu based question and answer format prompts the operator through programcreation. In most applications there is no need to memorize complex G and M codes.

Conversational programming is not only quick and easy, it's extremely powerful. Infact, many operations available in conversational programming are nearly impossibleto duplicate with G and M code programming. For instance the simple task ofincrementing a tool to depth with G and M codes usually involves complex looping ofsubprograms or many redundant commands. With conversational programming thistask is reduced to simple statements where only the cut increment and depths need tobe entered.

•Text Programming•All Centurion controls accept the G and M codes recognized as industry standard. If

you currently program in code, utilize a CAD CAM system, or are considering addinga CAD CAM system in the future, you can rest assured that compatibility will not bean issue.

A full word processor style editor is utilized on all CNC controls and offers helpfulfeatures such as search, search and replace, cut, copy and move. Programs as large as8 Mb can be edited concurrent to program execution.

•This useful feature allows an operator to take total control of machine movement andrun complex programs with confidence.

With this feature enabled program movement only occurs while the handwheel isbeing turned; stop turning the handwheel and machine movement stops immediately.The faster the handwheel is turned the faster the feedrate.

Ask any experienced CNC operator if they have ever crashed a machine and theanswer most likely will be yes. The usual cause is that the operator simply could notreact fast enough to the situation at hand. With this feature an operator can avoidcrashes and safely work near rotating lathe chucks or expensive fixtures.

•High Speed Control•All Centurion CNC controls have addressed the complex dynamics required for a

CNC to truly be categorized as high speed. The end result is that Centurion CNC'shave set the standard for performance in their class. Milltronics will benchmark ourcontrol against any other control in the industry!

Processor SpeedThere are literally thousands of calculations required for each and every axismovement. When trying to machine complex geometry, often the microprocessor ofthe control creates a bottleneck restricting the attainable feedrate. To minimize therisk of this processing bottleneck, Centurion CNC controls utilize two 32 bitprocessors providing over 150 megahertz combined processing speed. With these twoprocessors working together, over 1250 blocks per second can be achieved.

Intelligent Axis Acceleration And DecelerationControlling how an axis decelerates and accelerates is one of the most crucial factorsrelating to machine speed. Understanding that it is impossible for a servo motor tostop and start a heavy machine slide anywhere close to 1,000 times per second leavesthe only hope of achieving speed through greater intelligence of the acceleration anddeceleration slopes. All Centurion controls search ahead in a program as much as 255moves to determine the directional changes that lay ahead. Once these directionalchanges are known the CNC will dynamically adjust the deceleration and accelerationslopes to minimize stopping and starting.

AccuracyServo motors cannot instantaneously respond to a given command. This lack ofresponse negatively effects accuracy and only deteriorates as the feedrate increases.To counter the disastrous effects of servo response, Centurion CNC controls utilize anelaborate "Feed Forward" error correction algorithm that reduces inaccuracy withoutcompromising speed. Until now feed forward error correction has been found only ona handful of the world's most expensive CNC controls and should in no way beconfused with inferior error correction systems that rely on slowing feedrates tomaintain accuracy.

•Long List of Standard Features

on-line help.

If an operator has a question about a conversational programming screen, pressing theHelp button will pull down an illustration defining the operation at hand.

•Manual Operation with Teach Programming•The SLS control not only supports full manual operation of the machine, it also

allows a program to be constructed as the machine is operated manually.

When manually machining a part for the first time an operator simply needs to press abutton after each manual move and the present machine location is stored in anexecutable CNC program. The program is stored in both conversational and ISOformat making future editing easy.

•Dual Handwheel Operation (Option)•An electronic dual operator station can be added to any SLS control. This option

places the X and Y axis handwheels in a convenient location to reduce operatorfatigue.

•Manual Operation•The Centurion T CNC control fills the hole between manual engine lathes and

difficult to use CNC turning centers. Operation in full manual, simple MDI and fullyautomatic is standard.

For full manual operation a conveniently located remote panel places the necessarycontrols at the operator's fingertips. Single operations that cannot normally be madeby simply turning handwheels, such as tapers, radii and threading, can be madequickly and easily with conversationally prompted MDI screens.

•Teach Mode Programming•Teach mode programming allows an operator to construct a program through a

combination of manual and MDI commands.

Other teach systems only allow manual machine movements to be recorded into aprogram. These systems are highly restrictive in that it is impossible to cut threads,radii and tapers by simply turning a handwheel. The Centurion T control allows notonly manual moves to be recorded directly into a program, but also a series ofconversationally prompted MDI events including threading, tapers and arcs.

•Automatic Operation•Like the other Centurion CNC controls, the Centurion T has all of the advanced

features you could ask for: Conversational programming, Trig Help, Graphics andmore are all standard.

Virtually any part can be programmed quickly and easily with conversationalprogramming.

•Digitizing•Digitizing option permits quick, easy and cost effective duplication of parts with

unattended operation.

In lathe applications a digitized 2D part profile is ready to run at the CNC with no

additional processing. Output file is standard ISO G and M code. Not only can it beedited with any text editor, it can also be input into other CNC controls to maximizeproductivity.

In milling applications both 2D part profiles and complex 3D surfaces can becaptured. Output is standard ISO G and M code as well. With the use of the off-lineDigiscan software a digitized file can be inverted (male to female), cuttercompensated, scaled, rotated, mirror imaged and more It can also translate the fileinto a DXF or CDL format for input into popular CAD CAM systems.

Even if your needs do not call for Digitizing now it can be installed on all Centurioncontrols at a later date - installation is a simple four wire connection.

•Off-line Software^Off-line software of all Centurion CNC controls is available. Off-line software allows

programs to be created and graphically verified the same as they are at the machine.

The software also serves as a storage library for part programs and supports RS232communications for trouble-free communication with the CNC.

An additional feature allows import of DXF or CDL CAD files which expandsdifficult part programming capabilities.

•Increased Data Storage•Battery backed up SRAM program storage can be increased to 512K or 720K, or add

a hard disk to increase program storage to over 1 Gig.•Tool Offset Probing

• A table-mounted probe allows tool radius and length offsets to be set quickly andconsistently. The probe can be used in-process to determine tool breakage.

•Workpiece Probing•The Workpiece Probing option aids in setup of difficult parts. It provides the ability

to automatically set and correct work coordinates, tool offsets, rotation angle andmore after inspection of a fixtured part.

•General•Microprocessor - 32-bit IBM compatible PC based 1000 blocks/sec DNC with up to 5

axis of control Multi processor/parallel processing capability. Feed Functions: Jogfeed, rapid and incremental. Electronic handwheel, Feedrate override, Programmableacceleration and deceleration, Excess error fault protection, Minimum programmingresolution 0.0001", Mid program restart, Automatic start, stop, reverse, RPMoverride on Spindle, Tool Functions: 99 tool length and radius offsets, One buttontool setting routine.

Graphics Functions: Large color LCD screen, Full 3D view with rotational, iso,zoom, and window. Program verify, Runtime display (excellent forestimating). Feedrate, rapid rate, part and offset toolpath display.

Distinctive Programming Functions: Built-in engraving Linear, circular & helicalinterpolation Advanced trig help Part rotation Scaling (each axis individually if

ILL1R0NI.Manufacturing Company

CENTURION IV USERSGo From This - TO THIS1

CENTURION 7 PC Based CNC

CNC is self-contained in thecompact operator's station

AFF0RDABLY11

SPECIFICATIONS

FEATURES Centurion 7

Absolute / Incremental StdInch / MetricConversational ProgrammingTrigonometry Assist ('Trig Help")Corner Chamferinq And RoundingCutter CompensationColor Graphics - Tool Path and

Part ProfileCanned Drilling CyclesDiagnosticsExcess Error ProtectionFull Language Errors MessageBacklash CompensationBall Screw Pitch Error CorrectionMirror, Scale And RotateEIA/ISO Code (Fanuc®)

Compatibility*Macro ProgrammingSubprogram Looping And Nesting3 Point Circular InterpolationPolar CoordinatesAuto / Block OperationProgrammable DwellBlock SkipConcurrent ProqramminqHard Tapping (Optional)Digitizing ReadyProgram Interrupt And ResumeGraphics Based Mid-Program StartProgram Start from Block or Tool #Hand wheel RunTeach ProgrammingFeed Forward Error CorrectionSelectable Corner AccuracyAutomatic HomingCircular InterpolationAxis JogSoftware LimitsUnidirectional ApproachDry RunAutomatic Tool Setting ProgramSelectable LanguagesMultiple Work Offsets1 Button Tool / Fixture Offset Entry8 Mb Text Editing with Cut, Copy,Move and Search/ReplacePocketing and Framinq CyclesTapered And Round Walls3D Sweep RoutineHelical InterpolationBolt Hole Drill CycleEnqraving, with SerializingSpeed And Feed CalculatorOnline Help ScreensIrregular Pocket ClearingAuxiliary Keyboard JackCurrent MeterTrue Spindle Speed FeedbackNetwork CapableElectronic HandwheelPolygon Milling Cycles60 Work OffsetsParts Counter

StdStdStdStdStdStd

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adadadadadadadadOpt.adadadadadNAOpt.adadadadadadadadadadadad

adadadadadadadNAOpt.adadOpt.Opt.adadadad

* Compatibility varies with control version

Centurion 7 SLS

StdStdStdadStdStdStd

StdStdStdStdStdStdStdStd

StdStdStdStdStdStdStdStdOpt.StdStdStdadStdStdOpt.StdStdStdStdadStdStdStdStdStdStdStd

StdStdStdStdStdStdNAStdOpt.StdOpt.Opt.Opt.StdStdStdStd

CONTROL

Processor: Motion ControlProcessor Operator Interface

Program ThroughputAxis Control

Motorola 32 bitPentium 130 Mhz(Or greater)

Over 1300 blocks/sec4Axes- Standard

MEMORY - DATA STORAGEFloppy Disk 3 1/2" 1.44 Mb - Standard100 Mb Zip® DriveRAM Memory - Volatile

Optional16 Mb Standard32 Mb Optional

RAM Memory - Program Storage 12 Mb StandardNon-volatile 256 Mb - Optional

"SLS" Skill Level SelectFor machines without automatic tool changers, thisinnovative feature allows the CNC control to beconfigured to match the skills of the CNC operator.We have worked with a number of first-time CNCoperators and have recognized that the more fea-tures, screens and selections a CNC control has,the more intimidating it is for the operator. Oftenthese selections overwhelm the new operator,undermining confidence and lengthening thelearning curve. Skill Level Select solves this byallowing the operator to enable/disable features toa comfortable level. Operate the CNC in an easy touse two axis format, step up to a simplified threeaxis operation and, when ready, turn on all thefeatures to maximize productivity. In the highestskill level you will be ready for even the mostchallenging programs — from custom codes toparametric programming. Truly a control thatmeets all needs of toolroom milling!

A TRUSTEDNAME IN CNCFOR 30 YEARS!

PROPOSAL

UPGRADE PACKAGECPU assembly, PC based with upgrade adapter kit $6,995Operator's Station with new LCD screen, electronic handwheel and tactile keys 1,995Subtotal $8,990Less Milltronics User Special Discount - 2,490TOTAL $6,500

PARTS REUSED - Typically Reusable Unless Defective

Servo plate (if not reusable add $455 per axis for a used or reconditioned unit)Servo motors (if not reusable add $600 per axis for a used or reconditioned unit)Magnetics (will propose replacement of defective parts)Encoders (if not reusable add $200 per axis)

INSTALLATION - In The Field

Field installation will be arranged by Milltronics and performed by Milltronics or acertified dealer. A customer should not attempt to install this himself.

Installation $1,100.00PLUS

Expenses - air, auto, lodging Actual costsOr

Flat fee anywhere in the USA $1,900.00 + Air Ticket(Air ticket can be proposed prior to order)

INSTALLATION - In Our FactoryInstallationCustomer pays machine

ACCESSORIES

freight each way, estimated at $500.00 to. .$900$1,000

00.00

Upgrade to 12" Color LCD with Discrete Pushbutton Keys $900.00Off-line FastCAM Software $400.00Large Program Package $4,000.00

Includes: 256 Mb solid state non-volatile memory upgrade, Zip® drive,additional 16Mb extended program execution memory,feed forward and look-ahead for high speed machining or 3-Dmilling, and networking option with 30 day phone support

DRIVE SYSTEMConversion of Reeves drive system to an inverter or controlled direct drive system, upto 7 V2 HP (Must be done at the factory) $2,800.00

Centurion 7 Upgrade includes the following:Large color LCD display with 3D graphicsOperator's controls, pushbuttons, and panelElectronic handwheel with handwheel verifyKeyboard jack for PC keyboardCPU, PC-based with 1300 block/sec processing and 12 Mb parts storage

memory plus large program editing/execution capabilitySoftware features including conversational, G & M code programming,

3D part and tool path graphics, engraving, helical interpolation, autoroutines, user-definable macros with trig assist, coordinate rotation,scaling, mirror image, irregular pocket clear and much, much more.See the Centurion full catalog for a complete description.

3 V2" 1.44 Mb floppy driveInterface cable and hardware

WARRANTYAll new or replaced parts have a one-year parts warranty for normal usage. Originalreused parts have no warranty.

SPECIAL NOTEBecause we have concerns on the reusage of some machines, special softwarerequirements or other unusual circumstance, we reserve the right to refuse the sale ofthis upgrade package.

TERMSAny freight or rigging is not included with proposal. Customer should be prepared toincur additional expenses if original parts are found not to be reusable. This proposaldoes not include any replaced machine parts or repairs. New parts have a one-yearwarranty for normal usage. Original reused parts have no warranty.

Payment: 80% down with order20% net 30 days after installation

Make The

^HlLLlRONICSContact the factory for special offers or financingoptions. Subject to credit approval and approval by 1400 Mill Lane • Waconia • MN • 55387

your local distributor. 952-442-1410 • 952-442-6457 (Fax)www.milltronics.net

Milltronics reserves the right to amend or change without notice.Centurion 4 Upgrade Rev. 2 9-17-03

SINUMERIK 840D:The Digital System for Almost All Applications ..

The SINUMERIK 840D offers a convincingrange of innovative technology-specificfunctions.

Standard cycles are available for frequentlyrecurring machining operations in the drilling,milling and turning technologies.

And even extremely exacting applications, like5-axis milling in the manufacture of tools andmolds, are no problem for the SINUMERIKgeneration. The continuity from the CADsystem right through to the workpiece andintelligent motion control allow fast, preciseproduction of even highly complex parts. Theseparation of geometry and technology withRTCP (remote tool center point) and 3D tooloffset simplifies alterations. And the promptmachine stop facility, in the event of toolbreakage, for example, protects both machineand workpiece.

Solving digital tasks fast andprofessionally

The standard SINUMERIK 840D control in-cludes tailor-made functions for high produc-tivity and precision for grinding, flexible axismovements with the aid of positioning axesand reciprocating functions, short machiningtimes using multiple feed values in a blockand fast set-up by means of handwheel over-lay.

Time-critical process signals are connected todirect CNC inputs/outputs and programmedby synchronous actions. Special axis couplingscan be defined using cam tables, e.g. forswing-frame grinding. Transformation of aninclined axis also permits inclined bed appli-cations, and tool compensation is includedon-line to permit simultaneous grinding anddressing (continuous dressing).

In conjunction with adaptive control, theSINUMERIK 840D enables optimum utili-zation of spindle power, prevents overload,protects the workpiece, reduces machiningtimes and improves surface quality withoutthe need for additional hardware.

Handling tasks, such as work-piece mani-pulation, machine loading, packaging andpalletizing, can be easily performed byconnecting the handheld terminal (HT 6).

In the same way, an "electronic gear with non-linear coupling" is also possible. In additionto the manufacture of convex gear tooth sur-faces, it is thus possible to compensate fornonlinear characteristics of the process.

Technical Specifications:Impressive Performance Data

Control typeModular 32-bit microprocessor CNCcontinuous-path control for turning,drilling, milling and grinding machinesand handling with integrated powerfulPLC.The control consists of a 50-mm-widemodule and a choice of external intel-ligent operator panels to meet all typesof operator requirements.

Function overviewx Drilling, turning, milling, grinding,

nibbling, punching, laser machiningand handling technologies

x Optimum, complete digital solutionwith SIMODRIVE 611 digital

o Up to 10 mode groups, 10 channelsand 31 axes/spindles

o Channel structure: Simultaneousasynchronous processing of partsprograms

o OA open-ended NCK softwarex Feedrate and rapid traverse:

103 mm/min to 999 m/minx Endlessly rotating rotary axesx 2D+n helical interpolationx Spindle package with extensive

range of functions, for example,various thread cutting functions,variable pulse evaluation, orientedspindle stop

o 5-axis machining package with5-axis transformation, 5-axis toolcompensation, oriented tool retrac-tion (RETTOOL) remote tool centerpoint (RTCP)

o Spline interpolationo Polynomial interpolation of the

third degreeo Control value linking and curve

table interpolationo Electronic gearboxo Link axiso Axis containero Electronic transfero Axis and spindle movements from

synchronous actionso Speed-dependent analog value

outputo Sensor-controlled 3D distance con-

trol

o Evaluation of internal drive variableso Continuous dressingx Acceleration with jerk limitationx Programmable accelerationx Synchronized actions (SYNACT)x Coordinate transformation and

inclined-surface machining withFRAME

o Fast retraction from the contourwith RETT routines

x Direct/indirect measuring systemswitchover for high degree ofprecision and fast positioning

o Extensive motion control for veryfast machining with Look Aheadfunction and dynamic feed-forwardcontrol

x Travel to limit stop with adaptableforce or limited torque

x Follow-up modex Advanced detection of contour

violationso Tool-oriented RTCPx Configurable number of inter-

mediate blocks with tool radiuscompensation

x Tool radius compensation withapproach and exit strategies andcalculation of intersection

o Tool length compensationo Interpolation leadscrew error com-

pensation and measuring systemerror compensation

o Multidimensional sag compensationx Backlash compensationx Quadrant error compensationo Automatic quadrant error compen-

sation with neuronal networkx Safety routines permanently active

for measuring circuits, overtemper-ature, battery, voltage, memory,limit switch, fan monitoring, EPROM

x Working area limitationx Software limit switchx Contour monitoringx Spindle monitoringx Diagnostic functions from interface,

PLC and NC with plaintext displayson screen

o Interrupt routines with fast retrac-tion from the contour

o Safety Integrated

PLCx Integrated SIMATIC S7-compatible

CPU 315-2DPor314C-2DPo Program and data memory expand-

able to 288 KB or 460 KBx Programming language STEP 7o I/O modules expandable to 2048

digital inputs/outputsx Max. 4096 flags, 128 or 256 timers,

64 or 256 counters, 256 FBs/FCsand 399 DBs

o Servo or step motor PLC positioningaxis

o S7 HiGraph programmingo Distributed I/Os via PROFIBUS-DP

Operating componentsThe operator panels are modular instructure and can be assembled to pro-vide specific levels of performance.

o OP 01 OS operator panel (310 mmwide), 10.4" TFT display, VGA(640 x 480), mechanical keys

o Machine control panel (310 mmwide) with 16 customer keys,1 slot 22 mm dia. and 6 slots16 mm dia.

o Full CNC keyboard (310 mm wide)o OP 010 operator panel (19" wide),

10.4" STN color display, membranekeyboard

o OP 010C operator panel (19" wide),10.4" TFT color display, mechanicalkeys

o OP 012/OP 015A operator panel(19" wide), 12.1715" TFT color dis-play, membrane key board and in-tegral mouse, vertical soft keys canbe used as direct keys in the PLC

o OP 015 operator panel (19" wide),15" TFT color display, membranekeyboard

o TP 012 touch operator panel(400 mm wide)

o Machine control panel (19" wide)with 30 customer keys and key-switches

o MPI interface module for customermachine control panel

o Full CNC keyboard (19" wide)

o MFII PC standard PC keyboardo OP 030 slimline operator panel

(280 mm wide)o Handheld control terminalo HT6 handheld terminalo PCU 20

- COM 1 (V.24/TTY), COM 2 (V.24)- PS/2 keyboard- Multipoint interface (MPI)- USB, 2 channels (1 x internal/

1 x external)- Ethernet 10/100 Mbit/s (optional)- Cardbus (max. Type III)- Disk drive interface (option)

o PCU 50Industrial PC with 566 MHz/128 MBSDRAM or 1.2 GHz/256 MB SDRAM- Removable hard disk with trans-

portation lock (1 Gbyte for userdata)

- Microsoft Windows NT 4.0 (US)or XP operating system

- COM 1 (V.24/TTY), COM 2 (V.24)- LPT1 parallel port- PS/2 mouse, PS/2 keyboard- Multipoint interface (MPI)- USB, 2 channels (1 x internal/

1 x external)- Ethernet 10/100 Mbit/s (option)- Cardbus (max. type III)- Disk drive interface- Expansion slots:

1 x PCI/ISA + 1 x PCIo PCU 70

- Expansion slots: 1 x PCI/ISA +3 x PCI (otherwise the PCU 70is exactly as the PCU 50)

Operation and displaysx Clear operation with operating

areas with 8 horizontal and verticalsoftkeys each

x Operator panel disablex User-oriented hierarchical access

protectionx Supplement operator interface

(user-specific)o OA Windows operator interface

configurableo Control unit management (up to

8 PCUs to max. 8 NCUs)

Operating modes:x AUTOMATICx JOG (set-up)x TEACH IN (program generation

interactively with the machine)x MDA (processes manually entered

block)x The operating modes are supple-

mented by the machine functions:- PRESET to set a new coordinate

reference point- Simultaneous traversing of axes

with up to 2 handwheels- Overstoring machine functions in

setup mode and AUTOMATIC mode- Program selection via directory

Displays:o Screen text in several languages

(English, German, Spanish, French,Italian), other languages on request

x Program window for block displayx Positional actual values, 2- to 5-fold

character sizex Screen saverx Plaintext display for operating status

Programming:x User-friendly programming language

editor to DIN 66025 with comprehen-sive range of high-level languageelements

o Technology cycles for drilling, turningand milling

x Tapping without compensation chuckx Dimension input metric, inch or mixedx Extensive parameter technologyx Program generation parallel to

machiningx Reference point approach ace. to

programo Measuring cycles, measurement in

JOG modex Fast NC-PLC data exchange via

dualport RAMx Contour and cycle programmingx Simulation for turning and millingo AutoTurn - programming software

for simple turned partso ManualTurn - simple operating and

programming interface for turningo ShopTurn - convenient operating

and programming interface forturning and milling

o ShopMill - convenient operatingand programming interface formilling and drilling

o SinuTraino On-line ISO dialect interpretero CAD reader, converts DFX files into

drilling patterns and contoursx Dynamic block buffer (FIFO)x Configurable number of zero offsetsx Up to 2.5 MB NC user memory (RAM)

for parts programs, tool offsets, offsets

Communicationx RS232C (V.24)/TTY universal opera-

tor interface, configuration viaplaintext screenforms

x Read in/read out via universal inter-face during machining

x Extensive archiving procedureso Serial data transmission with

SinuCom PCINo Archive and transmit data with

DNCNT2000o Data transmission via standard

network with SinDNCo Communication of tool require-

ment via SinTDIo Communication to host computer

via SinCOMo Data exchange between production

planning and manufacturing viaWinBDE

x Program coordination via CNChigh-level language

x CNC-PCU multipoint interfacex 2nd serial interface (HMI via

external PC)o I/O interface via PROFIBUS-DP

(master or slave)

Keyx CNC functions included in the basic

configurationo Option or Accessory

HMI - Human machine interfaceMPI - Multi Point InterfaceNC - Numeric controlOA - Open architecturePLC - Programmable logic

controller

SIEMENS

SINUMERIK 802S & STEPDRIVESINUMERIK 802C & SIMODRIVE

Catalog September 2001

•*

J 1 ?••'

Mill UK

•

Function OverviewSINUMERIK 802S/SINUMERIK 802C

CNC memory (non-volatile) for programs and data, 256 KBPart program memory, up to 50 programsMax. 3 axes + 1 spindleSpindle positioningIncremental encoder RS 422Additional spindle encoder RS 422Resolution 1 jim/0.00001 inches

Look ahead, 1 block

Programming language, DIN 66025 and SINUMERIKhigh-level languageInch/metric dimensionsContour programmingAbsolute/incremental programmingX axis diameter/radius programmingArithmetic and trigonometric functionMenu programmingSubroutine callSkip functionChamfer/radius transitionPlane selectionWorkpiece coordinate system

Linear interpolation, max. 3 axesCircular interpolationHelical interpolation

RS 232 C serial interfaceData transmission from ECU to ECU

Slimline operator panel, monochrome, 5.7*Full CNC keyboard2 electronic handwheels can be connectedGraphical cycle support2 languages available in the system/switchable online,English/customer-specific (German/Chinese etc.)8 access protection levelsProgram execution via external DNC

AutomaticDNC modeMDA modeJOG modeTeach inReference point approach manual/via CNC programIncrement weighting with handwheelManual mode interruptJOG and handwheel simultaneous modeIncremental axis approachDry runSingle block

Block number searchProgram number searchBackground editing

Graphical displayStatus displayCurrent position displayProgram displayProgram error displayParameter displayOperator error displayAlarm displayServo setting displaySpindle displaySelf-diagnostics functionStatus signal output(NC ready, servo ready, automatic operation, etc.)

Length/radius compensationTool management15 tools30 tool offsetsTool radius offset in the planeCollision monitoring, machining areaTool tip radius compensationTool position compensationGeometry/wear compensationTool length measurement

Standard features at no additional costs

Option or accessory

Siemens Catalog SINUMERIK 802S/802C • September 2001

Function OverviewSINUMERIK 802S/SINUMERIK 802C

Zero offsets, adjustable, max. 4Zero offsets, programmable

Cycles for turningCycles for drilling/milling

Limit switch monitoring2 software limit switchesContour monitoringPosition monitoringClamping monitoring

Stored leadscrew error compensationBacklash compensationMeasuring system error compensationDrift compensation for analog set points

Velocity (max. default 100,000 mm/min / 40,000 inch/min)Feedrate override, 0% to 120%Feedrate per minFeedrate per revolutionTangential velocity constant controlJerk limitationJOG override

Miscellaneous function M (2 digit)Max. 3 auxiliary functions per block

Spindle speed, programmable (max. 999,999.9 rpm)Spindle override 0% to 120%5 gear stagesAutomatic gear stage selectionOriented spindle stopConstant cutting speedThread cuttingTapping/rigid tapping

SIMATIC S7-200 software CPUUser memory, 4000 instructionsLadder programmingDigital inputs/outputs, 16/16Digital inputs/outputs, 64/64 in 16/16 steps1024 flags16 timers32 countersTypical processing time for bit commands 1.8 p.s

Diagnostics basic functionsPLC status

Alarms selectable in the part programAlarms and messages from PLC

Start-up tools, running on external PCSeries start-up via serial interface

The manual machine version contains in additionthe following functions:

Constant oriented spindle stop for material changeThreading with constant cut profile at working spindleCutting of multiple threadsCutting of conic threadsCutting of transversal threadLimit stop turning in X and Z axisConic turning over the complete working areaRepair thread cutting

Standard features at no additional costs

Option or accessory

Siemens Catalog SINUMERIK 802S/802C • September 2001

SIEMENS

SINUMERIK 802D withSIMODRIVE 611 universal

Catalog • June 2000

System OverviewCNC Control

SINUMERIK 802D panel control unit, keyboards

The SINUMERIK 802D combines all CNC, PLC, HMI and com-munications tasks in a single component. The maintenancefreehardware integrates the PROFIBUS interface for the drives andthe I/O modules with the slimline operator panel in a ready-to-install unit.

The SINUMERIK 802D can digitally control up to 4 axes and1 spindle. The SIMODRIVE 611 system, which is modular indesign and PROFIBUS compatible, is used as the drive system.Consequently the drive power can be individually structured inevery respect. Alternatively, the spindle can also be connectedvia an analog interface, which means that universal solutionscan be implemented even for simple machines. The SIMATICS7-200 facilitates straightforward adaptation to the machine.

Workpiece programming can not only be carried out universallyon the SINUMERIK, but also allows the use of non-SiemensG codes.

The following components can be connected to theSINUMERIK 802D:

Full CNC keyboard (vertical format or horizontal format)I/O module PP 72/48 via PROFIBUS connectionConverter system SIMODRIVE 611 universal E via PROFIBUSElectronic handwheels (max. 3)Mini handheld unit

I/O module PP 72/48

The I/O module is connected to the PROFIBUS and offers72 digital inputs and 48 digital outputs (24 V, 0.25 A).The 3 connectors for the I/Os comply with MIL-C-83-503 (flatribbon cables).

The I/O module provides:3 x 24 digital inputs and 3 x 1 6 digital outputsIntegrated power supply 24 V DC with electrical isolationbetween I/Os and PROFIBUS

Machine control panel MCP

The machine control panel offers a simple and cost-effectivestandard solution for turning and milling machines. In addition to6 customized keys (with LED) all the keys and switches that areneeded to operate a machine are provided.

All wiring work for mode type selection, 2 override switches, NCstart/stop, spindle function and reset are taken care of by simpleconnection to the PP 72/48 I/O module using 2 ribbon cables.The EMERGENCY STOP switch is fitted with a break contact anda make contact.

aaaaaao

GDOS ana

SINUMERIK 802D panel control unit with full CNC keyboardvertical format (beside) or alternatively horizontal format (below)

I/O module PP 72/48

Machine control panel

• Siemens Catalog SINUMERIK 802D June 2000

SINUMERIK 802DFunction Overview

CNC user memory (non-volatile) for programs and data,256KBPart program memory, up to 100 programsMax. 4 axes + 1 spindleSpindle positioningIncremental encoder sin/cosAbsolute encoder EnDatAdditional spindle encoder RS 422Resolution 0.1 nm/0.00001 inches

Look ahead, 10 blocksFRAME concept (mirror image, scaling, rotation)1 measuring probe, with/without delete distance-to-go

Programming language, DIN 66025 and SINUMERIKhigh-level language, online interpreter for other G codesInch/metric dimensionsContour programmingAbsolute/incremental programmingX axis diameter/radius programmingDirect drawing dimension programmingArithmetic and trigonometric functionMenu programmingSubroutine callSkip functionChamfer/radius transitionPlane selectionWorkpiece coordinate system

Slimline operator panel, monochrome, 10.4"Slimline operator panel, color, 10.4"Full CNC keyboard3 electronic handwheels can be connectedGraphical cycle supportDIN simulation2 languages available in the system/switchable online,English/customer-specific (German/Chinese etc.)6 access protection levelsWorkpiece counterProgram execution via external DNC

AutomaticDNC modeMDA modeJOG modeReference point approach manual/via CNC programFollow-up modeIncrement weighting with handwheelManual mode interruptJOG and handwheel simultaneous modeIncremental axis approachDry runSingle block

Block number searchProgram number searchBackground editing

Linear interpolation, max. 3 axesCircular interpolationHelical interpolationPolar coordinate interpolation

RS 232C serial interfaceData backup and start-up with PC cardPROFIBUS

Graphical displayStatus displayCurrent position displayProgram displayProgram error displayParameter displayOperator error displayAlarm displayServo setting displaySpindle displaySelf-diagnostics functionStatus signal output(NC ready, servo ready, automatic operation, etc.)

Standard features at no additional costsOption or accessory

• Siemens Catalog SINUMERIK 802D June 2000

SINUMERIK 802DFunction Overview

Length/radius compensationTool management32 tools64 tool offsetsTool radius offset in the planeCollision monitoring, machining areaTool tip radius compensationTool position compensationGeometry/wear compensationAutomatic tool length measurement

Zero offsets, adjustable, max. 6Zero offsets, programmable

Working area limitationLimit switch monitoring2 software limit switchesContour monitoringPosition monitoringZero speed controlClamping monitoring

Spindle speed, programmable (max. 999,999.9 rpm)Spindle override 0% to 200%5 gear stagesAutomatic gear stage selectionOriented spindle stopConstant cutting speedThread cuttingTapping/rigid tapping

Cycles for turningCycles for drilling/milling

SIMATIC S7-2OO software CPUUser memory, 6,000 instructionsLadder programming languageWindows programming toolMax. 144/96 digital inputs/outputs2048 flags32 timers32 countersTypical processing time for bit commands 0.4 us

Stored leadscrew error compensationBacklash compensationMeasuring system error compensationFeedforward control

Rotary axis turning endlesslyVelocity (max. default 100,000 mm/min / 40,000 inch/min)Feedrate override, 0% to 200%Feedrate per minFeedrate per revolutionTangential velocity constant controlJerk limitationJOG override

Miscellaneous function M (2 digit)2nd auxiliary function H (6 digit)Max. 3 auxiliary functions per block

Diagnostics basic functionsPLC status

Alarms and messages selectable in the part programAlarms and messages from PLC

Axis limitation from PLCProtection zone

Start-up tools, running on external PCSeries start-up via serial interfaceSeries start-up via PC card

Standard features at no additional costsOption or accessory

Siemens Catalog SINUMERIK 802D • June 2000

*hriM \ * 1X111. Page 1 of4

De: Guerrero Roger <roger.guerrero@siemens.com>A: '"A00773434@itesm.mx"1 <A00773434@itesm.mx>Cc:Asunto: RV: Presupuesto RetrofitFecha: Tue, 26 Apr 2005 10:27:23 -0500

David,Anexo la respuesta por parte del desarrollador de producto.Saludos cordiales, Roger

Mensaje originalDe: Schneider WolfgangEnviado el: Martes, 26 de Abril de 2005 10:13 a.m.Para: Guerrero RogerAsunto: AW: Presupuesto Retrofit

Hi Roger,

Following situation:Our best block cycle times are:802C bl - 24 milli sec802D - 12 miili secBut more important for the processing are the time the processor realy hasto do the interpolation. If you have a one processor controller. Thiscontroller has to do all the work.If the partprogram is also well prepared via a post processor you can alsosave steps and get a higher speed.Next point is the requested or realiced accuracy of the part. I f accuracyis not necessary or not possible by the controller you very often get muchbetter surface.Last but not least is important how good is the optimisation of the mechanicparts of the machine.

If you have more questions please contact me again.

Best regardsWolfgang

Urspriingliche NachrichtVon: Guerrero Roger [mailto:roger.guerrero@siemens.com]Gesendet: Freitag, 22. April 2005 16:05An: Schneider WolfgangBetreff: RV: Presupuesto Retrofit

Hi dear Wolfgang. How are you? Long time since have talked each other.

A university of Mexico is interested in doing a retrofit with 802C BL and802D. They have a question that I couldn't answer. They are asking me howmany blocks per second are able to process?

RegardsRoger

Mensaje originalDe: David Reyes Luna [mailto:A00773434@itesm.mx]Enviado el: Jueves, 21 de Abril de 2005 05:57 p.m.Para: Guerrero RogerAsunto: RE: Presupuesto Retrofit

Roger,

Gracias por las propuestas. Pienso que la mejor opcion seria el 802C.

http://mailserver 1. itesm.mx/mail/MessagePrintView?sid=6ED0683EEB7C68452D7E 17F1173 A8... 5/20/2005

POS.

1

3

6

CANT.

2

1

1

MLFB

1FK7042-5AF

6FC55000AA

6FC55480AC

DESCRIPCION

SERVOMOTOR SINCRONO 1FK7COMPACT,3,0 NM, 100 K, 3000 R/MINREFRIGERACION NATURAL,IM B5 (IM V1, IM V3)CONECTOR POTENCIA/SENALESCONECTOR GIRABLE 270 GRADOS,SIS. CAPTADOR RESOLVER 2 POLOS;(RESOLVER P=1);EJE CON CHAVETA, TOLERANCIA NSIN FRENO DE MANTENIMIENTO;GRADO PROTECCION IP64;

SINUMERIK 802C BASE LINEPAQUETE BASE COMPUESTO DE:CONTROL DE PANEL MANDO INCL:PANEL DE MANDO DE MAQUINAPERIFERIA 48/16 E7S DIGITALESTOOLBOX LOGBOOK

SIMODRIVE BASE LINECONVERTIDOR PARA DOSSERVOMOTORESCON RESOLVER 2 POLOS 6+3NMDEL TlPO 1FK7 INTENSIDAD 2X5 A

PRECIO

737.59

4,393.58

2,887.65

1,475.19

4,393.58

2,887.65

POS.

1

3

4

CANT.

2

1

1

MLFB

1FK7042-J

6FC5600-C

6FC5603-C

DESCRIPCION

SERVOMOTOR SINCRONO 1FK7COMPACT,3,0 NM, 100 K, 3000 R/MINREFRIGERACION NATURAL,IMB5(IMV1,IMV3)CONECTOR POTENCIA/SENALESCONECTOR GIRABLE 270 GRADOS,SISTEMA CAPTADOR INCREMENTAL;(ENCODER I-2048);EJE CON CHAVETA, TOLERANCIA NSIN FRENO DE MANTENIMIENTO;GRADO PROTECCION IP64;

SINUMERIK 802D PAQUETE BASE 1:-TECLADO CNC COMPLETO VERT.-1 X SIMODRIVE 611 UNIVERSAL E-1 X MODULO MOTION CONTROLCON PROFIBUS-DP-1 X MODULO PERIFERIA PP 72/48-3 X CONECTORES PROFIBUS-SINUMERIK 802D TOOLBOXSINUMERIK 802DPANEL DE MANDO DE MAQUINAFORMATO ELEVADOMONTAJE JUNTO A LA PANTALLA24V, CONEXION CABLE PLANOADAPTADO 6FC5611-0CA01 -0AA06FC5611-0CA01-0AA0

PRECIOUNITARIO

1,117.96

6,955.20

607.03

TOTAL

2,235.91

6,955.20

607.03

11

16

1

1

6SL3000-0

6SN1145-'

SINAMICS / SIMODRIVE 611PAQUETE FILTRO RED 16KWENTRADA: 3AC 380-480V, 50/60HZCOMPUESTO DE: BOBINA DE RED HFTIPO 6SN1111-0AA00-0BA1 YFILTRO DE REDTIPO 6SL3000-0BE21-6AA0SIMODRIVE 611MODULO E/R, 16/21 KWREGULADO,EVACUACION DE CALOR INTERNA,PROTECCION DE RED CONCONTACTO ABIERTO

1,280.81

2,468.48

1,280.81

2,468.48

The Powerful HEIDENHAIN Contouring Control

iTNC 530

Built for the workshopThe machine operator can programhis operations in dialog with thecontrol. For simple work it is easyto operate the machine manuallywith the iTNC 530.

Fast block-processing times andoptimum motion control make theiTNC the perfect choice for HSCmachining

Automated manufacturingOn machining centers the iTNC 530manages tools and pallets. Overthe data interfaces you can eveninterrogate operating conditions oroperate the machine remotely.

For 20 years, TNC contouring controls have been proving themselves in daily use on milling machines,drilling and boring machines, and machining centers. This success is due in part to its shop-orientedprogrammability, but also to its compatibility with the programs of its predecessor versions. TheiTNC530 is also compatible in its operation and programming with its predecessor models.

The machinist who has already worked with TNC does not have to relearn. On the iTNC 530 heimmediately uses all of his previous experience with TNCs, programming and machining as before.

The iTNC 530 features a new, more powerful processor architecture, to enable you to finish your jobsin the workshop even more quickly:. With its sophisticated closed-loop control methods and short block processing times, the iTNC

530 mills your workpieces faster then ever., With the fast editor of the iTNC 530 you can edit and add to you existing programs in seconds.. You can verify even complex programs quickly and simply with the iTNC 530 through its optimized

graphic buildup.

# Over its Fast Ethernet data interface (100 megabaud) you can transfer long programs quickly froma remote programming station to the control.

The new iTNC 530 therefore combines modern technology with the well-known user friendliness of aTNC.

Specifications

Components

Program memory

Input resolution and display step

Input range

Interpolation

Block processing time(3-D straight line without radiuscompensation)

Axis feedback control

Traverse range

Spindle speed

Error compensation

Data interfaces

Ambient temperature

# MC 422 main computers CC 422 controller unit. TE 420 keyboard unit# TFT color flat-panel display with soft keys: BF 120 with 10.4

inches or BF 150 with 15.1 inches

Hard disk

. To 0.1 urn for linear axes# To 0.0001° for angular axes

Maximum 99999 999 mm (3.937 inches) or 99999.999°

# Straight line in 4 axes. Straight line in 5 axes (export permit required)

^•software option 2# Circle: in 2 axes

in 3 axes with tilted working plane„ Circle in 3 axes with tilted working plane

^-software option 1. Helix:

Combination of circular and linear motion, Spline:

Execution of splines (3rd degree polynomials)^•software option 2

# 36 ms# Option: 0 5 ms

^software option 2

, Position loop resolution: Signal period of the positionencoder/1024

, Cycle time of position controller: 1.8 ms» Cycle time of speed controller: 600 us# Cycle time of current controller: minimum 100 MS

Maximum 100 m (3937 inches)

Maximum 40000 rpm (with 2 pole pairs)

, Linear and nonlinear axis error, backlash, reversal spikesduring circular movements, thermal expansion

„ Stick-slip friction

# One each RST232-C / V.24 and RS-422 / V. 11 max. 115 Kbfe. Expanded data interface with LSV2 protocol for remote

operation of the iTNC 530 through the data interface with theHEIDENHAIM software TNCremo

# Fast Ethernet interface 100BaseT

. Operation- 0 "C to +45 °C (32 "F to 113 °F)

. Storage: -30 "C to t-70 °C (-22 °F to +158 *F)

Software Option 1

Machining with a rotary table

Coordinate transformations

Interpolation

v Programming of cylindrical contours as if in two axes# Feed rate in mm/min

* Tilting the working plane

# Circle: in 3 axes with tilted working plane

Software Option 2

3-D machining

Interpolation

Block processing time

# Motion control with minimum jerk, 3-D tool compensation through surface normal vectors. Tool Center Point Management (TCPM): Using the electronic

handwtieel to change the angle of the swivel head duringprogram run without affecting the position of the tool point

. Keeping the tool normal to the contoura Tool radius compensation normal to the direction of traverse

and tool# Spline interpolation

a Straight line: in 5 axes (export permit required)# Spline:

Execution of splines (3rd degree polynomials)

. 0.5 ms

APPENDIX D.- Actuator Specifications

79

www.DanaherMotion.com

HoUmorgen ServoMotors & Drives

Pacific ScientifStep Motors

& Drives

Pnctfic ScientificSynchronous

Motors

Servo & StepMotors and Drives

Sttmims,DANA HERMOTION

Product Selection Tree

Specialty Motors

Call 1-866-993-2624 or emailcontactus@danahermotion.com

Step, Sync, PMDC

DDL - Ironless _

DDL • Ironcore —I

Call 1-866-993-2624 or email

contactus@danahermotion.comCall 1-866-993-2624 or email

contactus@danahermotion.com

www.DirectDriveRotary.com

Conventionalwww.ServoMotorProducts.comwww.DirectDriveLinear.com

0.18-16.8 0.18-41.6 0.84-16.5 | 1.2-53 ! 0.70-124

Encoder, Resolver Encoder, Resolver Encoder, Resolver ! Encoder, Resolver j Resolver

SERCOS interface™ SERCOS interface™ SERCOS interface™ i SERCOS interface™ I SERCOS interface™PROFIBUS PROflBUS PROflBUS ! PROFIBUS i

CANOpen, DeviceNet CANOpen, DevlceNet CANOpen, DeviceNet I CANOpen, DeviceNet I

Online Product Selector

Go to www.DanaherMotion.com/advisor to use our intuitive, one-of-a-kind.Online product selector. This product attribute search engine allows you toexamine our vast database of produas to choose from the many solutionsKollmorgen and Pacific Scientific products offer.

10

MOTION PRODUCTS

FlexDrive77/ Flex+Drive77

Servo Controls

Installation Manual

10/02 MN1902

Introduction 2

2.1 FlexDrive77 features

Throughout this manual, both the FlexDrive11 and the Flex+Drive11 will be referred to simply asFlexDrive11. Where there is a difference in specification it will be clearly marked.The FlexDrive77 is a versatile compact control, providing a flexible and powerful solution forsingle axis rotary systems. Standard features include:

• Single axis AC brushless drive• Wide range of models with continuous current ratings from 2.5A to 27.5A• Direct connection to 115VAC or 230VAC single-phase or 230-460VAC three-phase

supplies (model dependent)• Resolver or encoder feedback• Velocity and current control, with pulse and direction input for position control• Auto-tuning wizard (including position loop) and software oscilloscope facilities• 8 optically isolated digital inputs• 3 optically isolated digital outputs• 1 general-purpose analog input (can be used as a speed or torque command reference)• 1 control relay• Selectable RS232 or RS485 communications

Flex+Drive^only:• Integrated motion controller for rotary and linear positioning systems• Programmable in Mint• Up to 16 programmable preset moves (expandable to 256 with factory-fitted CAN and I/O

option)• Position control using preset moves, software gearing and point to point moves• Flash memory for program storage (64k).• Motion controller for rotary and linear positioning systems

Factory-fitted options expand the I/O capabilities of the FlexDrive77 and provide CANopen,DeviceNet or Profibus connectivity. See Appendix A for details about options. FlexDrive77 willoperate with a large number of brushless servo motors - for information on selecting Baldorservo motors, please see the sales brochure BR1202 (BR1800 for linear motors) availablefrom your local Baldor representative.

This manual is intended to guide you through the installation of FlexDrive77. The sectionsshould be read in sequence.

The Basic Installation section describes the mechanical installation of the FlexDrive77, thepower supply connections and motor connections. The other sections require knowledge ofthe low level input/output requirements of the installation and an understanding of computersoftware installation. If you are not qualified in these areas you should seek assistance beforeproceeding.

MN1902 Introduction 2-1

B.1.3 Position control (Pulse and Direction)Setting the control mode to Position Control (Pulse and Direction) configures the FlexDrive77

as a positioning system, as shown in Figure 45, capable of following a position commandsignal.

The profiler interprets the pulse and direction signals and uses them to generatecorresponding position, speed and acceleration demand signals.

The position and speed demand signals are fed into a position controller and used, togetherwith the position measured from the feedback device, to generate a suitable speed demandsignal. If the position controller is tuned correctly, the measured position will accurately trackthe position demand.

The speed demand signal from the position controller is fed into the speed controller and used,together with the speed measured from the feedback device, to generate a torque demandsignal. If the speed controller is tuned correctly, the measured speed will accurately track thespeed demand. To improve the tracking performance of the speed controller, the profileracceleration demand is fed in at this point.

Finally, the torque demand signal is fed into a torque controller, which determines theappropriate amount of current to apply to the windings of the motor. This demand current iscompared with the actual winding current measured from sensors, and a suitable pulse widthmodulation (PWM) signal is generated. This PWM signal is fed to the power electronics in thedrive.

Position reference(Pulse and Direction)

n n_n t

Profiler

}tAccnSpeeiPosrti

- J PositionlEJ controller

. Speed[demanc

.I Speedcontroller

Torquedemanc I ToI?HPcontroller

tPWM Power stage!

+ motor r~"l

Measured current I IMeasured speed 1Measured position

Figure 45 - Control structure in Position control (Pulse and Direction)

B-4 Control System MN1902

DJ\ NA HERMOTION

Ing. David Reyes LunaAsistente de Docencia Dpto. MecanicaITESMTel. 8358-2000 ext. 5454mail. a00773434@itesm.mx

APPLIEDMexico, S. A. de C. V. ®

Mexico D.F. a 15 de Febrero 2005

Ponemos a su consideracion la siguiente cotizacion, esperamos vernos favorecidos con su pedido

QtY11

111

1

1

1

1

11

1

1

ModelAKM21E-ANCNC-00S20360-VTS

CP-102AAAN-03-0CF-DA0111N-03-0PMA22B-00100-00

PC832-001-T

PFC-010101-010

PPC-010101-010

S30361-NA

BAR-300-66BSM50N-133AA

FDH1A02TB-RN20

CBL030SP-SF-MHMALMAKM21E-ANCNC-00S20360-VTSCP-102AAAN-03-0CF-DA0111N-03-0

BrandKollmorgenKollmorgen

KollmorgenKollmorgenPacificScientificPacificScientificPacificScientificPacificScientificKollmorgen

KollmorgenBALDOR

BALDOR

BALDOR

DescriptionAKM series brushless servomotorS200 series brushless servo drive, alimentacion de 115 vac, 3amp.Power cableFeedback cablePMA series brushless servomotor

PC800 series brushless servo drive, alimentacion de 115 vac.2.5 ampMotor Feedback Cable

Motor Power Cable

S300 series brushless servo drive. Opcional en lugar de la serieS200300 Watt, 66 ohm regen resistor. OpcionalSERVOMOTOR SIN ESCOBILLAS CON RESOLVER

SERVOANPLIFICADOR ALIMENTACION DE 115 VAC,CORRDSNTE DE 2.5 AMP. CON FUENTEINTEGRADA DE24 VDC, RESISTENCIA REGENERATIVA, 8 ENTRADAS,3 SALIDAS CONFIGURABLESJUEGO DE CABLE DE FUERZA Y RESOLVER DE 3METROS DE LONG.

Unit Price Net Price581.00797.75

124.40124.40737.65

1173.50

205.75

205.75

1016.50

250.75496.90

974.65

190.75

Total amount

EL TIEMPO DE ENTREGA para la marca BALDOR DE 4 semanas, para Kollmorgen y Pacific Scientific de 6-7 semanas UNA VEZCONFIRMADA LAORDEN DE COMPRACONDICIONES DE VENTA LAS GANADAS POR SU EMPRESA.LAB. ALMACEN MEXICO. Los precios antes mencionados son netos en Dolares Americanos y se les cargara el 15 % de I.V.A. almomenta de facturar en pesos al tipo de cambio vigente en esa fecha.

Atentamente,

Ing. Jose Juan Ortiz V.

200V Three-phase Sigma II Servo Systems

General PurposeS G M G H S e r V O m O t O r S -With Incremental /Absolute Encoder

Rated Output: 0.45kW, 0.85kW,1.3kW,1.8kW, 2.9kW,4.4kW, 5.5kW, 7.5kW,11kW, 15kW.

For Additional Information

SGMGH Ratings & SpecificationsSGMGH Speed/Torque CurvesSGMGH DimensionsSGMGH Selection/Ordering InformationSGDH Ratings & SpecificationsSGDH Dimensions

Page(s)

585960 - 6263 - 6899 -100

101 -112

Design Features

1. Compact• Small sized motor

Compatible with previous generation G series motorsTen types of rated outputs ranging from 0.79 to 1988in • Ib of peak torqueOptional built-in holding brake available

2. Higher Speed and acceleration• Up to 3000rpm maximum• High torque to inertia ratio

3. Encoders• 17-bit (32,768 ppr x 4) incremental encoder (standard)• 17-bit absolute encoder (optional)

4. Enhanced Environmental Resistance• Totally enclosed, self-cooled IP67 (excluding shaft)• Shaft seal (optional)

5. Application Emphasis• Machine tools and woodworking machines• Packaging machines• Gantry Robots• Press Automation• Thermoforming

6. Certified International Standards• UL, cUL recognized (File #: E165827) CE compliance

200V Three-phase Sigma II Servo Systems

Servomotor Ratings and SpecificationsTime Rating:Insulation:Vibration:Withstand Voltage:Insulation Resistance:

ContinuousClass F15nm or less1 5 0 0 ^10MQ minimumat 500Vnc

Enclosure: Totally-enclosed, self-cooledIP67 (except for shaft opening)

Ambient Temperature: 0 to 40°CAmbient Humidity: 20 to 80%

(non-condensing)Rated Speed*: 1500rpm

Maximum Rotational Speed*:

Excitation:Drive MethodMounting:

0.45to7.5kW: 3000rpm11and15kW: 2000rpmPermanent magnet

: Direct driveFlange-mounted

Values when the servomotor is combined with an SGDH servo amplifier

MOTORS:SGMGH-

05ADA

09ADA

13ADA

20ADA

30ADA

44ADA

55ADA

75ADA

1AADA

1EADA

RatedOutput*

kW(hp)

0.45(0.6)

0.85(1.1)

1.3(1.7)

1.8(2.4)

29(3.9)

4.4(5.9)

5.5(7.4)

7.5 (10)

11(15)

15(20)

RatedToque'

N«m

2845.39

8.34

11.5

18.6

28.4

35.0

48.0

70.0

95.4

b f in (KG* cm)

25(29)

48(55)

74(85)

102(117)

165(190)

252(290)

310(357)

425(490)

620(714)

845 (974)

Instantaneous PeakTorque*

N«m

89213.8

23.3

28.7

45.1

71.1

87.6

119175224

Ibf in(KG-cm)

79(91)

122(141)

207(238)

254(293)

400(460)

629(725)

775(894)

1053(1210)

1550(1790)

1988(2290)

RatedCurrent*

A * .387.110.7

16.7

23.8

32.8

42154.7

58.6

78.0

InstantaneousMaximumCurrent*

An , ,

111728425684110130140170

MOTORSSGMGH-

05AOA

09ADA

13ADA

20ADA

30ADA

44ADA

55AQA

75ADA

1AAOA

1EAOA

Values when the servomotor is combined with an SGDH servo amplifier.

TorqueConstant

73(0.82)

7.3(083)

7.4(0.84)

6.5(0.73)

7.3(082)

8.0(0.91)

7.8(0.88)

8.2(0.93)

11(1.25

11.7(1.32)

Moment of Inerta

Ib-in'S2

xitr3

6.41

12.3

18.2

28.1

40.7

59.8

78.8

111

249

279

KC'tn2

xVt*

7.24

13.9

20.5

31.7

46.0

67.5

89.0

125

281

315

Hddhig Brake (at 20*C)

Capacity

W

9.85

18.5

23.5

320

35.0

Torque

N-m

441

12.7

43.1

726

84.3

115

Col.Resistance

W

58.5

31.1

24.5

18.0

16.4

RatedCurrent

A

0.41

0.77

0.98

1.33

146

AddionalInertia

Ib-in-s2

x1O*

1.85

7.75

7.75

16.7

33.2

AllowableLoadInertia

KG-rn 2

x io 4

36.2

69.5

103

159

230

338

445

625

1405

1575

RatedPowerRate*

kW/s

11.2

20.9

33.8

41.5

75.3

120

137

184

174

289

RatedAngular

Acceleration*

ratfs2

3930

3880

4060

3620

4050

4210

3930

3850

2490

3030

InorksTime

Constant

ms

5.0

3.1

2.8

2.2

1.9

1.3

1.3

1.1

1.2

0.98

InductiveTime

Constant

ms

5.1

5.3

63

128

125

15.7

16.4

18.4

226

27.2

* Values when the servomotor is combined with an SGDH servo amplifier at an armature winding temperature of 20°C." These characteristics can be obtained when the following heat sinks (steel plates) are used for cooling purposes:

Type 05ADA to 13ADA: 15.75 x 15.75 x 0.79 (in) (400 x 400 x 20 (mm))Type 20ADA to 75ADA: 21.65 x 21.65 x 1.18 (in) (550 x 550 x 30 (mm))Type 1AADA to 1EADA: 25.59 x 25.59 x 1.38 (in) (650 x 650 x 35 (mm))

56

100/200V Sigma II Servo Systems

S G D H SerVO A m p l i f i e r - For Speed, Torque, & Position ControlWith Incremental or Absolute Encoder

Single-phase Three-phase

For Additional Information

SGDH Ratings & SpecificationsSGDH DimensionsSGDH Internal ConnectionsConnection Diagram, Single PhaseConnection Diagram, Three PhaseConnector Terminal Block UnitTerminal Block Pin NumbersAmplifier/Encoder ConnectionsCable Specs and PeripheralsSGMAH Sigma II Servo SystemSGMPH Sigma II Servo SystemSGMPHGearmotorSGMGH Sigma II Servo SystemSGMGH GearmotorSGMSH Sigma II Servo System

Page(s)

99-100101-112113-114115116117118119121-12511 -2829 -4647 -5657 -6865 -8485 -96

Design Features

1. Improved Performance• Higher bandwidth response (400Hz speed loop frequency response)• Positioning settling time shortened to 1/2 to 1/3• Smooth control at low rpm made possible by Sigma II servomotors'

high resolution feedback2. Easy Operation

• All-in-one model (speed, torque, and position control)• PC monitoring function available including graphical tuning and file storage• Adaptive-tuning function

Online auto-tuning• Multi-axis communication provided as standard

One PC can communicate with up to 14 SGDH units by parameter setting• Built-in parameter setting device• On-board storage of alarm history• Automatic determination of motor settings at connection

3. Additional functionality with ready-to-install application modules• Configurable single axis controls including serial networking capability• Fieldbus connectivity (Devicenet™, Profibus™, etc.)• Full closed loop (optional position feedback)• Yaskawa MP940 single axis motion controller

4. Certified International Standards• UL, cUL listed (File #: E147823), CE compliance

95

100/200V Sigma II Servo Systems

SGDH Amplifier Ratings and Specifications

Bas

ic S

peci

ficat

ions

Spe

ed/T

orqu

e C

ontro

l Mod

e

Inpu

t Pow

erS

uppl

y Main Circuit*

Control Circuit*

Control Mode

Feedback

Loca

tion Ambient/Storage Temperature**

Ambient/Storage Humidity

Vibration/Shock Resistance

Structure

Per

form

ance

Inpu

t Sig

nal

Speed Control Range

Spe

edR

egul

atio

n*** Load Regulation

Voltage Regulation

Temperature Regulation

Frequency Characteristics

Accel/Decel Time Setting

Spe

edR

efer

ence

Tor

que

Ref

eren

ceIC

onta

ct S

peed

Ref

eren

ce

Reference Voltage*"*

Input Impedance

Circuit Time Constant

Reference Voltage"**

Input Impedance

Circuit Time Constant

Rotation Direction Selection

Speed Selection

Three-phase (or single-phase) 200 to 2 ^ ^ +10% to -15% 50/60 Hz,or single-phase 100 to 1 ^ +10%to -15% 50/60 Hz

Single-phase 200 to 2 3 0 ^ (or 100 to 115^) +10% to -15% 50/60 Hz

Three-phase, full-wave rectification IGBT PWM (sinusoidal commutation)

Serial incremental encoder, absolute encoder

0to55°C/-20to85°C

90% or less (no-condensing)

4.9m/s2/19.6nVs2

Base mounted (duct ventilation available as option) and flat mount type

1:5000 (The lowest speed of the speed control range is the speed at which the servomotor will notstop with a rated torque load.)

0%to100% 0.01% max. (at rated speed)

Rated voltage ±10%: 0%(at rated speed)

25 ± 25°C: 0.1% maximum (at rated speed)

400Hz(atJL = . y

0 to 10s (Can be set individually for acceleration and deceleration).

±6VQC (variable setting range: ±2 to ±10VDC) at rated speed (forward rotation with positivereference); input voltage: ±12V (maximum)

Approximately 14k&

—

±3VDC (Variable setting range: ±1 to ±10V) at rated torque (forward rotation with positivereference), input voltage: ±12VQC (maximum)

Approximately 14kQ

Approximately 47us

Uses P control signal

Forward/reverse rotation current limit signals are used (1st to 3rd speed selection). When bothsignals are OFF, the motor stops or enters another control mode.

Notes: * The power voltage must not exceed 230V +10% (253V). If it is likely that it will exceed this limit, use a step-downtransformer. For types SGDH-08AE-S and SGDH-15AE-S, voltage is 200 to 230V + 10% -5%.

** Use the servo amplifier within the ambient temperature range. When enclosed, the temperatures inside the cabinetmust not exceed the specified range.

*** Speed regulation is defined as follows:

Speed regulation = (no-load motor speed - full-load motor s p e e d ) x 1 0 0 %

rated motor speed

**** Forward is clockwise viewed from the non-load side of the servomotor, (counterclockwise viewed from the load andshaft end).

97

APPENDIX F.- Case Study I Results

Data Processing test

1-D STRAIGHT LINE

Control Option:G64ONProgrammed Feed Rate Vfp (mm/min)

Total Time (s)Calculated time (s]Feedrate (mm/minBlock time(ms) jBlock /s (BPS)

500

84.084.0

500.012.083.3

1000

42.042.0

1000.06.0

166.7

2000

31.131.1

1350.04.4

225.0

3000 4000

31.131.1

1350.04.4

225.0

31.131.1

1350.04.4

225.0

1-D STRAIGHT LINE

Control Option:G64 ONProgrammed Feed Rate

Total Time (s)Calculated time (s]Feedrate (mm/minBlock time(ms)Block /s (BPS)

500

84.084.0

500.06.0

166.7

1000

62.262.2

675.04.4

225.0

) Vfp (mm/min)2000| 3000

62.262.2

675.04.4

225.0

62.262.2

675.04.4

225.0

4000

62.262.2

675.04.4

225.0

1-D STRAIGHT LINE

Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)

2503

Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)

500

124.4124.4337.5

4.4225.0

1000

124.4124.4337.5

4.4225.0

20001 3 0 0 0

124.4124.4337.5

4.4225.0

124.4124.4337.5

4.4225.0

4000

124.4124.4337.5

4.4225.0

Figure F1.1-D Straight line results.

101

Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)

500| 1000J 2000| 3000| 4000

Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)

84.584.0

500.0006.033

165.759

62.562.9

668.2164.464

224.000

62.562.9

668.2164.464

224.000

62.562.9

668.2164.464

224.000

62.562.9

668.2164.464

224.000

—

2-DS

Line

TRAIGI

700

•IT LINE

mm

•

28012 blocks

Controller BControl Option:G64 ON

Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)

127.0127.0330.7

4.5220.6

127.0127.0330.7

4.5220.6

127.0127.0330.7

4.5220.6

127.0127.0330.7

4.5220.6

127.0127.0330.7

4.5220.6

Figure F 2.2-D straight line results

3-D STRAIGHT LINE

Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)

Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)

5001,24.34

84.384.0

500.0006.020

166.121

10001,02.96

62.862.8

668.3644.487

222.852

2000

62.862.8

668.3644.487

222.852

30001,02.84

62.862.8

668.3644.487

222.852

4000

62.862.8

668.3644.487

222.852

102

3-D STRAIGHT LINE

Control Option:G64 ONProgrammed Feed Rate Vfp (mm/min)

250 500 1000 2000[ 3000 4000

Total Time (s)Calculated time (s)Feedrate (mm/min)Block time(ms)Block /s (BPS)

2,08128.0128.3

327.3584.6

218.8

2,08128.0128.3

327.3584.6

218.8

128.0128.3

327.3584.6

218.8

2,08128.0128.3

327.3584.6

218.8

128.0128.3

327.3584.6

218.8

Figure F 3.3-D straight line results.

Average Feedrate calculation Siemens 802D and 802C

SIEMENS 802DController Price (US$) 6,955.20Simodrive 611 U(US$) _[ 5,048.73Processing time** i 12

Line Segment (mm)

0.10.05

0.025** Manufacturer

Saturationfeedrate

(mm/min)

msTotal linedistance

(mm)700700700

Blocks

70001400028000

Calculedfeedrate

(mm/min)500250125

SIEMENS 802CController Price (US$)Simodrive Base Mne(US$]Processing time**

Line Segment (mm)

0.10.05

0.025

4,393.582,887.65

24Saturationfeedrate

(mm/min)

msTotal linedistance

(mm)700700700

** Manufacturer

Blocks

70001400028000

Calculedfeedrate

(mm/min)250125

62.5

Relative Value Evaluation for 3-D straight line

83J33I802D vs. 802C41.6

103

APPENDIX G. - Case Study II Results.

Data Processing test

For block processing evaluation DNC function was used. Centurion VII internet

brochure specifies that the two32 bit processors working together can achieve 1250

blocks/s. (For more detail specifications of hardware and software features see

APPENDIX C). Results for the block processing times are illustrated in Figure G 1.

£

seco

nd

,is

per

Blo

c)

500 •

400

(

300

200

(

1

500

- •

0*

00

00

00

1000 1500

- 0.1mm_DNC ON 255 LookAhead

CENTURION VII

X0

0

0

0

0)

„ . <0

2000 2500 3000

Programmed Feedrate Vfp, (mm/min)

\3•I

3500 4000

- ^ — 0.05mm_DNC ON 255 LookAhead • 0.025mm_PNC ON 255 lookahead

Figure G 1. Centurion VII block processing times for DNC On function.

Is not possible to quantify a real block processing time because the obtained

values didn't arrive to a saturation point.. The best value of BPS is 498, and corresponds

to a 2 ms processing time. Comparing with the manufactured brochure value of 1250

BPS, we find that a 60.1% of incredibility between the manufactured given value and the

obtained value from line segments experimentation.

104

Dynamic Measurement Results.

Contour error graphs, velocity and acceleration profile graphs were taken form [Ortega;

2004].

Programmed Feed Rate Vfp (mm/min)2000

Control OptionDNC ON | DNC OFF

4000Control Option

DNC ON | DNC OFF

7620Control Option

DNC ON | DNC OFF

I 4,0356 I 4.0356 I 2.76 | 2.7612 | 2.659 I 2.6622 I

AVERAGE FEEDRATE (mm/min)

Programmed Feed Rate Vfp (mm/mm)2000

Control OptionDNC ON | DNC OFF

4000Control Option

DNC ON | DNC OFF

7620Control Option

DNC ON | DNC OFF

Programmed Feed Rate Vfp (mm/min)2000

Control OptionDNC ON | DNC OFF

4000Control Option

DNC ON | DNC OFF

7620Control Option

DNC ON | DNC OFF

0.006243^010052721 0.0058771 0.0073681 0.0056051 0.00755

105

Co

nto

ur

erro

r (m

m)

o (D Q. 55" 8 o 3

O 00 O O O O

1

—

_Ci li

il

1 I 1 f-

.1 1-• 4

I !

1 1 I••I

_i

1\ \ 11•- iw

- •• t 1 • _0 M

•— M _

o o 3 c (D O 0) (Q 3 Ml Q.

(D 0) 3 o" o 0) o' 3

< o

• •

^^

^

jo

mo

<

0 ^

3 a

3 o

1 g

3 O

MACHINE VM16 DNC OFF

Vfp: 4,000 mm/min

iIoo

0.060.055

0.050.045

0.040.035

0.030.025

0.020.015

0.010.005

0-0.005

-0.01-0.015

-0.02-0.025

-0.03-0.035

-0.04-0.045

-0.05-0.055-0.06

Contour error, magnitude and location

% IMMmmM i

J• I4

j

|

L

IL

—i—'—'

J

11M

11

, •• i

S—i—

*1

111

1

20 40 60 80 100 120

Cumulative distance d, (mm)

107

Co

nto

ur

erro

r (m

m)

• O

ip

iO

ip

iO

iO

O

O

O

O

O

O

be

nb

-t»

.bc

ob

iob

-'b

o

ob

-'b

Na

bc

ob

-ii.

bc

nb

cnen

enen

-en

eoen

ioen

-en

oen-

enio

enco

en-

enen

encn

o

O c (D | o (D

o 00 o o o

1 I rr I I I F i A •!F r I 1 1»>

ft

T --« r TTTT

ft 11 I I 1I 1

1M

fl __

• _

-* •1 L

id

i m Ik

» to •

•

o o I Q o 0) Q.

(D 0) O O 0) o" 3

< o

•3"

5

o 3 5'

m a D O O

o oo

MACHINE VM16DNC ON

Vfp: 2,000 mm/min

Contour error, magnitude and location

0.06 n0 055 -0.050.045 -0.04 -

0.035-P 0.03= 0.025e 0 02"r* 0.015O 0.01C 0.005 -fc 0 -•_ -0 0053 -0.01 -O -0.015 -C -0.02 -O -0.025 -O -0.03

-0.035 --0.04

-0.045 --0.05 -

-0.055 --0 06 -

(

/>

i m

ii

!i i

JJ

1

M i

i i 1

J1114

Jt-— I — 1-1

) 20 40 60 80 100 120

Cumulative distance d, (mm)

109

Co

nto

ur

erro

r (m

m)

.6

.6

,6

.6

,6

,6

o o

o

o

o

o

Pd

Pd

°d

Pd

Pd

°d

d

Pd

°<

Dod

Pd

c>d

o

Otf

lOA

OO

OM

O-'O

O

00

-'O

I\)O

UO

A0

01

0a>

wovif

oic

ooi\

30io

iooiO

irooiw

oiu

oio

ioio

>

o c 5* <" Q.

| O (D Q. 3

00 o

r 4 vi fl

g

1 1 1 • I F 1

• •

•M ff

L 1

11 1

• T I 1 rrfl 1 1L

M • •-- ii J i!

• • »

o o (D o 0) CD a (D 0) o o 5" 3

O

<O

^

3 5"

O 2 O O

MACHINE VM16DNC ON

Vfp: 7,620 mm/min

0 06 -0.055 -0.05 i

0.045 -i0.04 -

0.035 -' ? 0.03 -C o 025E 0.02 1^ 0.015O 0.01 'fc 0.005 -o oZ -0.005 -3 -0 01 -O -0.015 -C -0.02 -O -0.025 -Q "0.03 -

-0.035 --0.04 -

-0.045 --0.05 -

-0.055 --0 06

(

Contour error, magnitude and location

t111m

t

mmm

J11I1 Jk

|111X4

J

!

\

i

1

/

•

•1 I

) 20 40 60 80 100 120

Cumulative distance d, (mm)

111

1000

800

600

400

200

0

-200

-400

-600

-800

-1000

MACHINE VM16 DNC OFF

Vfp: 2,000 mm/min

Velocity Profile

2000 - M M I

mno 1

oi

irIfV II11

ir11I I! "I

4-II1

IfiIIKT1

1

0.5 1.5 2 2.5 3 3.5

Cumulative time t, (s)

4.5 5.5

Acceleration Profile

9 L]l

I1 i• •1 1

••

•r•

f•

f•

8""rt

i1f I17

• i

IIIr•ni

0.5 1.5 2 2.5 3 3.5

Cumulative time t, (s)

4.5 5.5

112

Axi

s ac

cele

ratio

n a

m, (

mm

/sA2)

o i I I «

1? o o 3 O

S1 120°% 1000g 800g 600 !ra

400^200

0-200-400-600-800

-10001200

MACHINE VM16DNC OFF

Vfp: 7,620 mm/min

Velocity Profile Om

in)

1

Feed

Rat

e

5000

3000

2000

1000

ol

A/ \

i A •.it

A it iiL1

w\ r

\

i

\

1-MiI

\\

A aAA i\ nt-V-i w Vht-II 10 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75

Cumulative time t, (s)

Acceleration Profile

1. . . i 1

r s. i i • i •. I » k..

= 3*1

i—j

•

f I B "j*rw

I I »

1 j " •

0.25 0.5 0.75 1 1.25 1.5 1.75 2.25 2.5 2.75 3.25 3.5 3.75

Cumulative time t, (s)

114

^ 600 j

£ 400.

MACHINE VM16DNC ON

Vfp: 2,000 mm/min

Velocity Profile

0 0.5 1 1.5

Acceleration Profile

-400

-600

-800

-1000

o2000 l § m

1500-P

1000 |

0 *

f•

•

-ir*H 11

-1-111 11 w

If Tf

i•

442 2.5 3 3.5 4 4.5 5 5.5

Cumulative time t, (s)

r • IF

If 1* tI If9 i

f1

f**

1|

0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5

Cumulative time t, (s)

115

MACHINE VM16DNC ON

Vfp: 4,000 mm/min

Velocity Profile

4500

4000

3500

3000

2500

2000

i 1000

500

|-/1IIf

f

i\

r lifi//

li

1

ft-ft1

Mlf i / i i i fIf if 11 ififat

if iiV_T

If

"In•

1It

//IT1

r\\\

|-ii/I

Tii\

40.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75

Cumulative time t, (s)

3.25 3.5 3.75

Acceleration Profile

-20000.25 0.5 0.75 1.25 1.5 1.75 2 2.25 2.5 2.75

Cumulative time t, (s)

3.25 3.5 3.75

116

MACHINE VM16DNC ON

Vfp: 7,620 mm/min

6000

0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75

Cumulative time t, (s)

Acceleration Profile

2000

~ 1500

1000

°

500

-500

-1000

-1500

-2000

1

J IV1

JAmi

f 11 11

t0 0.25 0.5 0.75 1 1.25 1.5 1.75 2 2.25 2.5 2.75 3 3.25 3.5 3.75

Cumulatime t, (s)

117

APPENDIX E.- Drive Train Mechanisms Specifications

90

1. Ball Screw Products

Horizontal machining cento

NSK ball screws combine low friction characteristics and screw mechanismsto ball screw applications in facilitate conversion between linear rotarymotions, precise linear positioning, and force amplification.

Machine tools (Horizontal type machining centers)FeaturesSmooth motion and high accuracy, even with large cutting forces

Reasons for adoptionHigh accuracy, smooth motion, high load capacity, and high durability

• HMC Series: High-Speed; High Ridigity; High Load Capacity• HTF Series: High Load Drive Ball Screws• Hollow Shaft Series: Reduces Effects of Thermal Expansion; provides

stable, precise positioning• Custom Ball Screws: Let our Mechanical Engineering Department assist

you in designing a ball screw to fit your unique application• NDT Series: Rotating Nut Ball Screws• Rolled Ball Screws: Interchangeable screw shaft and nut; lower cost

due to shaft rolling process• Precision Rolled Screws: Compact Nut Design; High Speed; Tighter

Tolerances than standard rolled ball screws; Can be Preloaded

B-I-4 Procedures to Select Ball ScrewB-I-4.1 Flow Chart for Selection

There are several methods to select a ball screwwhich is most suitable both in type and size for aspecific use. The chart below is one of the selectionmethods. To take advantage of prompt delivery andreasonable prices, this method focuses on the

standardized series that are available in stock.NSK offers a ball screw selection program, and alsohas a service to select appropriate items using datafile compiled by our knowledge and experience.

NG

NG

Use conditionsLoad, speed, stroke, accuracy,required life (environment)

Basic factorsAccuracy grade (CO-CtiO)Screw shaft diameterLeadStroke

Pages B17 and B445

Is it a standard series and available in stock? The following arerecommendations for different needs.

A Series : If accuracy is important, and if you desire to use the ballscrew as it is delivered.

S Series : If accuracy is important, and if you desire a certain shapeof the shaft end.

KA Series : If you are concerned about rust.V Series : If you desire accuracy and low cost.R Series : If you desire low cost. Pages B19-22

NO

YES

Basic safety checks(D Limitation of buckling load(D Critical speed® Life expectancy

Page B451

Page B455

Page B461

Is it in the dimension table forcustom made ball screws? Nutshape, shaft end

OK

Factors to be checked to satisfy a need<D Heat displacement and lead accuracy@ Rigidityd> Drive torque@ Lubrication, rust prevention, dust

prevention, safety system(£> Consideration to assembly

OK

Summary of technical data for ordering

Page B447

Page B465

Page B469

Page B471

Page B475

Page B31

\ / Y E S

See Page B23

NO

Consult NSK

NSK

B16

B-1 -4.2 Accuracy Grades

Table 1-4*1 shows examples of how to select

accuracy grade for a specific use. These practical

cases are based on NSK's experience. Circle

indicates the range of the accuracy grade in actual

use. Double circle indicates accuracy grades most

frequently used among cases marked with a single

circle. These symbols help to identify general

information on the accuracy grade of ball screws. To

confirm whether a specific ball screw accuracy grade

satisfies requirements in positioning accuracy in

actual use, refer to "Technical Description" and

"Mean travel deviation and travel variation." (Page

B445)

App

licat

ion

Name of axis

grad

eac

ycc

ur

<

CO

C1

dzC3

G5

Ct7

CtflO

Table 1-4•1 Accuracy grades of ball screw and their application

NC machine tools

Lath

e

X

:O

op,o

* » •

ii

Z

O

••0

1

Millin

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achi

ne

Bor

ing m

achi

ne

XY

O

0

o

Z

oo

•,o:;

Mac

hini

ng c

ente

r

XY

O

O

o0

Z

Po

p

i

Dril

ling

mac

hine

XY

O

0

z

0o

Jig

borin

g m

achi

ne

XY

O

o

zoo

Grin

der

XY

O

O

o

Z

C)

oo

Ele

ctric

dis

char

ge

mac

hine

XY

O

O

o

z

oo0

Wire

cutti

ng

mac

hine

Ele

ctric

dis

char

ge

mac

hine

XY

O

oo

Z

oo.oo

;P

unch

pre

ss

XY

O

Lase

r cu

tting

mac

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XY

O

z

o'-€>•

Woodw

ork

ing

mac

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• • ©

O

App

licat

ion

grad

eac

yA

ccur

C0C1

c?C3

C5

Gen

eral

indu

stria

l m

achi

nes

, I

Mac

hine

s fo

r sp

ecifi

c us

e

|

i •

i

o0

Ct7 O

ctt41>

Semiconductor/associated industry

Lith

ogra

phic

mac

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•rO

O

IC

hem

ical

pro

cess

ing

equi

pmen

t

O

O

oQ

Wire

bon

der

O

O

Pro

ber

O

O

o

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ctro

nic

com

ponent

inse

rtin

g m

achi

ne

o-0

©

IPrin

ted c

ircuit

boar

d d

rillin

gm

achi

ne

O

O

o0

Industrial robots

Asse

mbl

y

othe

r C

arte

sian

type

purp

oses

oooo

ooo

Asse

mbl

y

othe

r A

rtic

ulat

e ty

pe

purp

oses

O

oo

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SC

AR

A typ

e

O

O

o

Ste

el m

ills

equi

pmen

t

O

O

Pla

stic

inje

ctio

n m

oldi

ng

Im

achi

ne

|

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IThr

ee-d

imen

sion

al c

oord

inat

e I

mea

surin

g m

achi

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|

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oo

Offi

ce m

achi

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O .

oO.j

Imag

e p

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quip

ment

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Nuclear power

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Q

B17

Technical Description of Ball ScrewsB-1 -1 AccuracyB-II-1.1 Lead AccuracyThe lead accuracy of NSK precision ball screws (C0-C5 grades) conforms to the four characteristicsspecified in JIS Standards. These characteristics areexpressed by codes ep, vu, v3mi and v^ .Fig.I-1'1 explains the definition of each characteristic,

and shows allowable value of each. Leads areclassified into two categories: C system forpositioning; Ct system for transportation. Table E-1*2, 3 and 4 show tolerance of each characteristic.

Travel length (/»)

Actual travel (la) Nominal travel (to)

Mean travel (lm) Specified travel (Is)

7 /

Fig. 1-1*1 Definition of lead accuracy

Table I -1*1 Terminology in lead accuracy

Term

Specified travel

Travel compensation

Actual travel

Actual mean travel

Tolerance on specified travel

Travel variation

Code

75

T

la

lm

ep

vu

U300

Description

Travel after the adjustment of thermal expansion and deformation

by the load have been made relative to the nominal travel.

Value obtained by subtracting the specified travel from the nominal travel basedon the effective length of thread. The value is to compensate the errors causedby thermal error and deformation by load.This value is determined by tests andexperience (See Page B447).

Actually measured travel

A straight line that demonstrates the direction of actual travel. This straightline is obtained from the curve that shows actual travel volume by least-squares method or by resemblinq approximation.

Obtained by subtracting the specified travel from the actual mean travel.

Maximum range of the actual travel which is between the two straightlines drawn parallel to the actual mean travel. There are three categoriesas shown below.• Maximum range relative to the effective length of thread.• Maximum range relative to the length of 300 mm anywhere within theeffective length of thread.

• Maximum range which corresponds to any single rotation (liurad.) withinthe effective length of thread.

Tolerance

Table 1-1-2

Table n-1-2

Table 1-1-3,4

Table 1-1-3

B445

Table 1-1*2 Tolerance on specifiedball screws

travel (±ep) and travel variation (vu) of the positioning (Ctype)Unit: fim

Accuracy grade

E

leng

thth

read

tive

o

LU

over

—

100

200

315

400

500

630

800

1000

1250

1600

2000

2500

3150

4000

5000

6300

8000

10000

or less

100

200

315

400

500

630

800

1000

1250

1600

2000

2500

3150

4000

5000

6300

8000

10000

12500

CO

±ep

3

5.5

4

5

6

6

7

8

9

11

3

3

3.5

3.5

4

4

5

6

6

7

C1

+ ep

3.5

4.5

6

78

9

10

11

13

15

18

22

26

30

vu5

5

5

5

5

6

7

8

9

10

11

13

15

18

C2

±ep

5

7

8

9

10

11

13

15

18

21

25

30

36

44

52

65

vu7

7

7

7

7

8

9

10

11

13

15

18

21

25

30

36

C3

±ep

8

10

12

13

15

16

18

21

24

29

35

41

50

60

72

90

110

uu8

8

8

10

10

12

13

15

16

18

21

24

29

35

41

50

60

C5

±ep

18

20

23

25

27

30

35

40

46

54

65

7793

115

14p170

210

260

320

t>.

18

18

18

20

20

23

25

2730

35

40

46

54

65

7793

115

140

170

Table II -1*3 Tolerance of travel variation relative to 300 mm (u ,) and onerevolution (vj of the positioning (C type) ball screws Unit ^

Accuracy grade

IV-,

Vat

CO

3.5

2.5

C1

5

4

C2

7

5

C3

8

6

C5

18

8

Remarks 1. JIS B1192 sets C type and Cp type standards for positioning ball screws. NSK uses thespecification of C type only.

2. Colored sections conform to JIS B1192 standards. Values in other areas are IMSK standards.

Table I -1*4 Travel variation (ux>) relative to 300 mm of transportation (Ct type) ball screwsUniti/im

Accuracy grade

vm

Ct7

52Ct10

210

Remarks 1. Tolerance on specified travel (ep) of the transportation (Ct type) ball screws is calculated asfollows.

2. JIS B1192 sets Ct1, 3, and 5 grade standards. NSK standards are integrated by C type only. Referto Table 1-1*2 for C type standard tolerance.

B446

//5 to/es Precision Hardened Way SlidesSaddle Widths: 7" to 32"Standard & Custom HS Series SlidesSlide Options & Accessories

US Series

Single Guide Rail Design (standard)All HS slides provide a single guide rail design for superior tracking accuracy. The single raildesign maximizes accuracy because the saddle movement is controlled by one support sidewall for smoother positioning.

As standard, all HS-series slideshave a guaranteed straightness oftravel(side-to-side and up-and-down)not to exceed 0.0005" in 12 inches,and with an accumulation not to exceed0.00025" in each additional 12" of travel.

Guide Rail

i

1

ft

1 — Reference Edge

Low-Friction Turcite™ Material (standard)As standard, HS-series slides are equipped with low friction, self-lubricating Turcitebound to the gib and saddle way surfaces to reduce the effects of friction on the slideassembly. This low-friction bearing material minimizes "stick-slip", and makes wearnegligible on guiding and sliding surfaces.

The use of a low-friction Turcitedoubles the load carrying capacityof a slide. The coefficient of frictionwith low-friction is 0.10; this dropsto 0.05 when combined with aforced lubrication system. (Whenneither is used, the coefficient offriction is 0.30.)

2. Linear Guides Machine ToolHorizontal machintig center

NSK Lineat guides

NSK linear guides are roller guides which utilize balls and are used forsupporting load and guiding precise linear motion with low friction.

Machine tools (Horizontal machining centers)FeaturesSmooth motion and high accuracy even with large cutting forces

Reasons for adoptionHigh accuracy, high load capacity, high speed, smooth motion, and highdurability

• LA Series: 6 Row Design; Shock Resistant; High Rigidity; ModerateFriction; High Load; High Accuracy

• LH Series: 4 Row Design; Shock Resistant; Self-Aligning;Interchangeable (Retained Balls); High Load Capacity

• LS Series: Low Profile; Shock resistant; Self-Aligning, Interchangeable(Retained Balls); High Load Capacity

• LY Series: 4 Row Design; High Stiffness; Equal Load Rating in AllDirections; High Dampening Characteristics

• Translide: 2 Row Design; High Load Capacity; High Dust-ProofCapability; Maintenance Free

A-1 -3 Procedures for Selecting Linear GuideA-1 -3.1 Flow Chart for Selection

The flow chart below indicates general steps for selection.

Set conditions for use

Select model

Select accuracy grade

Lubrication,dust protection,

surface treatment

Selection completed

• Machine structure• Guide installation space• Installation position• Stroke length• Load to be imposed• Speed

Required life, rigidity andaccuracyFrequency of use (dutycycle)Use environment (considermaterial, lubricant, andsurface treatment first forspecial environment)

Select based on theinstallation spaceSelect through experienceUse simple calculation

Select lubricant andlubrication methodDust prevention design (seal,bellows)Rust prevention, surfacetreatment

•PageA7

•Page A15

•PageA129

• P a g e A 2 1 ,119

•Page A 2 0,115

•Page A141

A14

A-1 -3.4 Accuracy and Preload

(1) Accuracy grades and types of preload

0 Accuracy grades• The accuracy grade which matches the

characteristic of each series is set for NSK linearguides.

• Table 1-3*1 shows accuracy grade set for eachseries.

• See Page A115 for accuracy specifications of each

series.Refer to "(2) Application examples of accuracy!grades and preload" which shows cases offappropriate accuracy grade and preload type for)specific purpose.

Table I -3*1 Accuracy grades and applicable series

Series

LH

LS

LA

LY

LW

LE

LU

LL

Preloaded assembly (non-interchangeable)

Ultra precision

P3

O

O

0

0

Super precision

P4

00

0

0

o

High precision

P5

0

00

0

00

0

Precision

P6

0

0

0

0

00

o

Normal grade

PN

00

0

0

o0

Interchanaeableassembly

Normal grade

PC

O

0

o0

0

A20

APPENDIX H.- UNC proposed scheme for connecting to Milltronics VKM3.

General system identification:

The studied system is the interface connection between the controller Centurion 7 to

Yaskawa Sigma II servo amplifiers in a Milltronics Knee Milling machine (Model

VKM03). This identification has the objective of to provide the information for a future

connection of the UNC to Yaskawa Sigma II amplifiers. First is necessary to identify all

the parts that involve the current control system:

• Servo motors• Drive (servo amplifier)• Controller

AC Servo Motors:The motor for the Z axis is a 900 watt Ac servomotor. The motors for X and Y axis are

both of 500 watts. (The present document just focuses on the control of X-Y axis). The

general parameters of X and Y axis which are:

Motor: AC servomotor

Type: SGMGH-05AC A61

Incremental encoder

450 W

3.8 A

2.84 Nm

200V

1500 r/min

InsF

Figure H 1 Nameplate of SGMGH Servo motor.

Servo Amplifiers:

Both axis servo amplifiers are equal. The Main power supplies, control supplies and

servo terminals (see Figure H 2 ) are provided by Milltronics current connection.

Servo Amplifier model:

SGDH 05 AE

118

SGDH Servo Amplifier Identification

.Version NumberM E M H U S Servo Anptfc. hanhnre Kfffcm aMsolware version (See -AmpMer Version Number")

Battery HolderUsed to house «ha bsduv battery for anabsoUe encoder

CN5 Analog Monitor ConnectorIked to monaor rotor epecd. tuM ie refer*ertoe. and other values tirouah a special cable.

KCM8 Battery Connector

Used lo cornea lo tw tac»v baaery tor anabsolulsnasier.

Panel DisplayRn-oUft 7-sojmenl «spar/ p a M u• -•- — - - rannalalut.ar>

used ». and dhor

Panel KaysIfted to aet pararheiert

Power ON IndicatorUgra* when If* eonrat aower *u&0ty is ON.

Charge IndicatorUahkt wrnn s » mam drcul poMer «««*/i«Cm and ataya aa rona aa trat oonvonenracaMdUnrnama craned Therefore. fflMa

taOtt doatdmuHttttmivoA ff >

M10 Connector for Option UnitCorvwcls oplian urtt fe» dpandrng Ute

N3 Connector to PC or Digital Operator

oorvwcl to art optional digHaf operator.

11/O Signal Connector

iked rbr bottt reference Input and sequence I O signals

-NameptateIndxies Ihe r a w arnpttfer model and Ksspedllc rabigs

Encoder ConnectorJslotneeno

Tenninal

"Main Circuit Power Supply TerminalUsed far ma main circUK power aicpry inpu

'Control Power Supply Terminal

Cbmw* to ma conM oo«er supply and lo eulernalrymounw ntenerattw roiator (where appfeaUe)

-Servomotor TerminalCoflnools toths aetvomokjr power ine.

Figure H 2. SGDH Servo amplifier identification

CNl I/O signal connector is plugged to Centurion 7 interface panel. Is necessary to

determine Yaskawa I/O wiring setup for speed control mode and compare this scheme

with Milltronics scheme. Figure H 2, shows all the connections required to set up the

servo amplifier as speed controller, were the reference speed is set by a host controller.

119

4WILL1RONICS Electrical ManualCEMB With Centurion 7

SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS

Yaskawa Axis Drive ParametersSigma 2 Axis Drive Parameters For MB/VKM Series

The following table lists the axis drive parameters changed by Militronics. All other parameters remain setto the Yaskawa factory default settings.

p#\000

100

101

201

300

408

409

40A

600

MB11&12X

0000H

130

400

1968

720

0

Y0000H

110

400

1968

72CL

0

Z0001H

55

400

1476

543

10

MB18/19X

0001H

75

700

1000

362

0000H

1000

70

0

Y0001H

75

700

1000

362

0000H

1000

70

0

Z0001H

75

700

500

183

O00OH

1000

70

10

MB20X

0000H

75

700

1000

362

0000H

1000

70

0

Y0001H

75

700

1000

362

0000H

1000

70

0

Z0000H

75

700

500

183

0000H

1000

70

10

P#\

000

100

101

201

300

408

409

40A

600

MB25X

0000H

75

700

985

362

0

Y0000H

75

700

985

362

0

Z0001H

75-

700

738

270

10

MB30X

0000H

75

700

985

362

0

Y0000H

75

700

985

362

0

Z0001H

75

700

738*1

270

10

VKMX

0000H

70

400

m000OH

350

50

0

Y0001

70

400

1000

369

0000H

1000

50

0

Z0000

50

400

1000

369

0000H

1000

70

10

28RRV 15

CNl Terminals layout is shown in Table H 1.

2

4

8

S

10

12

14

IS

IB

20

22

74

SG

SEN

SG

/PULS

SG

JSK3N

KLR

PL3

/PCO

BAT*-)

GNO

SEN signalinput

GND

Referencepuba Input

GNO

RefBranoftsymbol input

Clear input

Opea-oolec-lor referencepower apply

PGdtvtfed

C-ptana

Battery (•)

1

3

5

7

9

11

13

15

17

IS

21

23

25

SG

PL1

V-Rff

puts

T-REF

SIGN

PL2

CLR

PCO

BATH

/V-CMP+(COIN*)

GMD

Opea-cctec-Mrrefereeeepower aappV

Refareacaspeed inpui

RafBreacapulse input

Torquereference

input

Raferaacasign input

Opearcolec-janafauaui

Clear input

PG dividedodpat

C-phase

Battery H

Speed coina-dance detec-

tion outpal

77

7fl

31

«

37

>

41

41

45

47

4fl

/TOON+

S-RDY*

AIM*

PAO

PBO

AtOI

AIA3

^

NM3T

JP-Ct

+24V4N

IPSO

TOON sig-nal output

Servo readyoutput

Servo atomoutput

POdMdedoutput

PGdMdedOUtDUt

AJBTBIOOdeoutput

kroutpat

P oparsbonInput

Reverseowartravat

Input

Faward cur-rant I M ON

input

Externalinput power

Sitaaean-nal output

28

28

30

32

34

36

38

40

42

44

46

48

S3

rV-CM>-(JCOIN-)

/TGON

ALM

/PAO

.P80

ALD2

mm

P-OT

IfiiM-RST

IHCi

PSO

Spaed ooavndanoe

detactknoirtput

TGONslj-naloutwt

Senmreedyoinput

Servo alarmou^iut

PGdMoedOU|)Ut

A-phese

PGdMdadoinput

B-fhase

Alarm codeoufiut

SerwOMInput

Forward

Input

AtarrafasaiInput

Ftaveraecurrant Imt

ONinpat

&fhases i j a a t o *

put

Table H 1. CNl Terminal layout

121

Output Signals

Signal Name

Common

Speed

Position

Not used

ALM*ALU-

/TGON*flQQH-

/S-RDY+/SHRDY-

PAO/PAOPBO/PBOPCO/PCO

PSO/PSO

ALO1ALO2ALO3

F<3

A/-CMP+/V-CMP-

/CCHN*

Pin

Number

3132

2728

d30

H^35361820

4849

3738

39{1)

Shell

2526

2526

1fi17232450

Function

Servo alarm: Turns OFF when an error e detected.

tetection during servomotor rotation: detects wheBwrlhe servomotor Brotating at a speed higher than the motor speed selling. Motor speedBtectmn can be set via parameter

Servo ready: ON if tiiere is no servo alarm when the controMmaln circuittower supply »turned ON.

i phase signal(phase signal

C phase signal

S phase signal

Converted two-phase putse {A and B phase) encoderoutput signal and origin pulse (C phase) signal: RS-422or B>e equivalent

With an absolute encoder: outouts Bertal datacorresponding to 8w number of revokitionB (RS-422 orequivalent).

Alarm code output Outputs 3-brt alarm codes.Open-cofector: 30V and 20mA rating maximum.

lormected to frame ground If the ahieJd vwre of the UD signal cable isconnected to fte connector shel.

Speed coincidence {output in Speed Control Mode): detects whether thenotor speed ts wnMn the setting range and if it matches the refers nee* » e d value.Positioning completed {output in Position Control Mode): turns ON whenlie number of error putees reaches the value sat The setting is thelumbar of error pulses set in reference units (input putse units defned bylie electronic gear).

rtiese termnafs are not used.>o not connect relays to these terminals

Refersnc*

5.5.1

5.S.5

S.5.6

5.2.3

5.5.1

554

5.5.3

—

Note f. Pin numbers in parenthesis Q indkaJa signal g

2. The functions allocated to /TGON, /S-RDY. and Ar-CMP (/COLN") can be changed viaparameter* Functions CUT, ATCT, /BK, AVARN. and /NEAR signals can also be changed. (See5.3.4 Output Circuit Signal Allocation >

122

Input signals

Signal Name

Common

SpeedReferenceTorqueReference

PositionReference

S-ON

/P-CON

P-OTNOT

/P-CL/N-CL

/ALM-RST

•24V,N

8ENBATTf*}BATTM

V-REF

T-REF

PULS/PULSSIGN/SIGN

CLR/CLRPL1PL2PL3

PinNo.

40

41

4243

4546

44

47

4 P)2122

5(6)

»(10)

7a1112151431318

Function

Servo ON: Turns ON the servomotor when the gate Mock in the inverter isreleased.

* Function selected via parameter.

Proporkonat opera-ion reference

Direction reference

Control modeswitching

Zero-damp reference

Reference pulseblockForward RuntrahlbitedReverse Run

prohibited

Forward current limitONleverse current limit

ONInternal speedswitching

3wrtches the speed confroi loop from Pi (proportonaVntegral) to P {proportional} control when ONLIMtti internal reference speed selected: switches thedirection of rotation.

Position -» Speed)

Speed " Torque > Enables control mode switching

Torque « Speed j

Speed control with zero-clamp function: referencespeed is zero when ON.Position control wrth reference pulse stop: stopseference pulse input when ON

Overtravel prohibited: stops servomotor whenTKJvable part travels beyond the allowable range ofnotion

Current imit function used when ON.

rtrtti mtemal reference speed selected: switches thentarnal speed settings

Alarm reset Releases the servo alarm state

Control power supply input for sequence signals: users must provide the+24V power supply.Initial data request signal when using an absolute encoder.

Connecting pins for the absolute encoder backup battery

Speed reference Input ±2 to ±1 OV/rated motor speed (Input gain can bemodified with a parameter.)Torque reference input ±1 to ±1 OVfrated motor speed {Input 9am can bemodified wtti a parameter.)

Corresponds to refer-ence pulse inputLine-wvarOpen-collector

nputmode• Code + putoe string> CCWrCWpute«• Two-ptiase rxite« (90° phase cSffcrential)

Error counter dear: Clears the error counter during position control.

+12V pull-up power supply when PULS, SIGN and CLR reference signalsare ogen-collector outputs (*12V power supply is butt into the servoamplifier).

Reference

5.5.2

5.2.15.2.7

5.21

9J2.6

5.2.7

5.4.3

5.2.10

5.1.2

5.13

5.2.6

5-5.1

5 2 4

5.23

5.2.3

5.2.1

5.2.1

5.2.1

5.2.1

5.2.1

Note t. The funclions allocated to /S-(W,/P-CON. P-OT, hMK,/ALM-RiST,/P-CL, and/Nl-CL inputsignals can be changed with parameters. (See 5.3.3 Input Circuit Signal Alloeauon.j

2. Pin numbers in parenthesis ( ) indicate signal ground*.& The voltage input range for speed and torque references is a maximum of ± 12 V

123

Controller connections

Is important to identify the panel layout of Milltronics machine. Figure H 4 shows

the connections of the servo amplifier with Centurion interface panel.

Figure H 4. Milltronics VKM layout

Experimental tests

The experimental measurements were conducted on the Yaskawa Y axis servo

amplifier as shown in Figure H5. The plastic cover of the amplifier was removed for

measuring CN1 I/O signals.

124

(a) (b)

Figure H 5. (a) Y axis Servo amplifier, (b) CN1 connector close up.

Input Signals measurements

Before measuring input signals Pins 1,2, 6 were tested for ground continuity. Once

ground continuity was tested a common ground to connect the oscilloscope ground was

used. Table H 2, show the measured values for input signals.

Signal Name/S-ON Servo ON

Common + 24V INV-REF

Pin No.40

475(6)

Measured Value0 V when servo is ON24 V when servo is OFF24 VSpeed reference input +- 2 V to +- 10 V

The measured values for output signals are in Table H 3

Signal NameALM +ALM-PAO/PAOPBO/PBOPCO/PCO

Pin No.313233(1)3435361920

Measured ValueOV

ov

2.5 V

Table H 3. Output signals. Pins numbers in parenthesis ( ) indicate signal grounds..

125