Continuous-path

The continuous-path control system is also

known as the contouring system. It involves
simultaneous motion control of two or more
axes. The contouring system is more
complex because each axis of motion
requires separate position and velocity
loops. The contouring along a predefined
tool path is implemented by means of
interpolation, in which the system
generates a set of intermediate data points
between given coordinate positions

CNC Interpolation
An interpolator provides two functions:
It computes individual axis velocities to drive the tool along the
programmed path at the given feed rate.
It generates intermediate coordinate positions along the
programmed path. There are five types of interpolation: linear,
circular, helical, parabolic, and cubic.

Circular Interpolation
The interpolator computes the axial velocity components and
produces a sequence of reference pulses for each control axis
of motion. The advantage of circular interpolation is its ability
to generate an arc in a single program block. In some NC
controls, circular interpolation is limited to a 90 arc in a single
block.
The information required for programming a circular
interpolation includes:
(1) coordinates of the start point and end point,
(2) radius of the arc or coordinates of the arc centre, and
(3) direction in which the tool is to proceed (CW or CCW).
The circular interpolation is limited to the two-axis plane.

Helical Interpolation
It combines the two-axis circular interpolation
and a linear interpolation along the third axis.

Parabolic Interpolation
Parabolic interpolation uses three noncollinear points to
approximate free-form curves.
It can be used to cut either planar or spatial curves. It is
primarily used in mold and die making, where free-form
designs are preferred over precisely defined shapes.

Cubic Interpolation
It is of the third order and can be used to
generate complex tool path for machining
complicated shapes such as automobile sheet
metal dies with a relatively small number of
programmed points. However, it is very
complex and requires considerable computing
power and a large memory.

open-loop positioning systems

Typically uses a stepper motor, driven by pulses, generated by MCU.
Each pulse rotates the motor through a "step angle (in degree)
360
=
ns
: Step angle in degree.
ns : Number of step angles for the motor.

Am = n p

Am : Angle through which the motor rotates (degrees).

n p : Number of pulses received by the motor.

This image cannot currently be display ed.

: Step angle (degrees/pulses).

open-loop positioning systems

The motor shaft is generally connected to the lead screw through a

gearbox, so:
np
Am
Nm
A =
=
rg =
Where
rg
A
N

A : angle of lead screw rotation (degrees).

rg : Gear ratio.
N m : Rotational speed of motor (rpm).

N : Rotational speed lead screw (rpm).

open-loop positioning systems

Linear movement of work table is given by:

pA
x =
360

x : X-axis position relative to the starting position (mm, in).

p : Pitch of lead screw (mm/rev, in/rev).

A
: Number of lead screw revolutions.
360

The number of pulses required to achieve a specified x-position

increment is given by (using the preceding relationships):

rg A rg 360x
np =
=
=

p
Am

np =

360 x rg
p

n s x rg
p

np =

rg x ns
p

open-loop positioning systems

Control pulses are generated at a certain frequency, which drives
the worktable, where:
N =

60 f p
n s rg

N : Rotational speed of lead screw (rpm).

f p : Pulses train frequency ( Hz, pulses/s).
n s : Steps per revolution or pulses per revolution.
rg : Gear ratio .

open-loop positioning systems

The work table travel speed in the direction of lead screw axis is:

vt = f r = Np
vt : (mm/min, in /min)
f r : Table feed rate (mm/min, in /min).
p : lead screw pitch (mm/rev, in/rev).
N =

60 f p
n s rg

open-loop positioning systems

The required pulse train frequency to drive the table

at a given rate is :

fp =

vtnsrg
60 p

frnsrg
60 p

Numerical 1: NC Open-Loop Positioning

The work table of a positioning system is driven by a lead
screw whose pitch = 6mm .
The lead screw is connected to the output shaft of a stepper
motor though a gearbox whose ratio is 5 : 1
Motor

lead screw

The stepper motor has 48 step angles . The table must move a
distance of 250 mm at a linear velocity = 500 mm/min .

Open-loop positioning systems

Determine :

a) How many pulses required to move the table the

specified distance ?

b) The required motor speed and pulse rate to

achieve the desired table velocity ?

open-loop positioning systems

Solution:

a)

360 x 360 * 250

A=
=
= 15000
p
6
A : angle of lead screw rotations.

360 360
=
= 7.5
=
ns
48
360 * rg A * rg (15000)(5)
np =
=
=
= 10000 pusles
p

7.5

open-loop positioning systems

b)
vt 500
N= =
= 83.333 RPM
p
6
N
m
rg =
Nm = 5 * 83.333 = 416.7 RPM
N
500(48)5
v
tnsrg
fp =
=
= 333.333Hz
60 p
60(6)

Closed-Loop Positioning Systems

An optical encoder is a device for measuring rotational speed .
The equations that define the operation of a closed-loop NC
positioning system one similar to those for an open-loop system
. In the optical encoder , the angle between slots in the disk is:

360
=
ns
A
np =

: (deg/slot)

ns : number of slots in disk

np : # of pulses sensed by the encoder &emitted

A : angle of rotation of the encoder shaft

Closed-Loop Positioning Systems

x : worktable pos.

p * np
p : lead screw pitch(mm/rev)
x=
ns
vt : worktable velocity (mm/min)
60* p * fp fr : feederate (mm/min)
vt = fr =
fp : frequency of the pulse train
(Hz,pulse / sec )
ns
The pulse train generated by the encoder is compared with position and
feed rate specified in the pant program , and the difference is used by the
MCU to drive a servomotor , which drives the worktable .
Closed-loop NC is good for milling and turning because of the reactionary
force that resists the movement of the table .

Numerical 1: NC Closed-Loop Positioning

An NC work table operates by closed-loop positioning system consisting of

a servo-motor, lead screw and optical encoder. The lead screw has a pitch
= 6 mm and is coupled to the motor shaft with a gear ratio 5:1 (5 turns of
the drive motor for each turn of lead screw). The optical encoder generates
48 pulses/rev. of its output shaft. The encoder output shaft is coupled to the
lead screw with a 4:1 reduction (4 turns of the encoder shaft for each turn
of the lead screw). The table has been programmed to move a distance
300 mm at a feed rate = 600 mm/min.
Determine i) how many pulses should be received by the control system
to verify that the table has moved 300 mm
ii) the pulse rate of the encoder and
iii) the drive motor speed that corresponds to the specified feed rate.

Precision in NC Positioning
NC positioning system has three measures of precision :
1. Control resolution
2. Accuracy
3. Repeatability
Worstcase
scenario

Gear back
lash,
deflection,et
c..
(distinguishable
points) By the
MCU

Precision in NC Positioning

CR 1 =

ns * rg
L
CR 2 = B
2 1

CR1 : Electromechanical (mm)

CR2 : Computer control system (mm)
L : Axis range (mm)
B : Number of bits in the devoted bit storage register

Both equations can be used for open or closed loop.

CR = max{CR1, CR2}

* Typical value of CR is 0.0025

mm

CR
Accuracy =
+ 3
2

Standard-deviation