Monofásico 2

Evaluation of CNC Controllers in Milling
Machines-Relationship Between Dynamic

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

Between 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 29/03/2018 21:32:19
Link to Item http://hdl.handle.net/11285/567191

INSTITUTO TECNOLÓGICO Y DE ESTUDIOS
SUPERIORES DE MONTERREY
CAMPUS MONTERREY
DIVISIÓN DE INGENIERÍA Y ARQUITECTURA

PROGRAMA DE GRADUADOS EN INGENIERÍA
f
f
TECNOLÓGICO
DE MONTERREY
EVALUATION OF CNC CONTROLLERS IN MILLING

MACHINES - RELATIONSHIP BETWEEN DYNAMIC
CAPABILITY, PRODUCTIVITY AND COST
TESIS
PRESENTADA COMO REQUISITO PARCIAL

PARA OBTENER EL GRADO ACADÉMICO DE:
MAESTRO EN CIENCIAS
CON ESPECIALIDAD EN SISTEMAS DE MANUFACTURA
POR:
FERNANDO DAVID REYES LUNA
MONTERREY, N.L. JUNIO DE 2005

INSTITUTO TECNOLÓGICO Y DE ESTUDIOS
SUPERIORES DE MONTERREY
CAMPUS MONTERREY
DIVISIÓN DE INGENIERÍA Y ARQUITECTURA

PROGRAMA 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 González

ASESOR
Dr. Horacio Ahuett Garza Dr. Nicolás Hendrichs Troeglen

SINODAL SINODAL
APROBADO
Dr. Federico Viramontes Brown

Director 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.
MACHINE TOOL
COST DRIVERS
$ "0KUSD •Spindle type and
S20KUSD orientation
•Number of axis
•Size
•Accuracy and
repeatability
•Control type
S200KUSD
MANUFACTUREN
PRODUCT
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.
MACHINE TOOL
COST DRIVERS
Productivity.
• = machines •Spindle type and
/ \ orientation
Production \ •Number of axis
\ •Size
Molds •Accuracy and
repeatability
•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.
PRODUCTIVITY CAPABILITY COST ANALYSIS
Model/ Algorithm Model/ Algorithm
Evaluation Design Evaluation Design
Jerk limited
trajectory
[Altintas; 2001]
s generation.
Contouring
control of feed
drives.
Machine
Evaluation, Static
[Amone; 1998] s accuracy,
Dynamic
performance.
Qualification of
parallel
[Hascoét; 2003]
kinematics
machines.
Trajectory
[Lambrechts; planning, and
2005] feedforward
design.
Contour error
evaluation,
relationship
[Ortega; 2004]
between
accuracy and
productivity.
Look-ahead,
[Schuett, 1996] s accurate control,
processor
technology.
Contouring
control of
[Tomizuka;
machine tool
2001] feed drive
systems.
Parametric
interpolator with
[Yang; 2004] s a real timejerk-
limited
acceleration
Evaluation of
[Reyes; 2005] s s CNC controllers
considering cost
relationship
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 Architecture
SOFTWARE
Computer - > CNC. TG, PG,
CL.
PCI, I/O Board
(a) HARDWARE
SOFTWARE
Real Time Master procesing
Unit, TG. PG, CL. TG, PG, CL
PCI. DSP CPU
(b) HARDWARE
SOFTWARE
DNC, 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 Actuators Mechanisms
Conventional
machine
—^ rV)
CNU ]
A/IWA
^n=
i ^ ^ P i ^~~~
—• V
> 1 MI |
Siemens: ^ ^ B L____ £> ^ ^ k i L"
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.
Block PRICE
System
proccesing
architecture ($ USD)
time(ms)
PCI Board <4000
•
•
32 Bit-processor 40-24-12
4000 - 6000
<256 Kb **(600 bps)
32 Bit Processor 6 ms-4ms
6000- 9000
16-32 Mb **(1200bsp)
32 Bit processor 3.6 ms-0.5 ms

>10000
• >128Mb **(>1200 bps)
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).
Price Price
Motors Drives Description
($ USD) ($ USD)
m
Stepper motors 300 - 700 PWM 20 KHz <500
DC Servomotors 1000-1200 PWM 20 - 30 700-1000
AC Servomotors 900 - 2000

I KHz
Microprocessor 1500-4000
controller PWM
400Hz speed
loop frequency
AC Servomotors 900 - 2000 >1000Hz speed >10000

loop frequency
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).
Ball Screw Description Nut / yoke

Acmé screw
ftí
Balls screw O.OO1in/ft {25um/300mm)
Ground ball screw 0.0005 ¡n/ft 35»
^V. Bal tae* fat H&

(12.5um/300mrn)
M ) C5=18um/300mm (0.00072¡n/ft)
C1= 5um/300mm (0.0002 ¡n/ft) <
C3 = 8um/300mm (0.00032in/ft) i.i*H« bJl " * - . * ) : rOOM
C5=18um/300mm (0.00072¡n/ft)
<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 Bearing Description
systems
Solid ways. (Turcite)
Friction (0.2-0.02)
Ball type way

Friction
(0.002-0.003)
Roller type way
Friction (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
VKM3
3
O
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.
Produ ¿1 rvrf y
i
PtoJu •trvrty
SBflf
CONTROLLER
«TUATORS
MECHAIIISMS # • |
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.
VKM3 (V= 0.04 m3> VM16(V =0.156 m3)

Controller Centurión Vil Centurión Vil
Feed Forward and Look-Ahead for High
Speed Machining or 3-D Milling
Actuator •Yaskawa Ac servomotors: •Yaskawa Ac servomotors:

SGMGH-05AC A61 SGMGH-05AC A61
•Servo Amplifier: •Servo Amplifier:
SGDH 05 AE SGDH 05 AE Y220
•Feedback Resolution: 0.001 mm •Feedback Resolution: 0.001 mm
400 ipm rapids XY 200 ¡pm (5080 1000 ipm rapids XY300 ipm
mm/min) feedrates (7620mm/min) feedrates
Mechanism •Heavily Ribbed Cast I ron •Massive Heavily Ribbed Machine

Construction Tool Grade Cast I ron Construction
•Precisión Ground Double Anchored •Precisión Ground Double Anchored
Ball Screws Ball Screws With Dampening
•Ball Screw grade C5. Coupling
•Ball Screw Pitch lead 0.2 " (5.08mm) •Ball Screw grade C5.
•Fully Ground Solid Ways with Turcite • Ball Screw Pitch lead 10mm.
Surfaces •Ball type ways
Performance •Position Accuracy: 0.01 mm •Position Accuracy: 0.005 mm
•Repeatability: 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
IV.
RELATIVE
VALUÉ
111
o EVALUATION UI
> UJ
! * •
S ui Controller C | _l<
cea Characteristic UJ >
O z
u. — C1.C2
ce
ui Controller B
a.
Characteristic
B1.B2
Controller A
Characteristic
A1.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
Production Molds Static Dynamic
CONTROLLER
ACTUATORS
MECHANISMS
) 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
CAPABILITY
(CQNTOUR PERFORMANCE)
PRISMATIC PARTS SCULPTURED SURFACES
STATIC CAPABILITY DYNAMIC CAPABILITY
NOT NOT
CONSIDEREDIN CONSIDERED IN
CONSIDERED IN CONSIDERED
EVALUATION EVALUATION
EVALUATION IN EVALUATION
SPEC Á
[Momeal;2003]
BPS HEIDENHAIN
Q O
g
¡I [Amone; 1998]
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.
CONTROLLERS CONTROLLERS
OONTROL\ \ \ < (INTROL U W :
BPS \ OPTION: \ VEUXm. \ \ <ONTOVR
\ LOOK-AHEAD\ ACCELERATION
\ \ \ \ DYNAMIC
C.\PABnJTY
/ / /
/ / / /
DRIVE/ / / / BEARDMU
/ / / / Si-STEM
f MOTOR / 1'BAIXSC:REW
ACRiATORS MECHANISM ACTUATl. RS MECRW1SMS
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?G90721
G01X0YOZ0F500
XO.01443Y0.01443Z0.01443
XO.02886Y0.02886Z0.02886
XO.04329Y0.04329Z0.04329
l|(Pií¡^pl?2¥O.OS7?2Z0.05772 I
XO*. 08658Y0*. 08658Z0*. 08658
XO. 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.
¥
1-D STRAIGHT LINE
> •
•Total length: 700mm
X(mm) •Line segments: 0.1 mm, 0.05mm, 0.025mm
?'
£ 2-D STRAIGHT LINE
>-
/
•Une segments: 0.05mm , 0.025mm
X(mm)
£ 3-D STRAIGHT LINE
^ yS.
1
V X (mm)
•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 = 60X(LH-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.
Software implemented algorithms

Control Law (CL):
Dynamic capability
PID, Feedforward.
Trajectory Generation (TG):
Interpolation, spline interpolaron, polynomial
interpolation
Productivity Profile Generation (PG):
Trapezoidal velocity description, Trapezoidal
acceleration description (acceleration with
jerk 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.
Contour error, magnitude and location /

>
0.11
- . _
•p. o í
E 0.09 1
w
E 0.08
0.07
« 0.06 - -
i- 0.05 ''1
S 0.04 i
fe 0.03 'i
í
3 0.01
JiJE —?•
C -0.01
O -0.02
ü -0.03 ,v
-0.04
() 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
4000-
n i\A i\h i\n ir i- —
eedrate Vfp,
3500-
3000 II /i i\
IXix 11 n i4f
min)
2500
H 1500
rÍREB
Program
1000 —M
f
500 j
ol í T 0.5 1.5 2
Cumulative time t, (s)
2.5
T 3.5
Figure 20. Velocity profile at 4000mm/min of Milltronics VM16 machine.
^ 1500
Acceleration Profile
—o
ni
^s innn
•ation am, (mnr
' «I
Ufe
C
0 O O
I* I I . "ti fe **"
^H f
1
•J; I i
£ i w T
| -1000 T
x -1500 - —
-2000-
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
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)
«a
DYNAMIC MEASURMENTS
! •
i •-.
• =
ii íi | Í í
::
111111I [ [ 11 ¡ II CONSIDERATIONS
•Same Shape
i : : : : : : a
: ; :4^ m
S "1**r*r 141 F ^
•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
Hardware
M ) Médium Cost Controller
Hardware
High Cost Controller
Software
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].
Cost B - Cost A
Relative Valué of B/A= [2]
ABS(ControllerB-ControllerA)
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
ÍELATWE
o
VALUÉ
< Xi
2 ui ^ ^ ^ i Controller C j
£° *
2^
te.
^ ^ ^ Characteristic
C1.C2
UJ /
Q.
Controller B
Characteristic
J\ /
/
• B1,B2 >
^ ^ ^ | Controller A |
V /
^ ^ ^ Characteristic
A1,A2
B/A C/B
eos T$
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).
Productivity ifflSiJI bWI) r

fMMtoi J « » « j | SU* O" m e
CONTROLLER
- Í
ACTUATORS
KECHANISMS
• » •
/"
i
I. II. III.
fr
Machine: Hurón KX-10
Controller: Siemens 840D
Work Volume: 0.35 m3.
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
3-D STRAIGHT UNE
7.000
O Measured Valué
£ 6.000 --<1 — —
• Data Sheet
—•
*
/ Models
Vfa= 668.3 mm/mln ls= 0.05 mm

5.000 Vfa= 327.3 mm/mln ls= 0.025 mm
1
1
[• — •- — - 4 )1 - t
4.000
3.000
1000 2000 3000 4000
Programmed feedrate Vfp, (mm/min)
• • - 0.05mm -0.025mm
Figure 26.3-D straight line processing times
Siemens 840D
3-D STRAIGHT UNE
250.000
a.
&
W 225.000
o. , t
m
,'T 1. Vfa= 668.3 mm/mln ls= 0.05 mm
Vfa= 327.3 mm/mln
200.000 > ls= 0.025 mm
9 ® Nleasured Valué
175.000
• Data Sheet
^1
/ Models
150.000
1000 2000 3000 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.
Siemens 840D
2-D STRAIGHT
7.000 I
© Measured Value
• Data Sheet
,§.6.000 < — — — —
V
/ Models
<D
Vla= 668.2 mm/min ls= 0.05 mm
F 5.000 Vfa= 330.7 mrrvmln ls= 0.025 mrr
1 |
1i 41
4.000
i
3.000
1000 2000 3000 4000
- • - 0.05mm -0.025mm
Figure 28. 2-D straight line processing times.
Siemens 840D
2-D STRAIGHT
250.000
225.000
m f
*
Vfa= 668.2 mm/min ls= 0.05 mm
200.000
t
1 Vfa= 330.7 mm/min ls= 0.025 mm
© Measured Value
175.000 t
8 <\
H Data Sheet
m / Models
150.000
1000 2000 3000 4000
- • - 0.05mm -0.025mm
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.
Siemens 840D •]
Control Option G64: ON I

1-D STRAIGHT UNE
13.0 -i I
1
I o Measured Value
essing Time (t, (ms)
Data Sheet
b
\ • Models
\\
b
to
\
\
~i
b
\ Vfa= 1350 mm/min ls=0.1 mm

II 1 Vfa= 675 mm/mln ls= 0.0S mm
Vfa= 337.5 mm/min ls= 0.025 mm
2 5.0
1
3.0
T
() 1000 2000 3000 4000
—•—0.1mm - • - 0.05mm —•—0.025mm
Figure 30.1-D straight line processing time.
Siemens 840D
1-D STRAIGHT LINE
250.0
1
*
en" 200.0 Vfa= 1350 mm/min s=0.1 mm
a. Vfa= 675 mm/min s= 0.05 mm —•
m Vfa= 337.5 mm/min s= 0.025 mm
T3 1 \*^
•' )
8 150.0 •
/ 9 Measured Value
J2 100.0 S Data Sheet
1<
ffl / Models
50.0
1000 2000 3000 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
1-D STRAIGHT UNE

1400
(3) Measured Value
1200
Data Sheet
I Vfp > 2000 mm/mln I
1000 Models
800
600
400
200
0.025 0.05 0.075 0.125

Programmed line segment Is, (mm)
-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-
3-D STRAIGHT LINE
© Measured Value
^25 -
• Data Sheet
£20 / Models
Processing Time
en
o
yi
o
4,000 6,000 8,000 10,000 12,000 14,000

Controller Cost c,($USD)
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.
700
Relative Value of Siemens Controllers
X-
3-D STRAIGHT UNE
600
500
5^ 400 -
ID CO
ED 300
i ^ Measured Value
200
H Data Sheet
100
2 / Models
a.
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.
an
:ONTROLLER
HI
ACTUATORS ^ A
nu X •
MECHANISMS
• HI •J PRISH»T!C PMTS
I.
Machine: Milltronics VM16

Controller: CENTURION VII
Work 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
VM16 Average Contour Error Comparison / \
\ /
~ 0.008 -I
£ 0.007 - ... ... 1 ^
8 0.006 -
8 0.005
- 0.004 -
% 0.003
° 0.002 - ^
2 0.001
3 0 -I
2000 4000 7620
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
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% -- r_. .._. ^ — — — — ,

Z
= 99.96% - — — p- - -— ._ — _.
°" 99.95%
99.94%
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.
Average Average
COST SUSD Relative value SUSD/urn
Error(mm) Error (urn)
DNC OFF 1 8,000 0.0067296 6.7296301 DNC ON vs. DNC OFF 1826.6028561
DNC ON 9,500 0.0059084 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 Application
Interface
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
[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
[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 .
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
time
0 002 0.04 0.06 OOfl 0.1 0.12 014 0.16 0.18
T,
© ©
y time
0 0.02
- 2x10*; i Jerk
0.04 0-06
O 002 004 006 0.08 01 0.12 0.M tt16 CMS

Time (sec)
Urns
I .I.^.--,-,,-,-.
0 SO 100 150 200250 300350400450500
Frequency JHi]
(a) (b)
Figure B 1. (a) Kinematic profiles for Jerk-limited feedrate generation, (b) Comparison between jerk
limited 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.
Feedforward
Friction Compensation
1 z-1 O/> r 1 1— I ""^ DAC
\ 1d Axis Dynamics i
"HI >c
Resolution
CO X 1
i t AzPETC ] y
y -*- "•to
5 1
1
Feedforward L*. A
State t
Axis Dynamics , rg
Compensation
T,z
A Filter 'Ir'i
1
Gain
0) State and Tachometer
A Disturbance
J:
Estimator
Encoder
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
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)|
0 10 20 30 50 60
Figure B 3. Toolpath example of mixed blocks [Yang; 2004].
I4O00-, / . = 12000 (mm/min]

12000-
ft = 10000 [mm/min] \
sI0O00-
« e 8000- / \ / \
y E 6000- / \ / B \
B
o 4000- / > \ / \
h. 2000-
0- / VCVB, f * I *
04 0S I 0
g J^-1000-
<
-2000H
00 04 06 08 1 0
lime [sec]
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 Economy

of 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 System
The M-39 is the easiest control to integrate into your system. It uses a standard PC
with 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
Programming
Conversational Programming: Our easy conversational lets you program lines, arcs, pockets,
and drilling operations graphically. Canned cycles, mirror, rotate, repeat, copy, and Teach make
programming 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 existing
ZAD 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, and
lumbers. Engraving also includes 20 fonts. Also, you can easily create your own font library' from M-39: Tool Path Graphics
\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 Contouring

Dentroid'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 block
iccel/decel look-ahead. Even the largestfilescan be run without hesitation, thanks to the Unlimited
'art Program Size feature (optional, standard program size is 640Kb). The M-39 comes equipped
Wth a large capacity hard drive to store all of your programs on the control.
Deluxe Automatic M-Functions
Option #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-wired
contactors for flood, mist, lube, and other I/O. Option#3: PLC Direct™ Interface
let's you program your PLC Direct1" to control up to 64 I/O for automatic control of
multi-spindle applications, tool changer, and other special functions.
M-39 Options
'Engraving: Comes complete with 20 fonts; generates G-codes automatically. CENTROID
•Digitizing: Automatically copy any 3D surface and cut the 3D part on your M-39. 159 Gates Rd.
•4th Axis Use as a linear or rotary axis. Howard, PA 16841
•Auto Tool Measure: 11-1 touch-off block automatically measures tool heights. (814) 353-9256 Sales
(814) 353-9265 Fax
• Unlimited Prog. Size: Maximum part program size = available hard drive space. www.centroidcnc.oom
• Spindle Control: Automatically turn your spindle on/off and change direction CW/CCW.
• Spindle S-Function: Control spindle speed automatically; specify speed in tool library.
• Probing Cycles: Automatically find part centers/corners of bosses, bores, webs, pockets.
• WCS: Multiple work coordinate systems for multiple fixtures [G28-30, 52-59].
• Subs & Macros: Cut one part using a family of part programs [M98, G65].
• Mastercam, Level 2: Upgrade from Level 1.
• MPG Handwheel: Manual Puke Generator makes touching off a breeze.
CMayi7.1998 Central Cop.
I h i n thaII««.* (lie 0 In a 1 iu tile i i r s l o i l t i m u (o t l n « i « o p t i o n s dosii oil.
C0NTWX1ERCH0CE
1 CertroidM39S Base Price (Keyboard Jogging) $ 8,060.00 8,060.00
•60
0 Cenlroid M400S Base Price with 29 In. Lb. Motor Upgrade $ 9,550.00 $ -
CENTROID OPTIONS
0 10703 M39S Jog Pendant (Sane buttons as M400 S but Hand Held) $762.00 _
•60
010770 DP4 Digitizing Packageforallrigidsurfaces and software $4200.00 $ -
-
•60
010405 DP4 Probing package with probing software $1,825.00
0 10015 MPG on the pendant $490.00 $ -
010220 TT1 Todtouchoff probe $695.00 $ -
010730 Intercon Offline -
•60
$600.00
4th axis rotary kit (Drive, Motor, Cable and 140mm or 220mm table) From
010450 CNC-151R 150mm, 5.9 h. Rotary Table $5,091.00 $
_
0SC6CNC-151 Chuck $295.00 $ -
0AP-1CNC-151AP. $159.00 $ -
010451 CNC-201R 200mm, 7.8 in. Rotary Table $6,055.00 $ -
0SC-7CNC-201 Chuck $436.00 $ -
0AP-1CNC-201AP. $159.00 $ -
0 5CC-15C Manual chuck $365.00 $ -
0TSA530Tai Stock $825.00 $ -
010510 Linear 4th axis (Drive, Motor, Cable) $1,910.00 $ -
010740 Mil write engraving software on the controler $665.00 $ -
0 Software Pkg B (Mut V\CS, Subs and Macs, MnorfScaling) $1,850.00 -
•60
010620 Compression Tapping $350.00 -
•60
010630 Unlimited Fie Size Software Pkg C $1,699.00 $
010264 SPhase option High power option $850.00 $ -
010711 AI"M" functions prewired at Centroid $635.00 -
•60
010711s Prog. SS analog output wired win (10711) $635.00 -
•60
0 Installation $1,000.00 $ -
0 TRAINING OPTION: $550.00 $ -
$550.00 Per Day plus travel and expenses
Sub Total $ -
ELROD MACHNE RETRORT HARDWARE
1 ElrodZ Axis Qul Drive ModelQU2C4wih Quick Disconnect formanualZuse $1,624.00 $ 1,624.00
1 Ekod Smart Z on Qul Drive gives Z axisfeedback manual Z use $550.00 $ 650.00
0 Elrod Smart Stop helps with precise Z axis depth control in manual Z use $250.00 $ -
1 Elrod Machine X&Y Bracket Kit Model DOXLFT 2:1 Ratio $1,106.25 $ 1,10625
1 Elrod Machine Ground Bal Screw K*forX&Y Axis $1,450.00 $ 1,450.00
1 Autoway Lube Pump $192.00 192.00
•60
1 Elrod Heavy Duty Bal Screw Mounting Yoke $295.00 $ 295.00

0 Elrod Limit Switch Kit (Optional) $550.00 $ -
•60
Sub Total 5,31725

ACCESSORES
0 Kurt Vise D675 $440.00
•60 •60
010100 HenchFcgBusterCoolant Sprayer $355.00 -

Power Draw Bar
-
•60
0 TorqueRte Power Draw Bar $575.00

Cat 40 Tooing Package
•60
0R8tcoing Package $625.00 -

R8 Collet Rack on the Quil Drive
0R8CT-O9 $69.40 $ _
0 AL-250Z Power FeedforKnee $460.00 $ -
-
•60
Sub Total
CADCAM OPTION
0 Order Code "F+4" Vero VisHSeries 2M2D Sold Machining with Solid Operations $6,700.00 $
Order Code "G1 Vero VishSeries 2D/3D Solid Machining with CAD $14,220.00 Price w/o Options $ 13,37725
Total Options $ -
QhinrJnn
The Milltronics Centurion Control
Centurion VI Control
•Memory - Data Storage
•3-1/2" 1.44 MB - Standard
100 MB Zip ® Drive - Optional
Hard Disk 2 + Gig - Optional
RAM Memory - Volatile 16 MB - Standard
32 MB - Optional
RAM Memory - Program Storage 6 MB - Standard
140 MB-Optional
RAM Memory - Operating System 2 MB
• D u a l Processor Control Utilizes Latest Computer Technology
•It is estimated that 90% of all computer related engineering efforts are directed
towards the rapidly advancing PC arena. Centurion controls take advantage of these
advances by utilizing a PC based Pentium processor to handle the operator interface
and a robust 32 bit Motorola processor to handle the motion control. These combined
processors 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 PC
architecture of the Centurion CNC controls will allow service and upgrades to be
performed well into the future and at substantially less cost than other dedicated
systems. Additionally, all Centurion controls are five axis standard - allowing quick
and 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 communications
port, both standard on the Centurion controls. Networking and Iomega Zip® are also
offered 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 communications
as it provides transparent transfer of data at speeds of up to 100 MB/sec - more than
50 times faster than typical RS232 communications. Features built into the software
also enhance the network connectivity by allowing the user to easily save and load
files to and from the network.
•Zip® Drive
•Fully compatible with Iomega Zip® Drives, which allow the user to transfer up to 100
MB 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 resolution
active matrix LCD color screen rather than the tiny monochrome monitor often found
on other CNC's.
But we did not stop with the screen either. We listened to operators frustrated with
insensitive flat keypads and added a sealed full travel keypad. Machine function
buttons such as flood, mist and spindle illuminate when selected. In fact buttons that
require operator response, such as Cycle Start, flash as needed to prompt the operator
through the task at hand.
•Conversational Programming
• A menu based question and answer format prompts the operator through program
creation. 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. In
fact, many operations available in conversational programming are nearly impossible
to duplicate with G and M code programming. For instance the simple task of
incrementing a tool to depth with G and M codes usually involves complex looping of
subprograms or many redundant commands. With conversational programming this
task is reduced to simple statements where only the cut increment and depths need to
be entered.
• T e x t 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 adding
a CAD CAM system in the future, you can rest assured that compatibility will not be
an issue.
A full word processor style editor is utilized on all CNC controls and offers helpful
features such as search, search and replace, cut, copy and move. Programs as large as
8 Mb can be edited concurrent to program execution.
•This useful feature allows an operator to take total control of machine movement and
run complex programs with confidence.
With this feature enabled program movement only occurs while the handwheel is
being 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 the
answer most likely will be yes. The usual cause is that the operator simply could not
react fast enough to the situation at hand. With this feature an operator can avoid
crashes 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's
have set the standard for performance in their class. Milltronics will benchmark our
control against any other control in the industry!
Processor Speed
There are literally thousands of calculations required for each and every axis
movement. When trying to machine complex geometry, often the microprocessor of
the control creates a bottleneck restricting the attainable feedrate. To minimize the
risk of this processing bottleneck, Centurion CNC controls utilize two 32 bit
processors providing over 150 megahertz combined processing speed. With these two
processors working together, over 1250 blocks per second can be achieved.
Intelligent Axis Acceleration And Deceleration

Controlling how an axis decelerates and accelerates is one of the most crucial factors
relating to machine speed. Understanding that it is impossible for a servo motor to
stop and start a heavy machine slide anywhere close to 1,000 times per second leaves
the only hope of achieving speed through greater intelligence of the acceleration and
deceleration slopes. All Centurion controls search ahead in a program as much as 255
moves to determine the directional changes that lay ahead. Once these directional
changes are known the CNC will dynamically adjust the deceleration and acceleration
slopes to minimize stopping and starting.
Accuracy
Servo motors cannot instantaneously respond to a given command. This lack of
response negatively effects accuracy and only deteriorates as the feedrate increases.
To counter the disastrous effects of servo response, Centurion CNC controls utilize an
elaborate "Feed Forward" error correction algorithm that reduces inaccuracy without
compromising speed. Until now feed forward error correction has been found only on
a handful of the world's most expensive CNC controls and should in no way be
confused with inferior error correction systems that rely on slowing feedrates to
maintain accuracy.
• L o n g List of Standard Features
on-line help.
If an operator has a question about a conversational programming screen, pressing the

Help 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 a
button after each manual move and the present machine location is stored in an
executable CNC program. The program is stored in both conversational and ISO
format making future editing easy.
• D u a l 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 operator
fatigue.
•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 fully
automatic is standard.
For full manual operation a conveniently located remote panel places the necessary
controls at the operator's fingertips. Single operations that cannot normally be made
by simply turning handwheels, such as tapers, radii and threading, can be made
quickly 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 a
program. 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 not
only manual moves to be recorded directly into a program, but also a series of
conversationally 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 and
more are all standard.
Virtually any part can be programmed quickly and easily with conversational
programming.
•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 be
edited with any text editor, it can also be input into other CNC controls to maximize
productivity.
In milling applications both 2D part profiles and complex 3D surfaces can be

captured. Output is standard ISO G and M code as well. With the use of the off-line
Digiscan software a digitized file can be inverted (male to female), cutter
compensated, scaled, rotated, mirror imaged and more It can also translate the file
into 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 Centurion
controls at a later date - installation is a simple four wire connection.
•Off-line Software
Ôff-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 RS232
communications for trouble-free communication with the CNC.
An additional feature allows import of DXF or CDL CAD files which expands
difficult 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 and
consistently. 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 and
more 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: Jog
feed, rapid and incremental. Electronic handwheel, Feedrate override, Programmable
acceleration and deceleration, Excess error fault protection, Minimum programming
resolution 0.0001", Mid program restart, Automatic start, stop, reverse, RPM
override on Spindle, Tool Functions: 99 tool length and radius offsets, One button
tool setting routine.
Graphics Functions: Large color LCD screen, Full 3D view with rotational, iso,
zoom, and window. Program verify, Runtime display (excellent for
estimating). Feedrate, rapid rate, part and offset toolpath display.
Distinctive Programming Functions: Built-in engraving Linear, circular & helical

interpolation Advanced trig help Part rotation Scaling (each axis individually if
ILL1R0NI.
Manufacturing Company
CENTURION IV USERS
Go From This - TO THIS1
CENTURION 7 PC Based CNC
CNC is self-contained in the

compact operator's station
AFF0RDABLY11
SPECIFICATIONS
FEATURES Centurion 7 Centurion 7 SLS CONTROL
Absolute / Incremental Std Std Processor: Motion Control Motorola 32 bit
Inch / Metric Std Std Processor Operator Interface Pentium 130 Mhz
Conversational Programming Std Std (Or greater)
Trigonometry Assist ('Trig Help") Std ad Program Throughput Over 1300 blocks/sec
Corner Chamferinq And Rounding Std Std Axis Control 4Axes- Standard
Cutter Compensation Std Std
Color Graphics - Tool Path and Std Std MEMORY - DATA STORAGE
Part Profile
Canned Drilling Cycles ad Std Floppy Disk 3 1/2" 1.44 Mb - Standard
Diagnostics Std Std 100 Mb Zip® Drive Optional
Excess Error Protection ad Std RAM Memory - Volatile 16 Mb Standard
Full Language Errors Message Std Std 32 Mb Optional
Backlash Compensation ad Std RAM Memory - Program Storage 12 Mb Standard
Ball Screw Pitch Error Correction ad Std Non-volatile 256 Mb - Optional
Mirror, Scale And Rotate ad Std
EIA/ISO Code (Fanuc®) ad Std
Compatibility*
Macro Programming ad Std
Subprogram Looping And Nesting ad Std
3 Point Circular Interpolation ad Std
Polar Coordinates ad Std
Auto / Block Operation ad Std "SLS" Skill Level Select
Programmable Dwell ad Std
Block Skip ad Std For machines without automatic tool changers, this
Concurrent Proqramminq ad Std innovative feature allows the CNC control to be
Hard Tapping (Optional) Opt. Opt. configured to match the skills of the CNC operator.
Digitizing Ready ad Std We have worked with a number of first-time CNC
Program Interrupt And Resume ad Std
Graphics Based Mid-Program Start ad Std operators and have recognized that the more fea-
Program Start from Block or Tool # ad ad tures, screens and selections a CNC control has,
Hand wheel Run ad Std the more intimidating it is for the operator. Often
Teach Programming NA Std these selections overwhelm the new operator,
Feed Forward Error Correction Opt. Opt.
Selectable Corner Accuracy ad Std
undermining confidence and lengthening the
Automatic Homing ad Std learning curve. Skill Level Select solves this by
Circular Interpolation ad Std allowing the operator to enable/disable features to
Axis Jog ad Std a comfortable level. Operate the CNC in an easy to
Software Limits ad ad use two axis format, step up to a simplified three
Unidirectional Approach ad Std
Dry Run ad Std axis operation and, when ready, turn on all the
Automatic Tool Setting Program ad Std features to maximize productivity. In the highest
Selectable Languages ad Std skill level you will be ready for even the most
Multiple Work Offsets ad Std challenging programs — from custom codes to
1 Button Tool / Fixture Offset Entry ad Std
8 Mb Text Editing with Cut, Copy, ad Std parametric programming. Truly a control that
Move and Search/Replace meets all needs of toolroom milling!
Pocketing and Framinq Cycles ad Std
Tapered And Round Walls ad Std
3D Sweep Routine ad Std
Helical Interpolation ad Std
Bolt Hole Drill Cycle ad Std
Enqraving, with Serializing ad Std A TRUSTED
Speed And Feed Calculator ad NA
Online Help Screens NA Std NAME IN CNC
Irregular Pocket Clearing Opt. Opt.
Auxiliary Keyboard Jack ad Std
FOR 30 YEARS!
Current Meter ad Opt.
True Spindle Speed Feedback Opt. Opt.
Network Capable Opt. Opt.
Electronic Handwheel ad Std
Polygon Milling Cycles ad Std
60 Work Offsets ad Std
Parts Counter ad Std
* Compatibility varies with control version
PROPOSAL
UPGRADE PACKAGE
CPU assembly, PC based with upgrade adapter kit $6,995
Operator's Station with new LCD screen, electronic handwheel and tactile keys 1,995
Subtotal $8,990
Less Milltronics User Special Discount - 2,490
TOTAL $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 a
certified dealer. A customer should not attempt to install this himself.
Installation $1,100.00
PLUS
Expenses - air, auto, lodging Actual costs
Or
Flat fee anywhere in the USA $1,900.00 + Air Ticket
(Air ticket can be proposed prior to order)
INSTALLATION - In Our Factory

Installation . .$900 00
Customer pays machine freight each way, estimated at $500.00 to $1,000 .00
ACCESSORIES
Upgrade to 12" Color LCD with Discrete Pushbutton Keys $900.00
Off-line FastCAM Software $400.00
Large 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-D
milling, and networking option with 30 day phone support
DRIVE SYSTEM
Conversion of Reeves drive system to an inverter or controlled direct drive system, up
to 7 V2 HP (Must be done at the factory) $2,800.00
Centurion 7 Upgrade includes the following:

Large color LCD display with 3D graphics
Operator's controls, pushbuttons, and panel
Electronic handwheel with handwheel verify
Keyboard jack for PC keyboard
CPU, PC-based with 1300 block/sec processing and 12 Mb parts storage
memory plus large program editing/execution capability
Software features including conversational, G & M code programming,
3D part and tool path graphics, engraving, helical interpolation, auto
routines, 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 drive
Interface cable and hardware
WARRANTY
All new or replaced parts have a one-year parts warranty for normal usage. Original
reused parts have no warranty.
SPECIAL NOTE
Because we have concerns on the reusage of some machines, special software
requirements or other unusual circumstance, we reserve the right to refuse the sale of
this upgrade package.
TERMS
Any freight or rigging is not included with proposal. Customer should be prepared to
incur additional expenses if original parts are found not to be reusable. This proposal
does not include any replaced machine parts or repairs. New parts have a one-year
warranty for normal usage. Original reused parts have no warranty.
Payment: 80% down with order

20% net 30 days after installation
Make The
Contact the factory for special offers or financing

options. Subject to credit approval and approval by
^HlLLlRONICS
1400 Mill Lane • Waconia • MN • 55387
your local distributor. 952-442-1410 • 952-442-6457 (Fax)
www.milltronics.net
Milltronicsreservesthe 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 convincing In conjunction with adaptive control, the
range of innovative technology-specific SINUMERIK 840D enables optimum utili-
functions. zation of spindle power, prevents overload,
protects the workpiece, reduces machining
Standard cycles are available for frequently
times and improves surface quality without
recurring machining operations in the drilling,
the need for additional hardware.
milling and turning technologies.
And even extremely exacting applications, like Handling tasks, such as work-piece mani-
5-axis milling in the manufacture of tools and pulation, machine loading, packaging and
molds, are no problem for the SINUMERIK palletizing, can be easily performed by
generation. The continuity from the CAD connecting the handheld terminal (HT 6).
system right through to the workpiece and In the same way, an "electronic gear with non-
intelligent motion control allow fast, precise linear coupling" is also possible. In addition
production of even highly complex parts. The to the manufacture of convex gear tooth sur-
separation of geometry and technology with faces, it is thus possible to compensate for
RTCP (remote tool center point) and 3D tool nonlinear characteristics of the process.
offset simplifies alterations. And the prompt
machine stop facility, in the event of tool
breakage, for example, protects both machine
and workpiece.
Solving digital tasks fast and
professionally
The standard SINUMERIK 840D control in-
cludes tailor-made functions for high produc-
tivity and precision for grinding, flexible axis
movements with the aid of positioning axes
and reciprocating functions, short machining
times using multiple feed values in a block
and fast set-up by means of handwheel over-
lay.
Time-critical process signals are connected to
direct CNC inputs/outputs and programmed
by synchronous actions. Special axis couplings
can be defined using cam tables, e.g. for
swing-frame grinding. Transformation of an
inclined axis also permits inclined bed appli-
cations, and tool compensation is included
on-line to permit simultaneous grinding and
dressing (continuous dressing).
Technical Specifications:
Impressive Performance Data
Control type o Evaluation of internal drive variables PLC

Modular 32-bit microprocessor CNC o Continuous dressing x Integrated SIMATIC S7-compatible
continuous-path control for turning, x Acceleration with jerk limitation CPU 315-2DPor314C-2DP
drilling, milling and grinding machines x Programmable acceleration o Program and data memory expand-
and handling with integrated powerful x Synchronized actions (SYNACT) able to 288 KB or 460 KB
PLC. x Coordinate transformation and x Programming language STEP 7
The control consists of a 50-mm-wide inclined-surface machining with o I/O modules expandable to 2048
module and a choice of external intel- FRAME digital inputs/outputs
ligent operator panels to meet all types o Fast retraction from the contour x Max. 4096 flags, 128 or 256 timers,
of operator requirements. with RETT routines 64 or 256 counters, 256 FBs/FCs
x Direct/indirect measuring system and 399 DBs
Function overview switchover for high degree of o Servo or step motor PLC positioning
x Drilling, turning, milling, grinding, precision and fast positioning axis
nibbling, punching, laser machining o Extensive motion control for very o S7 HiGraph programming
and handling technologies fast machining with Look Ahead o Distributed I/Os via PROFIBUS-DP
x Optimum, complete digital solution function and dynamic feed-forward
with SIMODRIVE 611 digital control Operating components
o Up to 10 mode groups, 10 channels x Travel to limit stop with adaptable The operator panels are modular in
and 31 axes/spindles force or limited torque structure and can be assembled to pro-
o Channel structure: Simultaneous x Follow-up mode vide specific levels of performance.
asynchronous processing of parts x Advanced detection of contour
programs violations o OP 01 OS operator panel (310 mm
o OA open-ended NCK software o Tool-oriented RTCP wide), 10.4" TFT display, VGA
x Feedrate and rapid traverse: x Configurable number of inter- (640 x 480), mechanical keys
103 mm/min to 999 m/min mediate blocks with tool radius o Machine control panel (310 mm
x Endlessly rotating rotary axes compensation wide) with 16 customer keys,
x 2D+n helical interpolation x Tool radius compensation with 1 slot 22 mm dia. and 6 slots
x Spindle package with extensive approach and exit strategies and 16 mm dia.
range of functions, for example, calculation of intersection o Full CNC keyboard (310 mm wide)
various thread cutting functions, o Tool length compensation o OP 010 operator panel (19" wide),
variable pulse evaluation, oriented o Interpolation leadscrew error com- 10.4" STN color display, membrane
spindle stop pensation and measuring system keyboard
o 5-axis machining package with error compensation o OP 010C operator panel (19" wide),
5-axis transformation, 5-axis tool o Multidimensional sag compensation 10.4" TFT color display, mechanical
compensation, oriented tool retrac- x Backlash compensation keys
tion (RETTOOL) remote tool center x Quadrant error compensation o OP 012/OP 015A operator panel
point (RTCP) o Automatic quadrant error compen- (19" wide), 12.1715" TFT color dis-
o Spline interpolation sation with neuronal network play, membrane key board and in-
o Polynomial interpolation of the x Safety routines permanently active tegral mouse, vertical soft keys can
third degree for measuring circuits, overtemper- be used as direct keys in the PLC
o Control value linking and curve ature, battery, voltage, memory, o OP 015 operator panel (19" wide),
table interpolation limit switch, fan monitoring, EPROM 15" TFT color display, membrane
o Electronic gearbox x Working area limitation keyboard
o Link axis x Software limit switch o TP 012 touch operator panel
o Axis container x Contour monitoring (400 mm wide)
o Electronic transfer x Spindle monitoring o Machine control panel (19" wide)
o Axis and spindle movements from x Diagnostic functions from interface, with 30 customer keys and key-
synchronous actions PLC and NC with plaintext displays switches
o Speed-dependent analog value on screen o MPI interface module for customer
output o Interrupt routines with fast retrac- machine control panel
o Sensor-controlled 3D distance con- tion from the contour o Full CNC keyboard (19" wide)
trol o Safety Integrated
o MFII PC standard PC keyboard Operating modes: o ShopMill - convenient operating
o OP 030 slimline operator panel x AUTOMATIC and programming interface for
(280 mm wide) x JOG (set-up) milling and drilling
o Handheld control terminal x TEACH IN (program generation o SinuTrain
o HT6 handheld terminal interactively with the machine) o On-line ISO dialect interpreter
o PCU 20 x MDA (processes manually entered o CAD reader, converts DFX files into
- COM 1 (V.24/TTY), COM 2 (V.24) block) drilling patterns and contours
- PS/2 keyboard x The operating modes are supple- x Dynamic block buffer (FIFO)
- Multipoint interface (MPI) mented by the machine functions: x Configurable number of zero offsets
- USB, 2 channels (1 x internal/ - PRESET to set a new coordinate x Up to 2.5 MB NC user memory (RAM)
1 x external) reference point for parts programs, tool offsets, offsets
- Ethernet 10/100 Mbit/s (optional) - Simultaneous traversing of axes
- Cardbus (max. Type III) with up to 2 handwheels Communication
- Disk drive interface (option) - Overstoring machine functions in x RS232C (V.24)/TTY universal opera-
o PCU 50 setup mode and AUTOMATIC mode tor interface, configuration via
Industrial PC with 566 MHz/128 MB - Program selection via directory plaintext screenforms
SDRAM or 1.2 GHz/256 MB SDRAM x Read in/read out via universal inter-
- Removable hard disk with trans- Displays: face during machining
portation lock (1 Gbyte for user o Screen text in several languages x Extensive archiving procedures
data) (English, German, Spanish, French, o Serial data transmission with
- Microsoft Windows NT 4.0 (US) Italian), other languages on request SinuCom PCIN
or XP operating system x Program window for block display o Archive and transmit data with
- COM 1 (V.24/TTY), COM 2 (V.24) x Positional actual values, 2- to 5-fold DNCNT2000
- LPT1 parallel port character size o Data transmission via standard
- PS/2 mouse, PS/2 keyboard x Screen saver network with SinDNC
- Multipoint interface (MPI) x Plaintext display for operating status o Communication of tool require-
- USB, 2 channels (1 x internal/ ment via SinTDI
1 x external) Programming: o Communication to host computer
- Ethernet 10/100 Mbit/s (option) x User-friendly programming language via SinCOM
- Cardbus (max. type III) editor to DIN 66025 with comprehen- o Data exchange between production
- Disk drive interface sive range of high-level language planning and manufacturing via
- Expansion slots: elements WinBDE
1 x PCI/ISA + 1 x PCI o Technology cycles for drilling, turning x Program coordination via CNC
o PCU 70 and milling high-level language
- Expansion slots: 1 x PCI/ISA + x Tapping without compensation chuck x CNC-PCU multipoint interface
3 x PCI (otherwise the PCU 70 x Dimension input metric, inch or mixed x 2nd serial interface (HMI via
is exactly as the PCU 50) x Extensive parameter technology external PC)
x Program generation parallel to o I/O interface via PROFIBUS-DP
Operation and displays machining (master or slave)
x Clear operation with operating x Reference point approach ace. to
areas with 8 horizontal and vertical program Key
softkeys each o Measuring cycles, measurement in x CNC functions included in the basic
x Operator panel disable JOG mode configuration
x User-oriented hierarchical access x Fast NC-PLC data exchange via o Option or Accessory
protection dualport RAM HMI - Human machine interface
x Supplement operator interface x Contour and cycle programming MPI - Multi Point Interface
(user-specific) x Simulation for turning and milling NC - Numeric control
o OA Windows operator interface o AutoTurn - programming software OA - Open architecture
configurable for simple turned parts PLC - Programmable logic
o Control unit management (up to o ManualTurn - simple operating and controller
8 PCUs to max. 8 NCUs) programming interface for turning
o ShopTurn - convenient operating
and programming interface for
turning and milling
SIEMENS
SINUMERIK 802S & STEPDRIVE

SINUMERIK 802C & SIMODRIVE
Catalog September 2001
•*
J 1 ?••'
Mill UK
•
Function Overview
SINUMERIK 802S/SINUMERIK 802C
CNC memory (non-volatile) for programs and data, 256 KB Automatic

Part program memory, up to 50 programs DNC mode
Max. 3 axes + 1 spindle MDA mode
Spindle positioning JOG mode
Incremental encoder RS 422 Teach in
Additional spindle encoder RS 422 Reference point approach manual/via CNC program
Resolution 1 jim/0.00001 inches Increment weighting with handwheel
Manual mode interrupt
JOG and handwheel simultaneous mode
Incremental axis approach
Look ahead, 1 block
Dry run
Single block
Programming language, DIN 66025 and SINUMERIK

high-level language
Inch/metric dimensions Block number search
Contour programming Program number search
Absolute/incremental programming Background editing
X axis diameter/radius programming
Arithmetic and trigonometric function
Menu programming Graphical display
Subroutine call Status display
Skip function Current position display
Chamfer/radius transition Program display
Plane selection Program error display
Workpiece coordinate system Parameter display
Operator error display
Alarm display
Linear interpolation, max. 3 axes Servo setting display
Circular interpolation Spindle display
Helical interpolation Self-diagnostics function
Status signal output
(NC ready, servo ready, automatic operation, etc.)
RS 232 C serial interface

Data transmission from ECU to ECU
Length/radius compensation
Tool management
15 tools
Slimline operator panel, monochrome, 5.7* 30 tool offsets
Full CNC keyboard Tool radius offset in the plane
2 electronic handwheels can be connected Collision monitoring, machining area
Graphical cycle support Tool tip radius compensation
2 languages available in the system/switchable online, Tool position compensation
English/customer-specific (German/Chinese etc.) Geometry/wear compensation
8 access protection levels Tool length measurement
Program execution via external DNC
Standard features at no additional costs

Option or accessory
Siemens Catalog SINUMERIK 802S/802C • September 2001

Function Overview
SINUMERIK 802S/SINUMERIK 802C
Zero offsets, adjustable, max. 4 Cycles for turning

Zero offsets, programmable Cycles for drilling/milling
Limit switch monitoring SIMATIC S7-200 software CPU

2 software limit switches User memory, 4000 instructions
Contour monitoring Ladder programming
Position monitoring Digital inputs/outputs, 16/16
Clamping monitoring Digital inputs/outputs, 64/64 in 16/16 steps
1024 flags
16 timers
32 counters
Stored leadscrew error compensation
Typical processing time for bit commands 1.8 p.s
Backlash compensation
Measuring system error compensation
Drift compensation for analog set points
Diagnostics basic functions
PLC status
Velocity (max. default 100,000 mm/min / 40,000 inch/min)

Feedrate override, 0% to 120%
Feedrate per min Alarms selectable in the part program
Feedrate per revolution Alarms and messages from PLC
Tangential velocity constant control
Jerk limitation
JOG override
Start-up tools, running on external PC
Series start-up via serial interface
Miscellaneous function M (2 digit)

Max. 3 auxiliary functions per block
The manual machine version contains in addition
the following functions:
Constant oriented spindle stop for material change
Spindle speed, programmable (max. 999,999.9 rpm) Threading with constant cut profile at working spindle
Spindle override 0% to 120% Cutting of multiple threads
5 gear stages Cutting of conic threads
Automatic gear stage selection Cutting of transversal thread
Oriented spindle stop Limit stop turning in X and Z axis
Constant cutting speed Conic turning over the complete working area
Thread cutting Repair thread cutting
Tapping/rigid tapping

Option or accessory
Siemens Catalog SINUMERIK 802S/802C • September 2001

SIEMENS
SINUMERIK 802D with

SIMODRIVE 611 universal
Catalog • June 2000

System Overview
CNC Control
SINUMERIK 802D panel control unit, keyboards

The SINUMERIK 802D combines all CNC, PLC, HMI and com-
munications tasks in a single component. The maintenancefree
hardware integrates the PROFIBUS interface for the drives and
the I/O modules with the slimline operator panel in a ready-to-
install unit. aaaaaao
The SINUMERIK 802D can digitally control up to 4 axes and
1 spindle. The SIMODRIVE 611 system, which is modular in GDOS ana
design and PROFIBUS compatible, is used as the drive system.
Consequently the drive power can be individually structured in
every respect. Alternatively, the spindle can also be connected
via an analog interface, which means that universal solutions
can be implemented even for simple machines. The SIMATIC
S7-200 facilitates straightforward adaptation to the machine.
Workpiece programming can not only be carried out universally
on the SINUMERIK, but also allows the use of non-Siemens
G codes.
The following components can be connected to the
SINUMERIK 802D:
Full CNC keyboard (vertical format or horizontal format)
I/O module PP 72/48 via PROFIBUS connection
Converter system SIMODRIVE 611 universal E via PROFIBUS
Electronic handwheels (max. 3)
Mini handheld unit
SINUMERIK 802D panel control unit with full CNC keyboard

vertical format (beside) or alternatively horizontal format (below)
I/O module PP 72/48

The I/O module is connected to the PROFIBUS and offers
72 digital inputs and 48 digital outputs (24 V, 0.25 A).
The 3 connectors for the I/Os comply with MIL-C-83-503 (flat
ribbon cables).
The I/O module provides:
3 x 24 digital inputs and 3 x 1 6 digital outputs
Integrated power supply 24 V DC with electrical isolation
between I/Os and PROFIBUS
I/O module PP 72/48
Machine control panel MCP

The machine control panel offers a simple and cost-effective
standard solution for turning and milling machines. In addition to
6 customized keys (with LED) all the keys and switches that are
needed to operate a machine are provided.
All wiring work for mode type selection, 2 override switches, NC
start/stop, spindle function and reset are taken care of by simple
connection to the PP 72/48 I/O module using 2 ribbon cables.
The EMERGENCY STOP switch is fitted with a break contact and
a make contact.
Machine control panel
• Siemens Catalog SINUMERIK 802D June 2000

SINUMERIK 802D
Function Overview
CNC user memory (non-volatile) for programs and data, Slimline operator panel, monochrome, 10.4"
256KB Slimline operator panel, color, 10.4"
Part program memory, up to 100 programs Full CNC keyboard
Max. 4 axes + 1 spindle 3 electronic handwheels can be connected
Spindle positioning Graphical cycle support
Incremental encoder sin/cos DIN simulation
Absolute encoder EnDat 2 languages available in the system/switchable online,
Additional spindle encoder RS 422 English/customer-specific (German/Chinese etc.)
Resolution 0.1 nm/0.00001 inches 6 access protection levels
Workpiece counter
Program execution via external DNC
Look ahead, 10 blocks

FRAME concept (mirror image, scaling, rotation)
1 measuring probe, with/without delete distance-to-go Automatic
DNC mode
MDA mode
JOG mode
Programming language, DIN 66025 and SINUMERIK
high-level language, online interpreter for other G codes Reference point approach manual/via CNC program
Inch/metric dimensions Follow-up mode
Contour programming Increment weighting with handwheel
Absolute/incremental programming Manual mode interrupt
X axis diameter/radius programming JOG and handwheel simultaneous mode
Direct drawing dimension programming Incremental axis approach
Arithmetic and trigonometric function Dry run
Menu programming Single block
Subroutine call
Skip function
Chamfer/radius transition Block number search
Plane selection Program number search
Workpiece coordinate system Background editing
Linear interpolation, max. 3 axes Graphical display

Circular interpolation Status display
Helical interpolation Current position display
Polar coordinate interpolation Program display
Program error display
Parameter display
RS 232C serial interface Operator error display
Data backup and start-up with PC card Alarm display
PROFIBUS Servo setting display
Spindle display
Self-diagnostics function
Status signal output
(NC ready, servo ready, automatic operation, etc.)
•
Option or accessory
Siemens Catalog SINUMERIK 802D June 2000

SINUMERIK 802D
Function Overview
Length/radius compensation Spindle speed, programmable (max. 999,999.9 rpm)

Tool management Spindle override 0% to 200%
32 tools 5 gear stages
64 tool offsets Automatic gear stage selection
Tool radius offset in the plane Oriented spindle stop
Collision monitoring, machining area Constant cutting speed
Tool tip radius compensation Thread cutting
Tool position compensation Tapping/rigid tapping
Geometry/wear compensation
Automatic tool length measurement
Cycles for turning

Cycles for drilling/milling
Zero offsets, adjustable, max. 6
Zero offsets, programmable
SIMATIC S7-2OO software CPU

User memory, 6,000 instructions
Working area limitation Ladder programming language
Limit switch monitoring Windows programming tool
2 software limit switches Max. 144/96 digital inputs/outputs
Contour monitoring 2048 flags
Position monitoring 32 timers
Zero speed control 32 counters
Clamping monitoring Typical processing time for bit commands 0.4 us
Stored leadscrew error compensation Diagnostics basic functions

Backlash compensation PLC status
Measuring system error compensation
Feedforward control
Alarms and messages selectable in the part program

Alarms and messages from PLC
Rotary axis turning endlessly
Velocity (max. default 100,000 mm/min / 40,000 inch/min)
Feedrate override, 0% to 200%
Axis limitation from PLC
Feedrate per min
Protection zone
Feedrate per revolution
Tangential velocity constant control
Jerk limitation
JOG override Start-up tools, running on external PC
Series start-up via serial interface
Series start-up via PC card
Miscellaneous function M (2 digit)

2nd auxiliary function H (6 digit)
Max. 3 auxiliary functions per block

Option 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 Retrofit
Fecha: Tue, 26 Apr 2005 10:27:23 -0500
David,
Anexo la respuesta por parte del desarrollador de producto.
Saludos cordiales, Roger
Mensaje original
De: Schneider Wolfgang
Enviado el: Martes, 26 de Abril de 2005 10:13 a.m.
Para: Guerrero Roger
Asunto: AW: Presupuesto Retrofit
Hi Roger,
Following situation:
Our best block cycle times are:
802C bl - 24 milli sec
802D - 12 miili sec
But more important for the processing are the time the processor realy has
to do the interpolation. If you have a one processor controller. This
controller has to do all the work.
If the partprogram is also well prepared via a post processor you can also
save steps and get a higher speed.
Next point is the requested or realiced accuracy of the part. If accuracy
is not necessary or not possible by the controller you very often get much
better surface.
Last but not least is important how good is the optimisation of the mechanic
parts of the machine.
If you have more questions please contact me again.
Best regards
Wolfgang
Urspriingliche Nachricht
Von: Guerrero Roger [mailto:roger.guerrero@siemens.com]
Gesendet: Freitag, 22. April 2005 16:05
An: Schneider Wolfgang
Betreff: 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 and

802D. They have a question that I couldn't answer. They are asking me how
many blocks per second are able to process?
Regards
Roger
Mensaje original
De: David Reyes Luna [mailto:A00773434@itesm.mx]
Enviado el: Jueves, 21 de Abril de 2005 05:57 p.m.
Para: Guerrero Roger
Asunto: 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. CANT. MLFB DESCRIPCION PRECIO
SERVOMOTOR SINCRONO 1FK7

COMPACT,
3,0 NM, 100 K, 3000 R/MIN
REFRIGERACION NATURAL,
IM B5 (IM V1, IM V3)
CONECTOR POTENCIA/SENALES
CONECTOR GIRABLE 270 GRADOS,
SIS. CAPTADOR RESOLVER 2 POLOS;
(RESOLVER P=1);
EJE CON CHAVETA, TOLERANCIA N
SIN FRENO DE MANTENIMIENTO;
1 2 1FK7042-5AF GRADO PROTECCION IP64; 737.59 1,475.19
SINUMERIK 802C BASE LINE
PAQUETE BASE COMPUESTO DE:
CONTROL DE PANEL MANDO INCL:
PANEL DE MANDO DE MAQUINA
PERIFERIA 48/16 E7S DIGITALES
3 1 6FC55000AA TOOLBOX LOGBOOK 4,393.58 4,393.58
SIMODRIVE BASE LINE
CONVERTIDOR PARA DOS
SERVOMOTORES
CON RESOLVER 2 POLOS 6+3NM
6 1 6FC55480AC DEL TlPO 1FK7 INTENSIDAD 2X5 A 2,887.65 2,887.65
POS. CANT. MLFB DESCRIPCION PRECIO
UNITARIO TOTAL
SERVOMOTOR SINCRONO 1FK7

COMPACT,
3,0 NM, 100 K, 3000 R/MIN
REFRIGERACION NATURAL,
IMB5(IMV1,IMV3)
CONECTOR POTENCIA/SENALES
CONECTOR GIRABLE 270 GRADOS,
SISTEMA CAPTADOR INCREMENTAL;
(ENCODER I-2048);
EJE CON CHAVETA, TOLERANCIA N
SIN FRENO DE MANTENIMIENTO;
1 2 1FK7042-J GRADO PROTECCION IP64; 1,117.96 2,235.91
SINUMERIK 802D PAQUETE BASE 1:
-TECLADO CNC COMPLETO VERT.
-1 X SIMODRIVE 611 UNIVERSAL E
-1 X MODULO MOTION CONTROL
CON PROFIBUS-DP
-1 X MODULO PERIFERIA PP 72/48
-3 X CONECTORES PROFIBUS
3 1 6FC5600-C -SINUMERIK 802D TOOLBOX 6,955.20 6,955.20
SINUMERIK 802D
PANEL DE MANDO DE MAQUINA
FORMATO ELEVADO
MONTAJE JUNTO A LA PANTALLA
24V, CONEXION CABLE PLANO
ADAPTADO 6FC5611-0CA01 -0AA0
6FC5611-0CA01-0AA0
4 1 6FC5603-C 607.03 607.03
SINAMICS / SIMODRIVE 611
PAQUETE FILTRO RED 16KW
ENTRADA: 3AC 380-480V, 50/60HZ
COMPUESTO DE: BOBINA DE RED HF
TIPO 6SN1111-0AA00-0BA1 Y
FILTRO DE RED
11 1 6SL3000-0 TIPO 6SL3000-0BE21-6AA0 1,280.81 1,280.81
SIMODRIVE 611
MODULO E/R, 16/21 KWREGULADO,
EVACUACION DE CALOR INTERNA,
PROTECCION DE RED CON
CONTACTO ABIERTO
16 1 6SN1145-' 2,468.48 2,468.48
The Powerful HEIDENHAIN Contouring Control
iTNC 530
Built for the workshop
The machine operator can program
his operations in dialog with the
control. For simple work it is easy
to operate the machine manually
with the iTNC 530.
Fast block-processing times and

optimum motion control make the
iTNC the perfect choice for HSC
machining
Automated manufacturing
On machining centers the iTNC 530
manages tools and pallets. Over
the data interfaces you can even
interrogate operating conditions or
operate 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-oriented
programmability, but also to its compatibility with the programs of its predecessor versions. The
iTNC530 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 he
immediately 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 jobs
in 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 from
a remote programming station to the control.
The new iTNC 530 therefore combines modern technology with the well-known user friendliness of a
TNC.
Specifications
Components # MC 422 main computer

s 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
Program memory Hard disk

Input resolution and display step . To 0.1 urn for linear axes
# To 0.0001° for angular axes
Input range Maximum 99999 999 mm (3.937 inches) or 99999.999°
Interpolation # 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
Block processing time # 3 6 ms

(3-D straight line without radius # Option: 0 5 ms
compensation) ^software option 2
Axis feedback control , Position loop resolution: Signal period of the position
encoder/1024
, Cycle time of position controller: 1.8 ms
» Cycle time of speed controller: 600 us
# Cycle time of current controller: minimum 100 MS
Traverse range Maximum 100 m (3937 inches)

Spindle speed Maximum 40000 rpm (with 2 pole pairs)
Error compensation , Linear and nonlinear axis error, backlash, reversal spikes
during circular movements, thermal expansion
„ Stick-slip friction
Data interfaces # 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 the
HEIDENHAIM software TNCremo
# Fast Ethernet interface 100BaseT
Ambient temperature . 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 v Programming of cylindrical contours as if in two axes

# Feed rate in mm/min
Coordinate transformations * Tilting the working plane
Interpolation # Circle: in 3 axes with tilted working plane
Software Option 2
3-D machining # 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 during
program run without affecting the position of the tool point
. Keeping the tool normal to the contour
a Tool radius compensation normal to the direction of traverse
and tool
# Spline interpolation
Interpolation a Straight line: in 5 axes (export permit required)

# Spline:
Execution of splines (3rd degree polynomials)
Block processing time . 0.5 ms

APPENDIX D.- Actuator Specifications
79
www.DanaherMotion.com
HoUmorgen Servo
Motors & Drives
Pacific Scientif
Step Motors
& Drives
Pnctfic Scientific
Synchronous
Motors
Servo & Step

Motors and Drives
Sttmims,
DANA HER
MOTION
Product Selection Tree
Specialty Motors
Call 1-866-993-2624 or email Call 1-866-993-2624 or email Call 1-866-993-2624 or email
contactus@danahermotion.com contactus@danahermotion.com contactus@danahermotion.com
Step, Sync, PMDC

www.DirectDriveRotary.com
DDL - Ironless _
DDL • Ironcore —I
Conventional
www.DirectDriveLinear.com
www.ServoMotorProducts.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 to
examine our vast database of produas to choose from the many solutions
Kollmorgen 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 as
FlexDrive11. 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 for
single 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+Driveônly:
• 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 will
operate with a large number of brushless servo motors - for information on selecting Baldor
servo motors, please see the sales brochure BR1202 (BR1800 for linear motors) available
from your local Baldor representative.
This manual is intended to guide you through the installation of FlexDrive77. The sections
should be read in sequence.
The Basic Installation section describes the mechanical installation of the FlexDrive77, the
power supply connections and motor connections. The other sections require knowledge of
the low level input/output requirements of the installation and an understanding of computer
software installation. If you are not qualified in these areas you should seek assistance before
proceeding.
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 command
signal.
The profiler interprets the pulse and direction signals and uses them to generate
corresponding position, speed and acceleration demand signals.
The position and speed demand signals are fed into a position controller and used, together
with the position measured from the feedback device, to generate a suitable speed demand
signal. If the position controller is tuned correctly, the measured position will accurately track
the 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 demand
signal. If the speed controller is tuned correctly, the measured speed will accurately track the
speed demand. To improve the tracking performance of the speed controller, the profiler
acceleration demand is fed in at this point.
Finally, the torque demand signal is fed into a torque controller, which determines the
appropriate amount of current to apply to the windings of the motor. This demand current is
compared with the actual winding current measured from sensors, and a suitable pulse width
modulation (PWM) signal is generated. This PWM signal is fed to the power electronics in the
drive.
Position reference
(Pulse and Direction) Profiler
Accn .
. Speed Torque
n n_n t Speei - J Position [demanc I Speed demanc To
I?HP PWM Power
}t Posrti lEJ controller controller Icontroller stage!
+ motor r~"l
t Measured current
Measured speed
I I
1
Measured position
Figure 45 - Control structure in Position control (Pulse and Direction)
B-4 Control System MN1902

APPLIED
DJ\ NA HER Mexico, S. A. de C. V. ®
MOTION
Ing. David Reyes Luna
Asistente de Docencia Dpto. Mecanica
ITESM
Tel. 8358-2000 ext. 5454
mail. a00773434@itesm.mx
Mexico D.F. a 15 de Febrero 2005
Ponemos a su consideracion la siguiente cotizacion, esperamos vernos favorecidos con su pedido
QtY Model Brand Description Unit Price Net Price

1 AKM21E-ANCNC-00 Kollmorgen AKM series brushless servomotor 581.00
1 S20360-VTS Kollmorgen S200 series brushless servo drive, alimentacion de 115 vac, 3 797.75
amp.
1 CP-102AAAN-03-0 Kollmorgen Power cable 124.40
1 CF-DA0111N-03-0 Kollmorgen Feedback cable 124.40
1 PMA22B-00100-00 Pacific PMA series brushless servomotor 737.65
Scientific
1 PC832-001-T Pacific PC800 series brushless servo drive, alimentacion de 115 vac. 1173.50
Scientific 2.5 amp
1 PFC-010101-010 Pacific Motor Feedback Cable 205.75
Scientific
1 PPC-010101-010 Pacific Motor Power Cable 205.75
Scientific
1 S30361-NA Kollmorgen S300 series brushless servo drive. Opcional en lugar de la serie 1016.50
S200
1 BAR-300-66 Kollmorgen 300 Watt, 66 ohm regen resistor. Opcional 250.75
1 BSM50N-133AA BALDOR SERVOMOTOR SIN ESCOBILLAS CON RESOLVER 496.90
1 FDH1A02TB-RN20 BALDOR SERVOANPLIFICADOR ALIMENTACION DE 115 VAC, 974.65

CORRDSNTE DE 2.5 AMP. CON FUENTEINTEGRADA DE
24 VDC, RESISTENCIA REGENERATIVA, 8 ENTRADAS,
3 SALIDAS CONFIGURABLES
1 CBL030SP-SF- BALDOR JUEGO DE CABLE DE FUERZA Y RESOLVER DE 3 190.75
MHMALM METROS DE LONG.
AKM21E-ANCNC-00
S20360-VTS
CP-102AAAN-03-0
CF-DA0111N-03-0
Total amount
EL TIEMPO DE ENTREGA para la marca BALDOR DE 4 semanas, para Kollmorgen y Pacific Scientific de 6-7 semanas UNA VEZ
CONFIRMADA LAORDEN DE COMPRA
CONDICIONES 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. al
momenta 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 Purpose
S 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 Page(s)
SGMGH Ratings & Specifications 58

SGMGH Speed/Torque Curves 59
SGMGH Dimensions 60 - 62
SGMGH Selection/Ordering Information 63 - 68
SGDH Ratings & Specifications 99 -100
SGDH Dimensions 101 -112
Design Features
1. Compact
• Small sized motor
Compatible with previous generation G series motors
Ten types of rated outputs ranging from 0.79 to 1988in • Ib of peak torque
Optional 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 Specifications

Time Rating: Continuous Enclosure: Totally-enclosed, self-cooled Maximum Rotational Speed*:
Insulation: Class F IP67 (except for shaft opening) 0.45to7.5kW: 3000rpm
Vibration: 15nm or less Ambient Temperature: 0 to 40°C 11and15kW: 2000rpm
Withstand Voltage: 1500^ Ambient Humidity: 20 to 80% Excitation: Permanent magnet
Insulation Resistance: 10MQ minimum (non-condensing) Drive Method : Direct drive
at 500Vnc Rated Speed*: 1500rpm Mounting: Flange-mounted
Values when the servomotor is combined with an SGDH servo amplifier
Rated Instantaneous Peak Rated Instantaneous

Rated
MOTORS: Output* Toque' Torque* Maximum
Current*
SGMGH- Current*
kW(hp) N«m b f in (KG* cm) N«m Ibfin(KG-cm) A*. An,,
05ADA 0.45(0.6) 284 25(29) 892 79(91) 38 11
09ADA 0.85(1.1) 5.39 48(55) 13.8 122(141) 7.1 17
13ADA 1.3(1.7) 8.34 74(85) 23.3 207(238) 10.7 28
20ADA 1.8(2.4) 11.5 102(117) 28.7 254(293) 16.7 42
30ADA 29(3.9) 18.6 165(190) 45.1 400(460) 23.8 56
44ADA 4.4(5.9) 28.4 252(290) 71.1 629(725) 32.8 84
55ADA 5.5(7.4) 35.0 310(357) 87.6 775(894) 421 110
75ADA 7.5 (10) 48.0 425(490) 119 1053(1210) 54.7 130
1AADA 11(15) 70.0 620(714) 175 1550(1790) 58.6 140
1EADA 15(20) 95.4 845 (974) 224 1988(2290) 78.0 170
Values when the servomotor is combined with an SGDH servo amplifier.

Hddhig Brake (at 20*C)
Allowable Rated Rated Inorks Inductive
Torque Moment of Inerta Col. Rated Addional Load Power Angular Time Time
Constant
Capacity Torque Inertia Inertia Rate* Acceleration* Constant Constant
Resistance Current
MOTORS
SGMGH-
Ib-in'S2 KC'tn2 Ib-in-s2 KG-rn 2
W N-m W A kW/s ratfs 2 ms ms
xitr 3 xVt* x1O* xio4
73
05AOA 6.41 7.24 441 36.2 11.2 3930 5.0 5.1
(0.82)
7.3
09ADA 12.3 13.9 9.85 58.5 0.41 1.85 69.5 20.9 3880 3.1 5.3
(083)
12.7
7.4
13ADA (0.84) 18.2 20.5 103 33.8 4060 2.8 63
6.5
20ADA 28.1 31.7 159 41.5 3620 2.2 128
(0.73)
7.3
30ADA 40.7 46.0 18.5 43.1 31.1 0.77 7.75 230 75.3 4050 1.9 125
(082)
8.0
44ADA 59.8 67.5 338 120 4210 1.3 15.7
(0.91)
7.8
55AQA 78.8 89.0 445 137 3930 1.3 16.4
(0.88)
23.5 726 24.5 0.98 7.75
8.2
75ADA 111 125 625 184 3850 1.1 18.4
(0.93)
11
1AAOA 249 281 320 84.3 18.0 1.33 16.7 1405 174 2490 1.2 226
(1.25
11.7 146
1EAOA
(1.32)
279 315 35.0 115 16.4 33.2 1575 289 3030 0.98 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 S e r V O A m p l i f i e r - For Speed, Torque, & Position Control

With Incremental or Absolute Encoder
For Additional Information Page(s)
99-100
SGDH Ratings & Specifications 101-112
SGDH Dimensions 113-114
SGDH Internal Connections 115
Connection Diagram, Single Phase 116
Connection Diagram, Three Phase
Connector Terminal Block Unit 117
Terminal Block Pin Numbers 118
Amplifier/Encoder Connections 119
Cable Specs and Peripherals 121-125
SGMAH Sigma II Servo System 11 -28
SGMPH Sigma II Servo System
SGMPHGearmotor 29 -46
SGMGH Sigma II Servo System 47 -56
SGMGH Gearmotor 57 -68
Single-phase Three-phase SGMSH Sigma II Servo System 65 -84
85 -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 feedback
2. 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

Three-phase (or single-phase) 200 to 2 ^ ^ +10% to -15% 50/60 Hz,
Input Power
Main Circuit* or single-phase 100 to 1 ^ +10%to -15% 50/60 Hz

Supply
Basic Specifications
Control Circuit* Single-phase 200 to 2 3 0 ^ (or 100 to 1 1 5 ^ ) +10% to -15% 50/60 Hz
Control Mode Three-phase, full-wave rectification IGBT PWM (sinusoidal commutation)

Feedback Serial incremental encoder, absolute encoder
Ambient/Storage Temperature** 0to55°C/-20to85°C
Location
Ambient/Storage Humidity 90% or less (no-condensing)

Vibration/Shock Resistance 4.9m/s2/19.6nVs2
Structure 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 not
Speed Control Range
stop with a rated torque load.)
Load Regulation 0%to100% 0.01% max. (at rated speed)
Regulation***
Performance
Voltage Regulation Rated voltage ±10%: 0%(at rated speed)

Speed
Temperature Regulation 25 ± 25°C: 0.1% maximum (at rated speed)
Frequency Characteristics 400Hz(atJL = . y

Speed/Torque Control Mode
Accel/Decel Time Setting 0 to 10s (Can be set individually for acceleration and deceleration).
±6VQC (variable setting range: ±2 to ±10VDC) at rated speed (forward rotation with positive
Reference
Reference Voltage*"*
Speed
reference); input voltage: ±12V (maximum)

Input Impedance Approximately 14k&
Circuit Time Constant —
±3VDC (Variable setting range: ±1 to ±10V) atratedtorque (forward rotation with positive
Reference
Reference Voltage"**
Input Signal
Torque
reference), input voltage: ±12VQC (maximum)

Input Impedance Approximately 14kQ
Circuit Time Constant Approximately 47us
Rotation Direction Selection Uses P control signal
Contact Speed
Reference
Forward/reverse rotation current limit signals are used (1st to 3rd speed selection). When both
Speed Selection
signals are OFF, the motor stops or enters another control mode.
I
Notes: * The power voltage must not exceed 230V +10% (253V). If it is likely that it will exceed this limit, use a step-down
transformer. 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 cabinet
must 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 and
shaft end).
97
APPENDIX F.- Case Study I Results
Data Processing test
1-D STRAIGHT LINE
Control Option:G64ON
Programmed Feed Rate Vfp (mm/min)
500 1000 2000 3000 4000
Total Time (s) 84.0 42.0 31.1 31.1 31.1

Calculated time (s] 84.0 42.0 31.1 31.1 31.1
Feedrate (mm/min 500.0 1000.0 1350.0 1350.0 1350.0
Block time(ms) j 12.0 6.0 4.4 4.4 4.4
Block /s (BPS) 83.3 166.7 225.0 225.0 225.0
1-D STRAIGHT LINE
Control Option:G64 ON
Programmed Feed Rate) Vfp (mm/min)
500 1000 2000| 3000 4000
Total Time (s) 84.0 62.2 62.2 62.2 62.2

Calculated time (s] 84.0 62.2 62.2 62.2 62.2
Feedrate (mm/min 500.0 675.0 675.0 675.0 675.0
Block time(ms) 6.0 4.4 4.4 4.4 4.4
Block /s (BPS) 166.7 225.0 225.0 225.0 225.0
1-D STRAIGHT LINE
3000
250 500 1000 20001 4000
3
Total Time (s) 124.4 124.4 124.4 124.4 124.4
Calculated time (s) 124.4 124.4 124.4 124.4 124.4
Feedrate (mm/min) 337.5 337.5 337.5 337.5 337.5
Block time(ms) 4.4 4.4 4.4 4.4 4.4
Block /s (BPS) 225.0 225.0 225.0 225.0 225.0
Figure F1.1-D Straight line results.
101
500| 1000J 2000| 3000| 4000
Total Time (s) 84.5 62.5 62.5 62.5 62.5

Feedrate (mm/min) 500.000 668.216 668.216 668.216 668.216
Block time(ms) 6.033 4.464 4.464 4.464 4.464
Block /s (BPS) 165.759 224.000 224.000 224.000 224.000
2-DS TRAIGI •IT

•
LINE
— Line 700 mm 28012 blocks

Controller B
Total Time (s) 127.0 127.0 127.0 127.0 127.0

Feedrate (mm/min) 330.7 330.7 330.7 330.7 330.7
Block time(ms) 4.5 4.5 4.5 4.5 4.5
Block /s (BPS) 220.6 220.6 220.6 220.6 220.6
Figure F 2.2-D straight line results
3-D STRAIGHT LINE
500 1000 2000 3000 4000
1,24.34 1,02.96 1,02.84
Total Time (s) 84.3 62.8 62.8 62.8 62.8
Feedrate (mm/min) 500.000 668.364 668.364 668.364 668.364
Block time(ms) 6.020 4.487 4.487 4.487 4.487
Block /s (BPS) 166.121 222.852 222.852 222.852 222.852
102
3-D STRAIGHT LINE
250 500 1000 2000[ 3000 4000
2,08 2,08 2,08
Total Time (s) 128.0 128.0 128.0 128.0 128.0
Feedrate (mm/min) 327.358 327.358 327.358 327.358 327.358
Block time(ms) 4.6 4.6 4.6 4.6 4.6
Block /s (BPS) 218.8 218.8 218.8 218.8 218.8
Figure F 3.3-D straight line results.
Average Feedrate calculation Siemens 802D and 802C

SIEMENS 802D
Controller Price (US$) 6,955.20
Simodrive 611 U(US$) _[ 5,048.73
Processing time** i 12 ms
Saturation Total line Calculed
Line Segment (mm) feedrate distance Blocks feedrate
(mm/min) (mm) (mm/min)
0.1 700 7000 500
0.05 700 14000 250
0.025 700 28000 125
** Manufacturer
SIEMENS 802C
Controller Price (US$) 4,393.58
Simodrive Base Mne(US$] 2,887.65
Processing time** 24 ms
Saturation Total line Calculed
Line Segment (mm) feedrate distance Blocks feedrate
(mm/min) (mm) (mm/min)
0.1 700 7000 250
0.05 700 14000 125
0.025 700 28000 62.5
** Manufacturer
Relative Value Evaluation for 3-D straight line
83J33I802D vs. 802C

41.6
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.
CENTURION VII 3
\
•I
500 •
„. <
0
0
£ 400
0
Bloc) is per second,
0
( X)
0
300 0
0
0
0*
0
200 0 0
0
(
500 1000 1500 2000 2500 3000 3500 4000

Programmed Feedrate Vfp, (mm/min)
- • - 0.1mm_DNC ON 255 LookAhead - ^ — 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].

2000 4000 7620
Control Option Control Option Control Option
DNC ON | DNC OFF DNC ON | DNC OFF 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 4000 7620

2000 4000 7620
0.006243^010052721 0.0058771 0.0073681 0.0056051 0.00755
105
Contour error (mm)
—w-
1
_Ci liil •—
••
1 o
o
I 3
1 c
(D
o
- < o
O • • ^^^
jo m
0) o <
(Q
(D 3 0 ^
Q.
55" O
f .1 Ml
3 a
- •
8 Q.
(D 3 o
o 0)
3
1 g
3
o" O
3
o
0)
00 1
O 0M o'
4 t 3
I !
1
1•
I _i M_
O
O
I •-
1\
1
\11
•i
O
•_
MACHINE VM16 DNC OFF
Vfp: 4,000 mm/min
Contour error, magnitude and location
0.06
0.055
0.05
0.045 J 11
0.04
4• I I M •
I
0.035
0.03
L
, —i—
0.025 •i 1
0.02 L 11
i
0.015
0.01
0.005
0
-0.005 % MMmm M i j J S *1
I
o
-0.01
-0.015
-0.02
-0.025
1
1
1
o -0.03
-0.035
-0.04
-0.045 |
-0.05
-0.055
-0.06 —i—'—'
20 40 60 80 100 120
107
Contour error (mm)
• O i p i O i p i O i O O O O O O O
benb-t».bcobiob-'bo ob-'bNabcob-ii.bcnb
cnenenen-êneoenioen-ênoen-ênioencoen-ênenencn
-«
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r
I
o » >
1rr -r
I o
o
II
» I Q
O F TTTT < o
o •3" 5
c
m
0)
(D iI o
3 a
o
| 1 -* Q. D
A (D
1
o 0) O
(D • 5' O
O
ft O
0)
00
•1 Lidto•
o o"
ft 3
11
I
I1 M i •
o
o m
I •
1 1
fl
_ _ _ Ik
o
oo
MACHINE VM16DNC ON
Vfp: 2,000 mm/min
/
Contour error, magnitude and location >
0.06 n
0 055 - i i 1
0.05 ! J
0.045 - J
0.04 -
0.035 i 1 1
1
-P 0.03 i i i
1
4t- -11
=
e
"r*
O
C
fc
0.025
0 02
0.015
0.01
0.005 -
•_ -0 005
0- i m
J Mi J
—I—
3 -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 -
() 20 40 60 80 100 120
109
Contour error (mm)
.6.6,6.6,6,6 o
o o o oo o c>
PdPd°dPdPd°d dPd°<D dPd d o
OtflOAOOOMO-'OO 00-'OI\)OUOA0010
a>wovifoicooi\30ioiooiOirooiwoiuoioioio>
r •
4
vi
fl
1 •
o
o
1
1 •• (D
o g
• o
c
5* 0)
<" CD O <
O ^
IF
Q.
1• M • -- 3
| a O
O (D 2
(D 0) 5" O
Q.
ff
1 L 1 1
O
o
3 o
Mi i
00
o 5"
1 T• 3
I
J »
1rrfl
1 •i!
1L
MACHINE VM16DNC ON
Vfp: 7,620 mm/min
Contour error, magnitude and location \ /
0 06 -
0.055 -
0.05 i
0.045 -i
0.04 -
0.035 -
t
1
1
J
1
1
|
1
1
i
'? 0.03 - •
C o 025 1 I 1
^
o
E
O
fc
0.02 1
0.015
0.01 '
0.005 -
o
m
mmm
1
k J
4
J
X 1
1 •I
Z -0.005 - t
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
() 20 40 60
! 80 100 120
111
MACHINE VM16 DNC OFF
Vfp: 2,000 mm/min
Velocity Profile
2000 - M M I
ir ir
If II 11 I! "
4-
II Ifi
II T1
mno 1
oi
V 1
1
I I
1
K 1
0.5 1.5 2 2.5 3 3.5 4.5 5.5
1000
800
600 • • ••
L I i 1 1
400
200 9 ]l 1
0
-200
-400 • 8"" i1
I1 III n
-600 r f f r
t
f 7 •r i
-800 • • • •
-1000 i
0.5 1.5 2 2.5 3 3.5 4.5 5.5
112
Axis acceleration am, (mm/sA2)
1?
o
o
i
I o
I 3
« O
MACHINE VM16DNC OFF
O
Vfp: 7,620 mm/min
Velocity Profile
• i a
A
i
A .it A A
5000
min)
\
1
A it ii \ A i\ n
/\ L 1\ t
3000
Feed Rate \
-Mi-V-
2000
1000
ol
0 0.25
1
0.5 0.75
w
1
\ r 1.25 1.5
I
1.75 2
i
2.25 2.5
w
2.75
Vht-
II 1
3 3.25 3.5 3.75
S1 120 °
% 1000
g 800 . i 1
g 600
400^
! 1. .
ra 200
0 r s. i i • i •. I » k..
II »
-200
-400 =3 i—j f IB "j
*
-600
-800
-1000
*1 •
rw
1 j "•
1200
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
114
o
MACHINE VM16DNC ON
Vfp: 2,000 mm/min
Velocity Profile
2000
l§m -i r* If Tf
1500-P
f H 11 4
-1-1 i• 4
1000 |
•
1
1 1
0*
0 0.5 1
•
1.5 2 2.5
1 3
w

3.5 4 4.5 5 5.5
^ 600 j
£ 400.
r • If 1* t f1 1
-400
-600
-800
I
F
I
f
9
i
I f
**
|
-1000
0 0.5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5
115
MACHINE VM16DNC ON
Vfp: 4,000 mm/min
Velocity Profile
4500
1
4000
|- r li ft -ft r |-
1 \\ / i //
3500
ii
3000
I/1i /fil f i / i i i f M
2500
2000 If \li / If if 11
if if ii If if It I \ I \
i 1000
500
f 0.25
1 at
0.5
V _
"In
T T
0.75
Ti4
1
1
1.25 1.5 1.75 2 •
2.25 2.5 2.75 3.25 3.5 3.75
-2000
0.25 0.5 0.75 1.25 1.5 1.75 2 2.25 2.5 2.75 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
2000
J
~ 1500
A
1
1000
JI mi
1 1t
500
° -500
V
-1000 1 f
1 1
-1500
-2000
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
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 mechanisms
to ball screw applications in facilitate conversion between linear rotary
motions, precise linear positioning, and force amplification.
Machine tools (Horizontal type machining centers)

Features
Smooth motion and high accuracy, even with large cutting forces
Reasons for adoption

High 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 Screw
B-I-4.1 Flow Chart for Selection
There are several methods to select a ball screw standardized series that are available in stock.
which is most suitable both in type and size for a NSK offers a ball screw selection program, and also
specific use. The chart below is one of the selection has a service to select appropriate items using data
methods. To take advantage of prompt delivery and file compiled by our knowledge and experience.
reasonable prices, this method focuses on the
Use conditions
Load, speed, stroke, accuracy,
required life (environment)
Basic factors
Accuracy grade (CO-CtiO) Pages B17 and B445
Screw shaft diameter
Lead
Stroke
Is it a standard series and available in stock? The following are

recommendations for different needs.
A Series : If accuracy is important, and if you desire to use the ball NO
screw as it is delivered.
S Series : If accuracy is important, and if you desire a certain shape
of 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
YES
Basic safety checks
NG Is it in t h e dimension table f o r
(D Limitation of buckling load
Page B451 custom made ball screws? Nut
(D Critical speed
Page B455 shape, shaft end
® Life expectancy
Page B461
OK
Factors to be checked to satisfy a need NO
Y E S
<D Heat displacement and lead accuracy \ /
NG @ Rigidity Page B447 See Page B23 Consult NSK
d> Drive torque Page B465
@ Lubrication, rust prevention, dust Page B469
prevention, safety system Page B471
(£> Consideration t o assembly Page B475
OK
Summary of technical data for ordering Page B31
NSK
B16
B-1 -4.2 Accuracy Grades
Table 1-4*1 shows examples of how to select information on the accuracy grade of ball screws. To
accuracy grade for a specific use. These practical confirm whether a specific ball screw accuracy grade
cases are based on NSK's experience. Circle satisfies requirements in positioning accuracy in
indicates the range of the accuracy grade in actual actual use, refer to "Technical Description" and
use. Double circle indicates accuracy grades most "Mean travel deviation and travel variation." (Page
frequently used among cases marked with a single B445)
circle. These symbols help to identify general
Table 1-4•1 Accuracy grades of ball screw and their application

NC machine tools
Woodworking machine
Laser cutting machine
Wire cutting machine
Jig boring machine
Electric discharge
Electric discharge
Machining center
Drilling machine
Milling machine
Boring machine
Application
Punch press
machine
machine
Grinder
Lathe
Name of axis X Z XY Z XY Z XY z XY z XY Z XY z XY Z XY XY z
CO :O O o O
C1 o O O o o O C) O O o
ccur acy grade
dz p, 0 o O
P o o O o o o.
C3 o O o o o o O o o o o o O O o
G5
* » •
••0 •,o:; 0 p 0 0 0 o '-€>• • • ©
< Ct7 o O
i 1
CtflO i i ;
General industrial machines , I
I
|
|
Machines for specific use |
Semiconductor/associated industry Industrial robots Nuclear power

Three-dimensional coordinate
Image processing equipment

Plastic injection molding
Printed circuit board drilling
Steel mills equipment
measuring machine
Cartesian type
Articulate type
Electronic component
Lithographic machine
Chemical processing
Mechanical snubber
Office machine
inserting machine
Fuel rod control

Application
SCARA type
Wire bonder
machine
Aircraft
equipment
machine
Prober
Assembly
Assembly
purposes
purposes
other
other
I
I
I
C0 i • •rO O O 0:
C1 O O O O o o
Accur acy grade
c? i
O o o- O o o
C3 o O 0 o o O O O O
C5 0 O © 0 o o o o O O O. Q
Ct7
ctt41>
O o
Q
o o o o o
o O
O o
o
o
O.j
,°. O
B17
Technical Description of Ball Screws
B-1 -1 Accuracy
B-II-1.1 Lead Accuracy
The lead accuracy of NSK precision ball screws (C0- and shows allowable value of each. Leads are
C5 grades) conforms to the four characteristics classified into two categories: C system for
specified in JIS Standards. These characteristics are positioning; Ct system for transportation. Table E-
expressed by codes ep, vu, v3mi and v^ . 1*2, 3 and 4 show tolerance of each characteristic.
Fig.I-1'1 explains the definition 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 Code Description Tolerance

75 Travel after the adjustment of thermal expansion and deformation
Specified travel
by the load have been made relative to the nominal travel.
T Value obtained by subtracting the specified travel from the nominal travel based
on the effective length of thread. The value is to compensate the errors caused
Travel compensation
by thermal error and deformation by load.This value is determined by tests and
experience (See Page B447).
Actual travel la Actually measured travel

lm A straight line that demonstrates the direction of actual travel. This straight
Actual mean travel line is obtained from the curve that shows actual travel volume by least-
squares method or by resemblinq approximation.
Tolerance on specified travel ep Obtained by subtracting the specified travel from the actual mean travel. Table 1-1-2
Maximum range of the actual travel which is between the two straight
lines drawn parallel to the actual mean travel. There are three categories
vu as shown below.
Travel variation • Maximum range relative to the effective length of thread. Table n-1-2
U300
• Maximum range relative to the length of 300 mm anywhere within the
effective length of thread. Table 1-1-3,4
• Maximum range which corresponds to any single rotation (liurad.) within
the effective length of thread. Table 1-1-3
B445
Table 1-1*2 Tolerance on specified travel (±ep) and travel variation (vu) of the positioning (Ctype)
ball screws Unit: fim
Accuracy grade CO C1 C2 C3 C5
over or less ±ep + ep vu ±ep vu ±ep uu ±ep t>.
— 100 3 3 3.5 5 5 7 8 8 18 18
100 200 5.5 3 4.5 5 7 7 10 8 20 18
200 315 4 3.5 6 5 8 7 12 8 23 18
315 400 5 3.5 7 5 9 7 13 10 25 20
400 500 6 4 8 5 10 7 15 10 27 20
500 630 6 4 9 6 11 8 16 12 30 23
E
630 800 7 5 10 7 13 9 18 13 35 25
tive thread length
800 1000 8 6 11 8 15 10 21 15 40 27
1000 1250 9 6 13 9 18 11 24 16 46 30
1250 1600 11 7 15 10 21 13 29 18 54 35
1600 2000 18 11 25 15 35 21 65 40
2000 2500 22 13 30 18 41 24 77 46
o 2500 3150 26 15 36 21 50 29 93 54
LU 3150 4000 30 18 44 25 60 35 115 65
4000 5000 52 30 72 41 14p 77
5000 6300 65 36 90 50 170 93
6300 8000 110 60 210 115
8000 10000 260 140
10000 12500 320 170
Table II -1*3 Tolerance of travel variation relative to 300 mm (u ,) and one

revolution (vj of the positioning (C type) ball screws Unit ^
Accuracy grade CO C1 C2 C3 C5
IV-, 3.5 5 7 8 18
Vat 2.5 4 5 6 8
Remarks 1. JIS B1192 sets C type and Cp type standards for positioning ball screws. NSK uses the
specification 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 screws
Uniti/im
Accuracy grade Ct7 Ct10
vm 52 210
Remarks 1. Tolerance on specified travel (ep) of the transportation (Ct type) ball screws is calculated as
follows.
2. JIS B1192 sets Ct1, 3, and 5 grade standards. NSK standards are integrated by C type only. Refer
to Table 1-1*2 for C type standard tolerance.
B446
//5 to/es Precision Hardened Way Slides
Saddle Widths: 7" to 32"
Standard & Custom HS Series Slides
Slide Options & Accessories
US Series
Single Guide Rail Design (standard)

All HS slides provide a single guide rail design for superior tracking accuracy. The single rail
design maximizes accuracy because the saddle movement is controlled by one support side
wall for smoother positioning.
As standard, all HS-series slides Guide Rail
have a guaranteed straightness of
travel(side-to-side and up-and-down) f
i t
not to exceed 0.0005" in 12 inches,

and with an accumulation not to exceed
0.00025" in each additional 12" of travel.
— Reference Edge
1
Low-Friction Turcite™ Material (standard)

As standard, HS-series slides are equipped with low friction, self-lubricating Turcite
bound to the gib and saddle way surfaces to reduce the effects of friction on the slide
assembly. This low-friction bearing material minimizes "stick-slip", and makes wear
negligible on guiding and sliding surfaces.
The use of a low-friction Turcite
doubles the load carrying capacity
of a slide. The coefficient of friction
with low-friction is 0.10; this drops
to 0.05 when combined with a
forced lubrication system. (When
neither is used, the coefficient of
friction is 0.30.)
2. Linear Guides Machine Tool
Horizontal machintig center
NSK Lineat guides
NSK linear guides are roller guides which utilize balls and are used for
supporting load and guiding precise linear motion with low friction.
Machine tools (Horizontal machining centers)

Features
Smooth motion and high accuracy even with large cutting forces
Reasons for adoption

High accuracy, high load capacity, high speed, smooth motion, and high
durability
• LA Series: 6 Row Design; Shock Resistant; High Rigidity; Moderate

Friction; 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 All
Directions; High Dampening Characteristics
• Translide: 2 Row Design; High Load Capacity; High Dust-Proof
Capability; Maintenance Free
A-1 -3 Procedures for Selecting Linear Guide
A-1 -3.1 Flow Chart for Selection
The flow chart below indicates general steps for selection.
• Machine structure Required life, rigidity and

Set conditions for use • Guide installation space accuracy
• Installation position Frequency of use (duty
• Stroke length cycle)
• Load to be imposed Use environment (consider
• Speed material, lubricant, and
surface treatment first for
special environment)
Select model •PageA7
Select based on the

installation space •Page A15
Select through experience
Use simple calculation
•PageA129
•PageA21,
119
•Page A 2 0,
Select accuracy grade 115
Lubrication, Select lubricant and •Page A141

dust protection, lubrication method
surface treatment Dust prevention design (seal,
bellows)
Rust prevention, surface
treatment
Selection completed
A14
A-1 -3.4 Accuracy and Preload
(1) Accuracy grades and types of preload
0 Accuracy grades series.

• The accuracy grade which matches the Refer to "(2) Application examples of accuracy!
characteristic of each series is set for NSK linear grades and preload" which shows cases off
guides. appropriate accuracy grade and preload type for)
• Table 1-3*1 shows accuracy grade set for each specific purpose.
series.
• See Page A115 for accuracy specifications of each
Table I -3*1 Accuracy grades and applicable series
Preloaded assembly (non-interchangeable) Interchanaeable

assembly
Ultra precision Super precision High precision Precision Normal grade Normal grade
Series P3 P4 P5 P6 PN PC
LH O 0 0 0 0 O
LS O 0 0 0 0 0
LA 0 0 0 0
LY 0 0 0 0
LW 0 0 0 o
LE 0 0 0 0
LU o 0 o o 0
LL 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 2.84 Nm 1500 r/min
3.8 A 200V 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
Battery Holder
.Version Number
Usedtohouse «ha bsduv battery for an
M E M H U S Servo Anptfc. hanhnre Kfffcm a M absoUe encoder
solware version (See -AmpMer Version Number")
C N 5 Analog Monitor Connector
Ikedtomonaor rotor epecd. tuMîe refer*
ertoe. and other values tirouah a special cable.
CM8 Battery Connector
K Used lo cornea lo t w tac»v baaerytoran

absolulsnasier.
Panel Display
Rn-oUft 7-sojmenl «spar/ p a M used
u »
• -•- — - - rannalalut.ar>
. and dhor
Panel Kays
Ifted to aet pararheiert
Power ON Indicator
Ugra* when If* eonrat aower *u&0ty is ON.
Charge Indicator
Uahkt wrnn s » mam drcul poMer «««*/i«
Cm and ataya aa rona aa trat oonvonenra
caMdUnrnama craned Therefore. fflMa
taOtt doatdmuHttttmivo
A ff >
M10 Connector for Option Unit

Corvwcls oplian urttfe»dpandrng Ute
N3 Connector to PC or Digital Operator
oorvwcltoart optional digHaf operator.
11/O Signal Connector

iked rbr bottt reference Input and sequence I O signals
-Nameptate
Indxies Ihe r a w arnpttfer model and Ksspedllc rabigs
Encoder Connector
Jslotneeno
Tenninal
"Main Circuit Power Supply Terminal

Usedfarma main circUK power aicpry inpu
'Control Power Supply Terminal

C b m w * to ma conM oo«er supply and lo eulernalry
mounw ntenerattw roiator (where appfeaUe)
-Servomotor Terminal
Coflnools 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
Electrical Manual
4WILL1RONICS CEMB With Centurion 7
SERVING YOUR METAL CUTTING NEEDS FOR MORE THAN 25 YEARS
Yaskawa Axis Drive Parameters

Sigma 2 Axis Drive Parameters For MB/VKM Series
The following table lists the axis drive parameters changed by Militronics. All other parameters remain set
to the Yaskawa factory default settings.
MB11&12 MB18/19 MB20

p#\ X Y Z X Y Z X Y Z
000 0000H 0000H 0001H 0001H 0001H 0001H 0000H 0001H 0000H
100 130 110 55 75 75 75 75 75 75

101 400 400 400 700 700 700 700 700 700
201 1968 1968 1476 1000 1000 500 1000 1000 500
300 720 72CL 543 362 362 183 362 362 183
408 0000H 0000H O00OH 0000H 0000H 0000H
409 1000 1000 1000 1000 1000 1000
40A 70 70 70 70 70 70
600 0 0 10 0 0 10 0 0 10
MB25 MB30 VKM

P#\ X Y Z X Y Z X Y Z
000 0000H 0000H 0001H 0000H 0000H 0001H 0000H 0001 0000
100 75 75 75- 75 75 75 70 70 50
101 700 700 700 700 700 700 400 400 400
201
300
985
362
985
362
738
270
985
362
985
362
738*
270
1 m 1000
369
1000
369
408 000OH 0000H 0000H
409 350 1000 1000
40A 50 50 70
600 0 0 10 0 0 10 0 0 10
28
RRV 15
CNl Terminals layout is shown in Table H 1.
Spaed ooav
rV-CM>- ndanoe
1 SG GMD 28 detactkn
(JCOIN-)
TOON sig- oirtput
2 SG GNO 77 /TOON+
Opea-cctec- nal output
TGONslj-
3 PL1 Mrrefereeee 28 /TGON
naloutwt
4 SEN SEN signal power aappV
7fl S- Servo ready
input RDY* output
Refareaca Senmreedy
5 V-Rff
speed inpui
30
oinput
8 SG GND Servo atom
31 AIM*
output
7 RafBreaca Servo alarm
puts 32 ALM
Reference pulse input POdMded ouîut
S /PULS puba Input PAO output
Torque PGdMoed
9 T-REF reference 34 /PAO OU|)Ut
input PGdMded A-phese
10 SG GNO « PBO OUtDUt
PGdMdad
11 Raferaaca
SIGN
sign input
36 .P80 oinput
RefBranoft AJBTBIOOde B-fhase
12 JSK3N 37 AtOI
symbol input output
Opearcolec-
Alarm code
13 PL2 janafauaui 38 ALD2
oufiut
14 KLR Clear input > AIA3 kroutpat
SerwOM
15 CLR Clear input 40 mm Input
P oparsbon
IS 41 ^
Input
Forward
17 42 P-OT
Opea-oolec- Reverse
Input
IB PL3 lor reference 41 NM3T owartravat
power apply PG divided Input
IfiiM- Atarrafasai
PGdtvtfed IS PCO odpat Faward cur- 44 RST Input
20 /PCO C-phase 45 JP-Ct rant I M ON
C-ptana input Ftaverae
21 BATH Battery H 46 IHCi currant Imt
External ONinpat
+24V
22 BAT*-) Battery (•) 47 input power
4N &fhase
23 48 PSO sijaato*
Sitaaean- put
74 4fl IPSO
Speed coina- nal output
25 /V-CMP+
(COIN*)
dance detec- S3
tion outpal
Table H 1. CNl Terminal layout
121
Output Signals
Pin
Signal Name Function Refersnc*
Number
ALM* 31
Servo alarm: Turns OFF when an error e detected. 5.5.1
ALU- 32
27 tetection during servomotor rotation: detects wheBwrlhe servomotor B

/TGON*
28 rotating at a speed higher than the motor speed selling. Motor speed 5.S.5
flQQH-
Btectmn can be set via parameter
/S-RDY+ d Servo ready: O N if tiiere is no servo alarm when the controMmaln circuit S.5.6
/SHRDY- 30 tower supply »turned O N .
PAO
/PAO
Common PBO
H^35
i phase signal Converted two-phase putse {A and B phase) encoder
(phase signal output signal and origin pulse (C phase) signal: RS-422
/PBO 36 C phase signal or B>e equivalent
PCO 18 5.2.3
/PCO 20
PSO 48 With an absolute encoder: outouts Bertal data
49 S phase signal corresponding to 8 w number of revokitionB (RS-422 or
/PSO
equivalent).
ALO1 37 Alarm code output Outputs 3-brt alarm codes.
ALO2 38 Open-cofector: 30V and 20mA rating maximum.
ALO3 39{1)
5.5.1
lormected to frame ground If the ahieJd vwre of the UD signal cable is
F<3 Shell connected to fte connector shel.
25 Speed coincidence {output in Speed Control Mode): detects whether the

A/-CMP+
Speed 26 notor speed ts wnMn the setting range and if it matches the refers nee 554
/V-CMP-
* » e d value.
Positioning completed {output in Position Control Mode): turns ON when
/CCHN* 25 lie number of error putees reaches the value s a t The setting is the
Position 5.5.3
26 lumbar of error pulses set in reference units (input putse units defned by
lie electronic gear).
1fi
17 rtiese termnafs are not used.
Not used 23 >o not connect relays to these terminals —
24
50
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 via
parameter* Functions CUT, ATCT, /BK, AVARN. and /NEAR signals can also be changed. (See
5.3.4 Output Circuit Signal Allocation >
122
Input signals
Pin
Signal Name Function Reference
No.
Servo ON: Turns ON the servomotor when the gate Mock in the inverter is
S-ON 40 released. 5.5.2
* Function selected via parameter. 5.2.1

5.2.7
Proporkonat opera- 3wrtches the speed confroi loop from Pi (proportonaV
ion reference ntegral) to P {proportional} control when ONL 5.21
Direction reference IMtti internal reference speed selected: switches the

9J2.6
direction of rotation.
Position - » Speed)
/P-CON 41
Control mode Speed " Torque > Enables control mode switching 5.2.7
switching
Torque « Speed j
Speed control with zero-clamp function: reference

Zero-damp reference 5.4.3
speed is zero when ON.
Reference pulse Position control wrth reference pulse stop: stops 5.2.10
block eference pulse input when ON
Common
Forward Run
Overtravel prohibited: stops servomotor when
P-OT 42 trahlbited
Reverse Run TKJvable part travels beyond the allowable range of 5.1.2
NOT 43
notion
prohibited
Forward current limit

ON Current imit function used when ON.
/P-CL 45 5.13
leverse current limit
/N-CL 46 ON
Internal speed rtrtti mtemal reference speed selected: switches the
ntarnal speed settings 5.2.6
switching
/ALM
44 Alarm reset Releases the servo alarm state 5-5.1
-RST
•24V,N 47 Control power supply input for sequence signals: users must provide the 524
+24V power supply.
8EN 4 Initial data request signal when using an absolute encoder. 5.23
P)
BATTf*} 21 Connecting pins for the absolute encoder backup battery 5.2.3
BATTM 22
Speed 5(6) Speed reference Input ±2to±1 OV/rated motor speed (Input gain can be
V-REF 5.2.1
Reference modified with a parameter.)
Torque
Reference
T-REF »(10) Torque reference input ±1 to ±1 OVfrated motor speed {Input 9am can be
modified wtti a parameter.)
5.2.1
PULS 7 Corresponds to refer- nputmode

/PULS a ence pulse input • Code + putoe string
5.2.1
SIGN 11 Line-wvar > CCWrCWpute«
/SIGN Open-collector
Position 12 • Two-ptiase rxite« (90° phase cSffcrential)
Reference CLR 15 Error counter dear: Clears the error counter during position control. 5.2.1
/CLR 14
PL1 3 +12V pull-up power supply when PULS, SIGN and CLR reference signals
PL2 13 are ogen-collector outputs (*12V power supply is butt into the servo 5.2.1
PL3 18 amplifier).
Note t. The funclions allocated to /S-(W,/P-CON. P-OT, hMK,/ALM-RiST,/P-CL, and/Nl-CL input

signals 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 Pin No. Measured Value

/S-ON Servo ON 40 0 V when servo is ON
24 V when servo is OFF
Common + 24V IN 47 24 V
V-REF 5(6) Speed reference input +- 2 V to +- 10 V
The measured values for output signals are in Table H 3

Signal Name Pin No. Measured Value
ALM + 31 OV
ALM- 32 ov
PAO 33(1)
/PAO 34
PBO 35 2.5 V
/PBO 36
PCO 19
/PCO 20
Table H 3. Output signals. Pins numbers in parenthesis ( ) indicate signal grounds..
125

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Evaluation of CNC Controllers in Milling

Machines-Relationship Between Dynamic

Title Evaluation of CNC Controllers in Milling Machines-Relationship

Issue Date 2005-12-01

Publisher Instituto Tecnológico y de Estudios Superiores de Monterrey

Item Type Tesis de maestría

Downloaded 29/03/2018 21:32:19

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

DIVISIÓN DE INGENIERÍA Y ARQUITECTURA

EVALUATION OF CNC CONTROLLERS IN MILLING

PRESENTADA COMO REQUISITO PARCIAL

MONTERREY, N.L. JUNIO DE 2005

DIVISIÓN DE INGENIERÍA Y ARQUITECTURA

Dr. Ciro A. Rodríguez González

Dr. Horacio Ahuett Garza Dr. Nicolás Hendrichs Troeglen

Dr. Federico Viramontes Brown

A mis padres Claudio y Aracely,

A mis hermanas Claudia y Pochi,

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

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

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

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

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

Table 1. Literature review of related work 4

am (mm/s2) Axis Acceleration

ASME.- American Society of Mechanical Engineers

1.1. Related Work

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

Productivity of CNC machines integrating the complete machining process has

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

Figure 3. Controller architectures for different markets

Controllers Actuators Mechanisms

Siemens: ^ ^ B L____ £> ^ ^ k i L"

PCI Board <4000

32 Bit processor 3.6 ms-0.5 ms

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

DC Servomotors 1000-1200 PWM 20 - 30 700-1000

AC Servomotors 900 - 2000

AC Servomotors 900 - 2000 >1000Hz speed >10000

Figure 6. Different motor types with their corresponding drives.

Ball Screw Description Nut / yoke

Ground ball screw 0.0005 ¡n/ft 35»

^V. Bal tae* fat H&

C1= 5um/300mm (0.0002 ¡n/ft) <

C3 = 8um/300mm (0.00032in/ft) i.i*H« bJl " * - . * ) : rOOM

Figure 7. Balls Screws accuracy performance for three levéis

Ball type way

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

This taxonomy does not include spindle technology. Its consideration is

Example of different machine tools taxonomies

Controller Actuators Mechanisms

Figure 9. Taxonomy of VKM3 and VM16 machines.

Figure 10. Application requirement comparison between VKM3 and VM16.

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

VKM3 (V= 0.04 m3> VM16(V =0.156 m3)

Actuator •Yaskawa Ac servomotors: •Yaskawa Ac servomotors:

Mechanism •Heavily Ribbed Cast I ron •Massive Heavily Ribbed Machine

Table 2. VKM3 and VM16 general comparison.

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

COST$ B/A C/B

3.1 STEPI. APPLICATION

As mentioned before the application for selecting or configuring a specific

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

C3 = 8um/300mm (0.00032in/ft) i.iH« bJl " - . * ) : rOOM