Performance analysis model for real-time Ethernet-based computer numerical control system

In order to optimize the embedded system implementation for Ethernet-based computer numerical control （CNC） system, it is very necessary to establish the performance analysis model and further adopt the codesign method from the control, communication and computing perspectives. On the basis of analyzing real-time Ethemet, system architecture, time characteristic parameters of control-loop ere, a performance analysis model for real-time Ethemet-based CNC system was proposed, which is able to include the timing effects caused by the implementation platform in the simulation. The key for establishing the model is accomplished by designing the error analysis module and the controller nodes. Under the restraint of CPU resource and communication bandwidth, the experiment with a case study was conducted, and the results show that if the deadline miss ratio of data packets is 0.2%, then the percentage error is 1.105%. The proposed model can be used at several stages of CNC system development.

Java Language for Numerical Control Simulation System Research

Java language is widely used in a variety of development platforms to develop all kinds of application software for its simple and efficient.The programming language owning platform independent is adopted to solve the image flicker,sound loading and other issues by the threading technology,multimedia technology,graphics and point by point comparison techniques.Dynamic real⁃time process simulation is implemented and a two⁃dimensional network of CNC machining simulation system is developed while Java applet application is as a carrier.The simulation results show that the system has a friendly interface and fast calculation speed,and platform portability has a certain practicality and application value.

Component-based Model Integration Approach for Computer Numerical Control System Development

A component-based model integration framework for computer numerical control system design and development is presented.The model integrates modeling,simulation,verification and implementation in a uniform environment.The computer numerical control(CNC) modeling language with well defined syntax and unambiguous semantics is developed.Using the proposed CNC model integration method,a three axis milling system model is developed in the case study.The approach is an attempt to create an infrastructure to support the CNC system design in an efficient way,while at the same time guarantees the function and performance requirements with advanced capability of the system such as modularity,flexibility,reusability,etc.

Key technologies for the novel distributed numerical control integrated system

A novel distributed numerical control (DNC) integrated system based on plug-in software technology is proposed. It connects new or old numerical control (NC) machine tools which have inhomogeneous numerical control systems with CAD/CAM system by CANbus network. A DNC computer is able to control 15 sets of NC machine tools reliably at the same time. The novel DNC system increases the efficiency of machine tools and improve the production management level by realizing non-paper production, agile manufacturing, networked manufacturing and so on in the near future. Key technologies to construct the novel DNC integrated system include the integration of inhomogeneous numerical control systems, NC program restart, and algorithm for communication competition. Such system has demonstrated successful applications in some corporations that have acquired good economic benefits and social effects.

Design and Implementation of Distributed Numerical Control in Flexible Manufacturing System

To monitor, control and manage the work process of computer numerical control machine tools in a flexible manufacturing system (FMS) effectively, the distributed numerical coutrol (distributed-NC) software should be innovated with the characteristics of modularization and reconfiguration. In this paper, firstly, distributed-NC functions in the FMS environment are described. Then, we present a design and development method of the real time distributed-NC that is on the basis of the re-coufigurable software and hardware platform and with an object-oriented model concept. Finally, to verify the proposed method, the distributed-NC software has been implemented in VC++ 6.0 and has been tested in connection with the different physical flexible manufacturing shops.

Effect of geometrical parameters on forming quality of high-strength TA18 titanium alloy tube in numerical control bending

The forming quality of high-strength TA18 titanium alloy tube during numerical control bending in changing bending angle β, relative bending radius R/D and tube sizes such as diameter D and wall thickness t was clarified by finite element simulation. The results show that the distribution of wall thickness change ratio Δt and cross section deformation ratio ΔD are very similar under different β; the Δt and ΔD decrease with the increase of R/D, and to obtain the qualified bent tube, the R/D must be greater than 2.0; the wall thinning ratio Δto slightly increases with larger D and t, while the wall thickening ratio Δti and ΔD increase with the larger D and smaller t; the Δto and ΔD firstly decrease and then increase, while the Δti increases, for the same D/t with the increase of D and t.

METHOD FOR SUPPRESSING CUTTING CHATTER IN NUMERICAL CONTROL MACHINE TOOLS

A new method for suppressing cutting chatter is studied by adjusting servo parameters of the numerical control （NC） machine tool and controlling the limited cutting width. A model of the cutting system of the NC machine tool is established. It includes the mechanical system, the servo system and the cutting chatter system. Interactions between every two systems are shown in the model. The cutting system stability is simulated and relation curves between the limited cutting width and servo system parameters are described in the experiment. Simulation and experimental results show that there is a mapping relation between the limited cutting width and servo parameters of the NC machine tool, and the method is applicable and credible to suppress chatter.

Numerical Controlled Rolling Process of Thick Metal Plate

Thick metal plate rolling process has become more and more important in building a flat roof of drilling on the bottom at sea. This is because not only the product quality requirement higher and higher but also the marketing competition. To improve the process of thick metal plate rolling and to increase productivity a numerical controlled rolling process is developed, which include the process planning, the mathematical model establishment and the numerical control system development. The process is for the 17 000 kN×3 000 mm movable up roller bending machine. According to the machine configuration non-symmetry rolling process is planed. This makes it possible to integrate all the steps of plate shaping up such as end side bending, several times of semi-shape bending and the last shape finishing. Since the process will perform under the numerical controlled condition whole steps of the process are considered can be worked in the automatic cycle. The mathematic model consists of two sections, the theory model and the experience parameters model. Which takes the original plate parameters such as geometry and mechanics, characters of the machine such as the movement limits, tonnage and so on as input and calculates all the parameters needed in process performing. Meanwhile, the mathematic Model is totally adapted to the control system. The numerical control system development scheme is based on all the works above. Here, a system plan is provided. The functional modules and hardware selection, in detail, are introduced. The system software on top level and the controlling software for controller are developed. And some unit techniques in the system such as timer setting, communication between system and controller, video integration, and the ability of resisting impact force are introduced. The process has been used successfully in production for more than two years. Practice approves that the process is robust.

Development of PLC-based Tension Control System

Fiber winding tension is an important factor in the molding techniques of composite material which influences the quality of winding product directly, and the tension control is a key technique in fiber winding techniques. This paper introduces a closed-loop tension control system with the programmable logic controller （PLC） with function modules as its control kernel, the alternating current （AC） servo motor as execute element and the radius-following device to accomplish the real-time radius compensation. The mechanism of the tension control system is analyzed and the numerical model is set up. The compensation technique of the radius of the scroll is analyzed. Experimental results show that the system is well qualified with high control precision and high reaction speed.

Deformation behaviors of 21-6-9 stainless steel tube numerical control bending under different friction conditions

For contact dominated numerical control(NC) bending process of tube, the effect of friction on bending deformation behaviors should be focused on to achieve precision bending forming. A three dimensional(3D) elastic-plastic finite element(FE) model of NC bending process was established under ABAQUS/Explicit platform, and its reliability was validated by the experiment. Then, numerical study on bending deformation behaviors under different frictions between tube and various dies was explored from multiple aspects such as wrinkling, wall thickness change and cross section deformation. The results show that the large friction of wiper die-tube reduces the wrinkling wave ratio η and cross section deformation degree ΔD and increases the wall thinning degree Δt. The large friction of mandrel-tube causes large η, Δt and ΔD, and the onset of wrinkling near clamp die. The large friction of pressure die-tube reduces Δt and ΔD, and the friction on this interface has little effect on η. The large friction of bending die-tube reduces η and ΔD, and the friction on this interface has little effect on Δt. The reasonable friction coefficients on wiper die-tube, mandrel-tube, pressure die-tube and bending die-tube of 21-6-9(0Cr21Ni6Mn9N) stainless steel tube in NC bending are 0.05-0.15, 0.05-0.15, 0.25-0.35 and 0.25-0.35, respectively. The results can provide a guideline for applying the friction conditions to establish the robust bending environment for stable and precise bending deformation of tube bending.

Bayesian networks modeling for thermal error of numerical control machine tools

The interaction between the heat source location, its intensity, thermal expansion coefficient, the machine system configuration and the running environment creates complex thermal behavior of a machine tool, and also makes thermal error prediction difficult. To address this issue, a novel prediction method for machine tool thermal error based on Bayesian networks (BNs) was presented. The method described causal relationships of factors inducing thermal deformation by graph theory and estimated the thermal error by Bayesian statistical techniques. Due to the effective combination of domain knowledge and sampled data, the BN method could adapt to the change of running state of machine, and obtain satisfactory prediction accuracy. Ex- periments on spindle thermal deformation were conducted to evaluate the modeling performance. Experimental results indicate that the BN method performs far better than the least squares (LS) analysis in terms of modeling estimation accuracy.

A Windows bitmap-based numerically controlled sculpture method and its application

Bitmap （BMP） is a widely used format in image processing. With the combination of the digital image processing and computer numerically controlled （NC） techniques, we developed a bitmap-based NC single-step and multi-dot method. An example was provided to illustrate the application and principle of this bitmap-based method in our newly innovated sandblasting glass NC sculpture system.

NOVEL STRUCTURE FOR DISTRIBUTED NUMERICAL CONTROL

Because of an unexpected signal noise within the network or an unpredictedfault with personal computers (PCs), many problems emerge in the implementation of distributednumerical control (DNC) with PCs-based network. To solve the problems, an industrial solution ofinvolving the field-bus technology in DNC communicating area is provided. A kind of advancedField-bus, named controller area network (CAN), is originally developed to support cheap and rathersimple automotive applications. However, because of its good performance and low cost, it is alsobeing considered in automated-manufacturing and process control environments to interconnectintelligent devices, such as modem sensors and actuators. Recently it creates a new role for CANBusin DNC that brings new thinking to DNC. CAN is used as the network platform for connecting machinetools to share information with each other reliably. Additionally, thanks to also applying of'plug-in' technology and a special interface of hardware, this solution exhibits some highcompatibility with different pedigree numerical control (NC) systems, such as Fanuc, Siemens,Cincinnati and so on. In order to improve CANBus for DNC application, a communicating competitionmodel of the basic CAN protocol, called CC model, is then highlighted. This model is able to satisfythe requirements that different machine tools share the communicating bandwidth fairly when theyrun concurrently. Finally the novel view of the latest advancement in CANBus-based DNC incombination with the manufacturing paradigm is also presented.

A Numerical-analytic Method for Quickly Predicting Springback of Numerical Control Bending of Thin-walled Tube

Springback is one of important factors influencing the forming quality of numerical control （NC） bending of thin-walled tube. In this paper, a numerical-analytic method for springback angle prediction of the process was put forward. The method is based on springback angle model derived using analytic method and simulation results from three-dimensional （3D） rigid-plastic finite element method （FEM）. The method is validated through comparison with experimental results. The features of the method are as follows： （1） The method is high in efficiency because it combines advantages of rigid-plastic FEM and analytic method. （2） The method is satisfactory in accuracy, since the field variables used in the model is resulting from 3D rigid-plastic FEM solution, and the effects both of axial force and strain neutral axis shift have been included. （3） Research on multi-factor effects can be carried out using the method due to its advantage inheriting from rigid-plastic FEM. The method described here is also of general significance to other bending processes.

Bayesian zero-failure reliability modeling and assessment method for multiple numerical control(NC) machine tools

A new problem that classical statistical methods are incapable of solving is reliability modeling and assessment when multiple numerical control machine tools(NCMTs) reveal zero failures after a reliability test. Thus, the zero-failure data form and corresponding Bayesian model are developed to solve the zero-failure problem of NCMTs, for which no previous suitable statistical model has been developed. An expert-judgment process that incorporates prior information is presented to solve the difficulty in obtaining reliable prior distributions of Weibull parameters. The equations for the posterior distribution of the parameter vector and the Markov chain Monte Carlo(MCMC) algorithm are derived to solve the difficulty of calculating high-dimensional integration and to obtain parameter estimators. The proposed method is applied to a real case; a corresponding programming code and trick are developed to implement an MCMC simulation in Win BUGS, and a mean time between failures(MTBF) of 1057.9 h is obtained. Given its ability to combine expert judgment, prior information, and data, the proposed reliability modeling and assessment method under the zero failure of NCMTs is validated.

A high-precision control system for robotic welding positioner

Aiming at the robotic welding positioner with characteristic of parameter change, load change, nonlinearity, and an intelligent control system was researched and developed. This control system used a two-mode controller that based on Fuzzy and PID control method. The results of simulation show that the dynamic and steady performances of the intelligent controller are better than that of single PID or Fuzzy controller. This paper has made a detail theoretical analysis of the constitution design and real-time controlled software and brought up the design and fulfillment method of multi-task real-time control software of high precisely and numerically controlled welding positioner, which has a good result in practice.

Application of Elastic Stiffness Damper with Disc Spring to Numerical Control Punch

The paper aims to analyze the impacts of punch damper stiffness on equipment base and vibration, andintroduce the development and application of a disc spring damper featured hard-soft-hard variable stiffness. Adamper has four damping columns with C-type disc springs whose laminates plate number gradually increases setby set. Compared with its counterparts, this kind of dampers has the advantages of high energy absorption andvibration damping effect, which not only can effectively reduce the vibration of the foundation of punch press,but also prevents the vibration range from increasing. Also, this kind of dampers is of low cost and convenient touse.

Method of triangular mesh modeling in numerical control machining simulation

In the process of numerical control machining simulation,the workpiece surface is usually described with the uniform triangular mesh model.To alleviate the contradiction between the simulation speed and accuracy in this model,two improved methods,i.e.,the local refinement triangular mesh modeling method and the adaptive triangular mesh modeling method were presented.The simulation results show that when the final shape of the workpiece is known and its mathematic representation is simple,the local refinement triangular mesh modeling method is preferred;when the final shape of the workpiece is unknown and its mathematic description is complicated,the adaptive triangular mesh modeling method is more suitable.The experimental results show that both methods are more targeted and practical and can meet the requirements of real-time and precision in simulation.

Carbon Emission Modeling and Analysis in Manufacturing Process for Numerical Control Machine Tools

Reducing carbon emissions( CEs) is the urgent demand all over the world. In order to realize the low-carbon numerical control( NC) machining, the evaluation model of a part's manufacturing carbon emission with NC machine tools was built by considering the influences of the cutting tool geometrical parameters.The manufacturing CEs were produced by electric power,cutting tools,and cutting fluid consumed in manufacturing process. The parameters of cutting tools affected not only the CEs,but also the machining quality. Then the actual constraint models of the machine performance,machining quality were given in order to optimize the cutting parameters and achieve the low-CEs. Finally,a case was given to analyze the influences of the cutting tool angles on the manufacturing CEs. The results show that the CEs decrease as the rake angle and edge angle increase under the constraints of the machine specifications and machining quality.

Heat regulating strategy in numerical control end milling for hard metal machining

The trend in die/mold manufacturing at present is towards the hard machining at high speed to replace the electron dis- charge machining. Failure forms of the AlTiN-coated micro-grain carbide endmill when used for the machining of JIS SKD61 (HRC 53), a widely used material in die/mold manufacturing, are investigated. The endmill shows a characteristic that tool life decreases greatly due to the chipping when overload occurs or the rapid increase of wear when over-heat accumulation in cutting edges. As a consequence of the investigation, a strategy to regulate heat generation in the end milling process is proposed. This is accomplished by controlling the cutting arc length, i.e. the length of each flute engaging workpiece in a cutting cycle. Case studies on the slot end milling and comer rounding are conducted. The results show that the proposed strategy suggests the optimal tool path as well as the optimal pitch between successive tool paths under the cutting time criterion.