CNC SYSTEMS

System Overview:
The CNC operator panel of the SINUMERIK 802D sl control system combines all
CNC, PLC, HMI and communication tasks in a single component. The
maintenance-free hardware integrates the DRIVE-CLiQ interface for the drives
and PROFIBUS interface for the I/O modules with the slimline operator panel,
creating a ready-to-install unit (Panel Control Unit). The SINUMERIK 802D sl
can perform digital control (with SINAMICS S120) or analog control (with ADI4)
of up to 6 axes.
Of the 6 axes, the following configurations are possible:
● A maximum of 5 NC axes and one PLC axis Up to 2 of these 5 NC axes can be
configured as a spindle.
● A maximum of 3 NC axes and 3 PLC axes.

Illustration of 6 Axes of CNC Machine

Components of SINUMERIK 802D sl
 CNC operator panel (PCU) :
It works together with a series of motors and drive components to move
and control the machine axes, executing the programmed motions. On
the industrial machines there is usually a sophisticated feedback system
that constantly monitors and adjusts the cutter's speed and position.

 Full CNC keyboard (vertical or horizontal ) :

These are used to control the movement of machine tools. Press the key
in it and it will feed quickly.

Horizontal Keyboard Vertical Keyboard

  MCP (machine control panel) :
Incorporates all keys and switches required for the operation of a machine.
The machine control panel is available in 2 versions:

[Link] control panel MCP to connect

via a PP 72/48 I/O module.
[Link] control panel MCP 802D sl to connect via
an MCPA module.

 MCPA module :
MCPA module features interfaces for the connection of an analog spindle the
mcp 802d sl machine control panel and terminal strips for additional, high
speed NC inputs and [Link] is mounted on the rear side of pcu of the
sinumerik 802d [Link] places the following resources at your disposal:

– Analog output for ± 10 V (X701) for connecting an analog

spindle
– Interface for connecting an MCP 802D sl external machine
control panel (X1, X2)
– Interface for connecting inputs and outputs (1 byte each) in
the form of high-speed inputs/outputs.
● PP72/48 I/O module :
The PP72/48 I/O module is a user-friendly and low-cost module (without a
separate housing) for connecting digital inputs/outputs within the framework
of an automation system based on PROFIBUS-DP. The module has the
following important features:
– Peripherals interface for connecting an external machine control panel
(MCP) or a terminal strip converter for the digital inputs and outputs (X111,
X222, X333)
– PROFIBUS-DP connection (max 12 Mbits/s)
– 72 digital inputs and 48 digital outputs
– On-board status display via four diagnostic LEDs To supply the module and
the digital outputs, an external voltage source (+24 V DC) is required .
–Automatic module detection by the CNC, no complex configuration required.

PP72/48 I/O Module

● ADI4 (analog drive interface for 4 axes) :

This module facilitates an analog drive interface for 4 axes/spindles, with or
without an incremental encoder.
Module features includes :
1. Profibus DP connection(max. 12Mbps)
2. 4 Servo interfaces
- Inputs: TTL/SSI encoders for incremental and absolute
measuring system.
- outputs : +10V analog
[Link] and drive specific digital input/output signals.
[Link] status display by means of 4 diagnostic LEDS.
[Link] supply : + 24 V DC supply.

Connection Overview of ADI4 :

  Drive units
SINAMICS S120:-
1. Communication between the SINUMERIK 802D sl control system and the
SINAMICS S 120 drive takes place via the DRIVE-CLiQ communication
system (Drive Component Link with IQ).

2. SINAMICS S120 offers high-performance individual AC/AC drives in the

Blocksize and Chassis formats as well as coordinated DC/AC drives for
multi-axis applications in Booksize, Compact, Chassis, and Cabinet
Modules.

3. The different SINAMICS S120 versions can be combined as required

through the DRIVE-CLiQ interface. For instance, Line Modules in the
Chassis format can be combined with Motor Modules in the Booksize
format to address multi-axis applications with a high total power rating.

SINAMICS S120
  DRIVE-CLiQ Hub Module DMC20 :-

 The DRIVE-CLiQ Hub Module DMC20 is used to implement

point-to-point distribution of a DRIVE-CLiQ line and to
enable direct measuring systems to be employed.

 The component is ideal for applications which require

DRIVE-CLiQ nodes to be removed in groups, without
interrupting the DRIVE-CLiQ line and, therefore, data
exchange.

Sensor Module CabinetMounted SMC10/SMC20/SMC30 :-

1. It evaluates sensor signals and transmits the speed, actual position
value, rotor position and, if necessary, the motor temperature and
home position via DRIVE-CLiQ to the Control Unit.

2. Its drives include high-performance single drives and coordinated drives

(multiple-axis applications) with vector or servo functionalities that
allow for implementation of truly customized high performance drive
solutions for the ultimate in flexibility and increased productivity.
3. A few of the popular modules for the SINAMICS S120 series of drives are
the SMC Sensor Modules.
4. The cabinet-mounted sensor module is necessary to evaluate the
encoder signals of motors without a DRIVE-CLiQ interface.

 SMC10– Used for determining the actual motor speed and

the rotor position angle.
 SMC20 –Used for determining the actual motor speed and
thepath length.
 SMC30 – Used for determining the actual motor speed.
The SMC10/20/30 Sensor Modules feature the following connections
and interfaces:
 1 encoding connection including motor temperature sensing via SUB D-
connector
 1 DRIVE-CLiQ interface
 1 power supply connection (24 V DC connection)
 1 PE connection

SMC-20
SMC -30

 Sy
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software
The following system software is installed in the retentive internal memory of
the PCU of each SINUMERIK 802D sl by default:
 Boot software - starts the system
 Human Machine Interface (HMI) software - realizes all operator
functions
 NCK software (NC Kernel) - realizes all NC functions.
 Programmable Logic Control (PLC) software - executes the integrated
PLC user program cyclically.
 Drive software - implements drive control.

 Toolbox:
A tool box is delivered on CD ROM together with the appropriate system
software.
The toolbox contains software tools for configuring the control system. It must
be installed on your PC/PG.
The following software can be found in the Toolbox:
 Configuration data for the SINUMERIK 802D sl:
 Setup files for the technologies.
 Cycle packages for the technologies.
 Retroloadable languages.
 SIMATIC Automation License Manager The Automation License Manager
is needed for managing license keys (e.g. for RCS802).
 RCS802 Commissioning and diagnostic tool (must be licensed for
Ethernet and remote control function) .This program can be used to
transfer texts, user data and programs from the PC to the CNC operator
panel (PCU) and vice versa.
 PLC 802 programming tool Tool to create PLC user program
 PLC user library PLC sample programs
 Startup Tool Tool for commissioning, in particular for drive optimization
this tool is an export from HMI Advanced.

Starter:
The STARTER commissioning tool is provided on DVD along with the relevant
system software.

Description of components:
The illustration below shows the CNC operator panel (PCU) with its interfaces
and front panel elements.
Power supply connection 3-pin screw-type terminal connection
X40 for connecting the 24 V load power
supply
Ethernet interface 8-pin RJ45 socket connector for
X5 connection to an Industrial Ethernet
USB port 4-pin USB port for connecting USB
X10 accessories
Full CNC keyboard connection 6-pin PS/2 socket for connecting the
X9 full CNC keyboard
RS232 COM port 9-pin Sub-D connector for connecting a
X8 PG/PC
PROFIBUS-DP interface 9-pin sub D socket for connection to
X6 PROFIBUS DP
DRIVE-CLiQ interface X1 and X2 8-pin RJ45 socket for connecting the
SINAMICS S120 drive
Handwheel connection 12-pin screw-type male connector for
X30 connecting a max. of 2 handwheels
Digital inputs/digital outputs 12-pin screw-type male connector for
X20 and X21 connecting the digital inputs and
outputs
Option interface 48-pin female connector for
X110 connecting the MCPA module
The PCU and its functions are described in the table below :

Interfacing of the CNC Components (Overview) :

Error and status displays:
LED displays on the CNC operator panel (PCU)

Slot for Compact Flash card :

The slot for the optional user CompactFlash Card is located at the front behind
the protective flap.

CompactFlash Card slot

Uses :
- For commissioning data
- For NC programs
- To carry out software updates
- For storing user data
- For saving set parameter
Precautions while inserting a CompactFlash Card :

● The SINUMERIK CNC supports the file systems FAT16 and FAT32 for
CompactFlash cards. You may need to format the memory card if you
want to use a memory card from another device or if you want to ensure
the compatibility of the memory card with the SINUMERIK. However,
formatting the memory card will permanently delete all data on it.

● Do not remove the memory card while it is being accessed. This can
lead to damage of the memory card and the SINUMERIK as well as the
data on the memory card. The yellow "CF" LED on the right flashes when
the memory card is accessed.

● If you cannot use a memory card with the SINUMERIK, it is probably

because the memory card is not formatted for the control system (e.g.
Ext3 Linux file system), the memory card file system is faulty, or it is the
wrong type of memory card.

● Insert the memory card carefully with the correct orientation into the
memory card slot (observe indicators such as arrow or similar), to avoid
any mechanical damages.

● Only use memory cards that have been approved by Siemens for use
with SINUMERIK.

PP72/48 I/O module interfaces

The diagrams below show the interfaces, the operator controls and
status displays, and the options for connecting to the I/O interface of
the I/O module.
Position of the interfaces and status displays on the I/O module with connection to the MCP
and a terminal strip converter.

Position of the interfaces and status displays on the I/O module when connecting 3 terminal
strip converters.
Interfaces for DRIVE-CLiQ Hub Module DMC20

Precaution:
The 50 mm clearances above and below the components must be observed.

Figure: Interface description of the DMC20.

Connecting the DRIVE-CLiQ Hub Module DMC20
Connect socket X1 or X2 on the CNC operator panel (PCU) to socket X500 on
the DRIVE-CLiQ Hub Module DMC20 using the DRIVE-CLiQ signal line. Using
sockets X501 to X505 on the DRIVE-CLiQ Hub Module DMC20, you can
establish a point-to-point connection of motors with direct measuring systems
to the DRIVE-CLiQ system, via the SMC20 module.

Connecting the DMC20 to SMC’s

Interfaces for Sensor Module Cabinet 10 (SMC10)

Interfaces for Sensor Module Cabinet 20 (SMC20)

Interfaces for Sensor Module Cabinet 30 (SMC30)
 Programmable Logic Controller
 CNC use PLC to do the miscellaneous task like coolant on
off,automatically tool change,Job loading and unloading,Job clamping
and unclamping.
 The programmable logic controller is defined as a digital electronic
device that uses a programmable memory to store instructions and to
implement functions such as logic, sequencing, timing, counting and
arithmetic words to control machines and processes.
 It consists of A central controller with central processing modules and
memory modules One or several expansion units where I/O modules can
be plugged.
 Components of a PLC:
[Link] supply.
[Link] module.
[Link] module.
[Link] (CPU)
[Link] unit (software)
 These are used widely in motion control, positioning control,and torque
controletc.

Methods of representation:
STEP 5 programming language can be represented in 3 different ways:
 Ladder Diagram(LAD)
 Control system flowchart(CSF)
 Statement list(STL)
 Absolute or symbolic designations can be used for operands with
all three methods of representation.
Software BLOCKS:
Five types of blocks are available in step 5 programming language :-

● Organization Blocks(OB):To Organize and manage the user program.

● Program Blocks(PB):To Structure the user program into sections.
● Functional Blocks(FB):For Recurring and complex functions.
● Data Blocks(DB):To store the Data.
● Sequence Blocks(SB):For the simple programming of sequence
controls
 PROGRAM STRUCTURE

The computer is connected to the PLC through Ethernet, RS-232, RS-485, or RS-
422 cabling.
● The programming software allows entry and editing of the ladder-style
logic.
● PLCs are armored for severe conditions (such as dust, moisture, heat,
cold), and have the facility for extensive input/output (I/O)
arrangements.
● This nature connects the PLC to sensors and actuators.
● PLCs read limit switches,analog process variables (such as temperature
and pressure)and the positions of complex positioning systems.
● On the actuator side,PLCs operate electricmotors, pneumatic or
hydraulic cylinders,magnetic relays, solenoids, or analog outputs.
Communications:
PLCs have built-in communications ports, usually 9-pin RS-232, but
optionally Ethernet.
● In machines they use Ethernet as well as Profibus. Which one to
choose for a PLC depends on the control system being used.
● For eg: If the PLC is manufactured by Siemens, then we need to use
Profibus-DP or Profinet and for Rockwell it is Ethernet-IP, Devicenet, etc
● PLC is sequential but CNC is conditional.

CNC Vertical Turning and Boring Machine

o Vertical turning and boring machine is used to bevel the edge of
the vessel.
o According to the diameter of the vessel there are SK25(skoda
25mm spindle diameter),SK40 and SK50 with respective bed size.
o It has a left hand and a right hand tool.
o We can operate the RHT in Auto mode,and LHT in manual mode.
o It is a 3 axis CNC drilling Machine. Those 3 axes are: X,Z,Spindle
 VTB machine

Before Bevelling After Bevelling

G codes and M codes of Siemens 802d:-
Motion Transfer
a) Servo Driving Mechanism
The command from NC makes the servo motor rotate, the rotation of the
servo motor is transmitted to a ball screw via a coupling, the rotation of the
ball screw is transformed into linear movement of a nut, and finally the table
with the workpiece moves [Link] summary, the servo driving mechanism
controls the velocity and torque of the table via the servo driving device of
each axis based on the velocity commands from NC.

b) Spindle Driving Mechanism

Spindle unit consists of a spindle motor and power transmission device. The
rotation of the spindle motor is transmitted to the spindle body via a belt and
the velocity ratio is dependent on the ratio of pulley sizes between the motor
and spindle body(In our VTB the ratio is 1:3).
Position Feedback system
Encoder:-
The device that detects the current position for position control is called an
encoder and, generally, is built into the end of the power-transmission shaft. In
order to control velocity, the velocity is detected by a sensor or is calculated by
position control data detected from the encoder. The method for detecting
velocity uses the encoder, a way of counting pulses generated in unit time and
a means of detecting the interval between pulses [Link] encoder that
detects rotation is called a rotary encoder, and an encoder that detects linear
displacement is called a linear encoder.
The method of controlling the motor rotation by detecting the motor rotation
speed and rotation angle using an encoder is called feedback control (closed
loop method).

An encoder detects the rotation of objects as a physical change amount by the

sensor element, and finally transmits rotation/angle information to the outside
as an electrical signal.

Optical type encoder

“Optical” Encoders interpret data in pulses of light which can then be used to
determine such things as position, direction, and velocity. The shaft rotates a
disc with opaque segments that represent a particular pattern. These encoders
can determine the movement of an object for “rotary” or “shaft” applications
while determining exact position in “linear” functions.

Two types of optical encoders:-

1. Rotary type encoder
2. Linear type encoder

1) Rotary Type Encoder

Absolute encoder:
The optical encoder's disc is made of glass or plastic with transparent and
opaque areas. A light source and photo detector array reads the optical
pattern that results from the disc's position at any one time. The Gray code is
often used. This code can be read by CPU to determine the angle of the shaft.
The absolute analog type produces a unique dual analog code that can be
translated into an absolute angle of the shaft.
Standard Binary encoding Grey encoding
Incremental Encoder:-
A rotary incremental encoder has two output signals, A and B, which issue a
periodic digital waveform in quadrature when the encoder shaft rotates. This is
similar to sine encoders, which output sinusoidal waveforms in quadrature
(i.e., sine and cosine), thus combining the characteristics of an encoder and
a resolver. The waveform frequency indicates the speed of shaft rotation and
the number of pulses indicates the distance moved, whereas the A-B phase
relationship indicates the direction of rotation.

2) Linear type encoder

The linear transducer operate on the photo electric scanning principle with line
gratings on glass as the measuring standards. By displacing the scale relative to
the scanning unit, solar cells generate cyclic sinusoidal signals which are phase
shifted to each other by 90 degrees.
Suppose that for positioning in the X direction, the tool has to move through a
distance of 50 mm. This distance is converted into pulses which is given as
feedback by encoder and one pulse for each micrometer (1/1000 of a mm).
EX: For 50 mm distance, a command signal of 50000 pulses is generated by the
control system