A LOW-COST, EXPANDABLE, OPEN-ARCHITECTURE GRINDING MACHINE CONTROL SYSTEM

1. A LOW-COST, EXPANDABLE, OPEN-ARCHITECTURE GRINDING MACHINE CONTROL SYSTEM John Moruzzi AMTReL Director of Studies: Dr Michael Morgan A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

2. AMTReLJones & Shipman 1300X • Universal grinding machine • External and Internal wheelheads • SAMM control (Servo Assisted Manual Machine) • Prototype machine based on Format 15 model • Built circa 1994, modified 2001 • Closed control system – Industrial PC / MS-DOS Used for previous AMTReL projects/PhD’s Adaptive control (Y Chen) Open CNC Interface (C Statham) High speed Internal grinding Industry co-operations (Timken, Lucas, …) Fluid delivery methods, nozzle design AE monitoring Dressing tool control (fluid coupling) A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

3. Aims of the project • Replace old ‘closed’ CNC control • New simplified operator panel • Touch screen operation • Implement existing cycles for External grinding • Enhance cycle programming and machine setup • Interface and integrate external process control equipment • Demonstrate optimised cycle • Modern software design and implementation • Expandable for intelligent and adaptive grinding features A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

4. Initial Objectives Machine Familiarity with machine & electrics Re-commission hardware Move axes Replace workhead drive Modifications to wiring Disable hardware limits Remove original control panel Control system Initial “desktop” PC control : ISA bus motion control card No Digital I/O card Standard mouse / keyboard / monitor Initial Software Windows 2000 (XP), Visual Basic Programming familiarity Axis configuration (Utility S/W) Axis movements (Utility S/W, libraries) Simple grinding cycles Simple cycle parameters No I/O features A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

5. Phase 2 Objectives Machine Modifications to hardware Optimise axes (drives) Replace original digital I/O wiring Activation of workhead external wheel coolant pump Modifications to wiring Enable hardware limits Interface to original control panel Interface external control devices (Power, AE) Implement new control panel Control system New “industrial” PC control : Rack mount case with Mini-ITX PC board PCI bus motion control card Digital I/O from motion card Standard mouse / keyboard / monitor LCD / Touchscreen monitor Developed software Windows XP, Visual Basic / .NET Program design & implementation Parameter definition & management Enhanced axis moves (MPG) Standard grinding cycles Enhanced cycle programming Initial IO features RS232 connectivity A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

6. Architecture of a CNC system Main Control ExecutorScheduling, program execution, monitoring IO routines HMI, programming, Digital, Bus Safety Machine logic Cycle management Sequencing, monitoring Motion ControlAxis movements, motors Process optimisation In-process Gauging Diameter, Shoulder Touch Detection AE, Power Wheel balancing Auto / Manual Probing Adaptive / Intelligent Control Adaptive strategy Parameter modification Selection strategy Rule / Case based Process models & rules Kinematic, Compliance Database Learning strategy, data A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

7. New Components • Workhead servo drive • Industrial PC • Motion control card • Touchscreen monitor • Console switches / lamps • Cabling / connectors A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

8. Grinding Wheel speed and Control Wheelspeed Rotational speed ns(RPM) Surface speed vs (m/sec) Fixed on 1300X machine , can be changed with gearing / pulleys (3 ratios) Control buttons: SB4 Start Wheel Green SB3 Stop Wheel Red Control relays: KA5 Wheelhead Stop Override KA12 Enable Internal Wheelhead KA13 Enable External Wheelhead A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

9. Workhead speed and control Workspeed Rotational speed nw (RPM) Surface speed vw (m/sec) Variable on most grinding machines Controlled by operator / program Open-loop motor drive control 3rd axis on motion card Calibration Reference Voltage => speed • Control buttons: W+ W- Speed Down / Up SB8 Start Workhead Green SB7 Stop Workhead Red Control relays: KA4 Workhead Stop Override • KA6 Workhead Start Override • KA7 Workhead Stop Relay A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

10. Deva 004 : Axis servo setup Z axis parameters PITCH = -10.0000 MAXVOLT = 3000 (2150) COUNT = 10000.0000 MAXSPEED = 60 MAXACCEL = 60 GAIN KV = 15 SPEED = 25 Motion card driver : Set up and adjust axis configuration parameters in, to match to real-world values and give satisfactory response characteristics. Optimization / minimization of lag and overshoot Axor MTS 400 VEL Fine speed adjustment • Offset Zero volt drift compensation kV Dynamic response (gain) Der Derivative gain Also : Adjust servo drive amplifier settings, to give satisfactory response characteristics. Tuning of amplifier trim-pots Optimization / minimization of drift and overshoot A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

11. Workhead drive setup #1 Original transformer (single phase) Original drive unit (with choke) • Non-standard drive and transformer (undocumented, unsupported) • Non-functioning A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

12. Workhead drive setup #2 New transformer (3 phase 2kW) New servo drive unit wheel power monitor A • Axor drive Masterspeed MTS-200-14/28 and transformer TT2000/200-300 • Matched to wheelhead motor SEM MT40-P4 • Equivalent to Control Techniques Maxi-Maestro DCD 200 25/50 A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

13. Motion Control Interfacing Problem : to integrate a new Motion card with the existing machine wiring. Original ISA bus Motion card – 4 axes on 2 boards: Conn 1 15W D Axis 0 encoder inputs Conn 2 15W D Axis 1 encoder inputs Conn 3 9W D Axis 0 , 1 servo outputs Conn 4 15W D Axis 3 encoder inputs Conn 5 15W D Axis 4 encoder inputs Conn 6 9W D Axis 2 , 3 servo outputs New PCI bus Motion card – 4 axes on 1 board + flyer cables: Conn 1 15W D Axis 0 encoder inputs / limit signals Conn 2 15W D Axis 1 encoder inputs / limit signals Conn 3 15W D Axis 2 encoder inputs / limit signals Conn 4 15W D Axis 3 encoder inputs / limit signals IO2 25W D Axis 0, 1, 2 , 3 servo outputs A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

14. Digital I/O Interfacing Problem: To integrate a new Digital IO card with the existing machine. Original ISA bus I/O card – 48 opto-isolated signals on 50W D connector: Conn 1 50W D 24 inputs, 24 Outputs, 2 x common New PCI bus Motion card – 48 opto-isolated signals on 2 flyer cables: IO1 25W D 12 inputs, 9 Outputs, 2 x common, 1 x WDog IO2 25W D 4 inputs, 3 Outputs, 2 x common Machine requirements: 16 Inputs, 7 Outputs, 1 x WDog Connection: To terminal rails in electrical cabinet To auxiliary control equipment A Low-Cost, Expandable, Open-Architecture Grinding Machine Control System

15. Signal Interface Unit To convert one set of signal configurations to be compatible with the machine wiring Control PC Interface Machine Encoder 0 Encoder 0 Encoder 1 Encoder 1 Encoder 2 Encoder 2 Encoder 3 Encoder 3 Servo 0 , 1 Servo 0, 1, 2, 3 Servo 2 , 3 IO1 Inputs, Outputs Inputs 0..15 IO2 Inputs, Outputs Outputs 0..11 Additional Additional A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

16. Signal Interface Unit cont... Implemented as 2U high 19” rack enclosure Rack assembly with connecting cables A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

17. Electrical cabinet :- I/O I/O terminals Relay board Fuses A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

18. Control PC hardware IEI Kino 945 GSE Further equipment 2U 19” rack PC case with PSU Operating system Windows XP 8.4” LCD Touchscreen (VGA, RS232) Deva 004 Motion card (4 axis + I/O) 2U 19” rack for signal interfacing Blank 19” rack panels • Industrial Mini ITX board with Intel Atom 1.6GHz CPU (Fanless) • 1 x PCI expansion slot • 1 x 200pin DDR2 SODIMM slot • 2 x SATA connectors, 1 x IDE • 2 x RS232 ports on rear I/O • 1 x RS232 port (internal) • 1 x RS232/422/485 port (internal) • 8-bit digital I/O Low-Cost, Expandable Open-Architecture Grinding Machine Control System

19. Control PC hardware cont... Front of 19” control console: VM20 unit 3U (balance / touch) Blank panel 1U PC rack unit 2U Signal Interface unit 2U Inside of control console: Axis cabling I/O cabling Cross connections An Introduction to Grinding Machine Control Systems

20. Software panel – main screen Main user interface Cycle start / stop and status Machine functions control Grinding mode and program control X axis status and Jog Z axis status and Jog Manual axis control Low-Cost, Expandable Open-Architecture Grinding Machine Control System

21. Software panel – program screen Cycle programming - Traverse A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

22. Common grinding cycles Dressing Single point “diamond” dressing: Wheel rotating (surface speed vc ) Wheel traverses past diamond tip (crossfeed velocity vf) Wheel infeeds an increment (infeed amount ad) Repeat until wheel surface fully dressed Plunge grindingWorkpiece / table positioned relative to wheel Wheel and workpiece rotating (vc and vw) Wheel infeed at Rapid speed to start position (dia) Wheel infeed at Coarse feed to Fine Feed start position (dia) Wheel infeed at Fine feed to Final Size position (dia) Sparkout or Dwell with no infeed Traverse grinding Workpiece / table set to oscillate across wheel Wheel and workpiece rotating (vc and vw) Wheel infeed at Rapid speed to start position (dia) Wheel infeed by Coarse increments to Fine Feed start position (dia) Wheel infeed at Fine feed to Final Size position (dia) Sparkout passes of wheel with no infeed A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

23. Automatic Plunge Cycle Cycle State Machine Motion parameters dblXMovespeed As Double dblXRapid As Double dblXCoarseFeedAs Double dblXFineFeed As Double dblXInfeed As Double dblXInfeedRate As Double intXDwell as Integer dblXStartPosition As Double dblXFinePosition As Double dblXSizePosition As Double dblZReversePositionL As Double dblZReversePositionR As Double dblZStartPosition As Double intFROSetting As Integer blnFeedHold As Boolean Cycle parameters PlungeCoarseInfeed As Double PlungeFineInfeed As Double PlungeFineDia As Double PlungeStartDia As Double PlungeSizeDia As Double PlungeDwell As Double Auxiliary variables WheelSpeed As Double WorkSpeed As Double WheelheadOn As Boolean WorkheadOn As Boolean CoolantOn As Boolean A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

24. Interfacing of Peripherals 1 Connect to 1300X Operator Panel via RS232: Read Data String: FRO value, button values, checksum Write Data String: Axis position displays, Workspeed display, LED values, checksum RS232: Com 1, 9600 Baud, No Parity A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

25. Interfacing of Peripherals 2 Connect to Balance Systems VM9 TD via RS232: Read Data String: Signal values, Parameter values, checksum Write Data String: Operating commands, Parameter settings, checksum RS232: Com 2, 38400 Baud, No Parity A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

26. Object Oriented Design • OOD (Object Oriented Design) models software as people would describe the objects in the world. • OOD takes advantage of class relationships where objects of a certain class (e.g. a class of Vehicle) have the same characteristics. (e.g. a Car, a Truck, a Bus). • OOD also takes advantage of inheritance relationships where a new class of objects is derived by absorbing characteristics of an existing class of objects and adding unique characteristics of its own. • An object of class Convertible has the characteristics of class Car, but additionally, has a convertible roof. A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

27. Introducing OO . . . cont • An Object has attributes . . . • i.e. size, shape, colour & weight. • . . . and exhibits behaviours. • i.e. a ball rolls, bounces, inflates & deflates. • A Class has Properties . . . • that describe its state and features • . . . and Methods • that allow it to perform and experience actions A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

28. OO Class example A fundamental object could be of type Parameter, with various Attributes and Operations (i.e. Properties and Methods) Class: Parameter Derived classes:CycleParameter AxisParameter VM9 Parameter …. Properties: Data Type Methods: ReadValue Decimal places WriteValue Group FormatValue LevelResetValue Value GetAddress Min Value …. Max Value …. A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

29. Some System Parameters Axis Configuration XAxisChannel As AxisParameter XAxisPitch As AxisParameter XAxisCount As AxisParameter XAxisKV As AxisParameter XAxisMaxSpeed As AxisParameter XAxisMaxVolt As AxisParameter RS232 Configuration Port As RS232Parameter Baudrate As RS232Parameter ParityChecking As RS232Parameter Handshaking As RS232Parameter InBufferSize As RS232Parameter OutBufferSize As RS232Parameter Traverse Cycle XCoarseInc As CycleParameter XFineInc As CycleParameter TraverseZFeed As CycleParameter TraverseStartDia As CycleParameter TraverseFineDia As CycleParameter TraverseSizeDia As CycleParameter Z0Dwell As CycleParameter ZRevDwell As CycleParameter TraversePasses As CycleParameter VM20 Balancer Function MinimumTolerance As BalanceParameter MaximumTolerance As BalanceParameter MaximumUnbalance As BalanceParameter NominalSpeed As BalanceParameter UnbalanceMeasuringUnit As BalanceParameter BalancingCycleTimeout As BalanceParameter CollectorType As BalanceParameter BalancingHeadType As BalanceParameter OptionRPMOutput As BalanceParameter A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

30. UML Class Diagram • Universal Modelling Language • The UML Class diagram allows us to model the classes in the system and their relationships. • Class diagrams : • model a class as a rectangle. • The top zone displays the class name. • The middle zone contains the class attributes. • The bottom zone contains the class operations. . . . ? A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

31. Progress So far..... Reactivation of machine tool Electrical modifications, new workhead drive Initial software with old hardware Development software with new hardware Axis configuration and movement Familiarity with motion control package Implementation of simple cycles Design and build of control unit, IO conversion Developed basic interface design Communication with external equipment Next steps.... Formal definition of software structure Integration of Touchscreen Connection with VM20 unit (RS232/Profibus) Axis movement via MPGs: Improved driver Issues.... Machine removed for workshop rebuild since August 2011 New workshop with machines available duringApril 2012 ????? VM9 Touch Detector unit with Hydrophone ? A Low-Cost, Expandable Open-Architecture Grinding Machine Control System

32. And finally... Any Questions ??? Thank you for your attention..... A Low-Cost, Expandable Open-Architecture Grinding Machine Control System