International Journal of Machine Tools & Manufacture 38 (1998) 10451065

Adjustment of CNC machine tool controller setting values by an experimental method

H.D. Kwona,*, M. Burdekinb
Industrial Automation Technology R & D Centre, Korea Institute of Industrial Technology (KITECH), San 17-1 HongChonRi IbJangMyun Chon An-Si, 330-820, South Korea b Department of Mechanical Engineering, University of Manchester Institute of Science and Technology (UMIST), PO Box 88, Manchester, M60 1QD, UK Received 1 February 1997; in nal form 13 August 1997
a

Abstract This paper presents an adjustment technique on controller setting values in CNC machine tools by measurement of servo induced feed drive errors. At high feed rate operations of CNC machine tools, servo induced errors are usually dominant and large compared with geometric errors. For measurement of the servo induced errors, an experimental equipment which incorporates two linear displacement sensors and a steel cube was developed, and servo feed drive errors were evaluated along a square corner test path. Based on evaluations of servo feed drive errors with different combination of parameters in machine control system, optimum setting parameters were found. The measuring equipment and optimisation method are described. 1998 Elsevier Science Ltd. All rights reserved.
Keywords: CNC machine tools; Servo error

1. Introduction At high feed rate operations of CNC machine tools, servo induced feed drive errors are usually dominant and large, compared with geometric errors of machines. The feed drive errors result from imperfection of machine control systems. In order to improve servo controller performance, various control techniques were applied to CNC machine tools in the past years [17].
* Corresponding author. Tel: + 82-2-3705-3721, Fax: + 82-417-5608-400, E-mail: kwonhd@mail.kitech.re.kr 0890-6955/98/$19.00 1998 Elsevier Science Ltd. All rights reserved. PII: S 0 8 9 0 - 6 9 5 5 ( 9 7 ) 0 0 0 5 8 - 8

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However, due to limitation in evaluating servo induced errors on CNC machines, adjustments of machine control parameters were usually carried out using simulation techniques of control systems, which inevitably involved some idealisations and assumptions, and might not be identical to real system, and machine controller specications therefore were not fully utilised. In order to achieve high utilisation of controller specications, adjustment of controller parameters was researched, based on experimental evaluations of servo induced feed drive errors, using a ball link system [8,9]. Although the ball link system provided some results related to geometric errors and dynamic errors of feed drive system in machine tools, full servo induced error features might not be observed. Because test path of the system was conned to a circle or an arc, and minimum link length was approximately 100 mm, which corresponded to length of a standard LVDT transducer. Therefore geometric error components could be included in the test results. To overcome problems of size and prole of test path, an alternative technique which uses a steel cube and two linear displacement sensors, was devised in this research. In the developed test system, a square corner test path was used, and servo induced feed drive errors were highlighted near corner of the test path. Controller setting values, such as velocity and positional gains with minimum available time constant were changed, and feed drive errors on the machining centre were evaluated. Based on the evaluations, optimum controller setting values were determined. The measurement and adjustment technique on controller setting values in CNC machine tools is detailed in the following order: servo control system in CNC machine tools experimental equipments application of the cube test system to a CNC machining centre adjustment of machine setting values in a CNC machine tool conclusions.

2. Servo control system on CNC machine tools Most CNC machine controllers are organised in the cascade structure, comprising the position, velocity and current control loops as shown schematically in Fig. 1. This type of controller structure provides the following advantages over other types: cascade control loop can be optimised from in to out, there are only a few parameters to adjust, necessary equipments for this organisation are simple and cost effective. Important components of the feed drive control system are position controller, velocity controller, current controller, electric motor, mechanical parts and measuring units. The feed drive control system can be simplied as shown in Fig. 1. The important position control system parameters inuencing on the tool path behaviour are positional gain, velocity gain and time constant. With too high values of positional and velocity gains, an overshoot from desired moving path

H.D. Kwon, M. Burdekin / International Journal of Machine Tools & Manufacture 38 (1998) 10451065 1047

Fig. 1. Block diagram of the positional control loop of an axis. [12]

occurs. With low values, rise time to the desired path is long. It is therefore necessary to select optimal values of the parameters. Basic criteria for determining these controller setting values are system stability and prevention of overshoot, which result in an excessive cutting in the workpiece. 2.1. Position control loop Requirement of the position control loop, is that the desired programmed position must be followed with minimum time delay and following error during movement of machine. Positional gain is dened by Kv = Vactual x (1)

where Vactual is actual velocity, x is error to be inputted to the positional control loop. Selection of positional gain value is important to improve the servo control performance. When selecting the positional gain, K , following error, overshoot, transient error and system stability must be taken into consideration. In order to investigate the control system performance with different positional gains, the position control loops in the control loop were simplied as shown in Fig. 2. With the simplied system as shown in Fig. 2, the uncontrolled system acts, as a second order system, and can be expressed as: G(s) = or G(s) =
2 0

1 TeTms + Tms + 1
2

(2)

s2 + 2D

s+

2 0

(3)

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Fig. 2. Simplied position control loops of machine axes.

where natural frequency =

= 1/TeTm,; damping coefcient = D =

constant; Tm = mechanical time constant. 3. Experimental equipments

1 2

Tm ; T = electrical time Te e

In order to assess servo induced feed drive errors on CNC machine tools, a system was devised. The test system incorporated a precision reference steel cube, two linear digital displacement sensors, PC-counterboard, micro-computer. Two digital displacement sensors were mounted orthogonally with respect to the reference cube as shown in Fig. 3. A third sensor can also be incorporated so that at the same setting, data can be obtained for the XY-, YZ- and ZX-planes. These digital sensors are interfaced to a microcomputer via PC-counterboard (Heidenhain IK120). In order to measure relative movement between the cube and the machine table, dened by an NC program, two linear digital displacement sensors (Heidenhain MT12B), employing a precision glass scale with incremental grating (grating period 10 um), were used for the measuring system. Important specications of the sensor are: measuring range: 12 mm measuring accuracy: 0.5 um gauging force: 0.60.85 N frictional force: 0.12 N

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Fig. 3. Schematics of the cube test system.

permissible measuring velocity: 0.25 m/s permissible shock: 1000 m/s2 operating temperature: 050c During movement of the machine table, relative displacements with respect to the cube, attached to the machine spindle, are detected by the sensors and recorded on the micro-computer. The cube test system can also be used to investigate machine performance when moving around a square corner test path (Fig. 4). Along the pre-dened square path, machine moves from the point A via B to C in Fig. 4, and returned via the point B to A. Servo induced feed drive error features are highlighted around sharp corner (Point B) on the path when machining components having pockets. Before undertaking above test path, a preliminary linear path (Fig. 5) had to be performed, to establish the alignment of the faces of the cube with respect to the axes of the machine. This alignment is achieved by recording data from the sensors when moving along each of the X, Y axis in turn. Angular offset of the cube with respect to the axes is determined by computing a least squares line through the alignment data. 4. Data acquisition When an NC program for the test path is performed, the sensors displacements are equivalent to the programmed positions. The sensors displacements in the X- and Y- directions have to be

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Fig. 4.

Square corner test path.

Fig. 5.

Preliminary test path.

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sampled by the computer. A sampling rate of up to 50 kHz can be achieved when two sensors are used simultaneously. In the developed measurement system, 20000 real data from two different sensors can be recorded in the RAM memory, i.e. 20000 samplings are possible. For safety reasons, the sampling time interval is long enough to sample all the data during the test path. The maximum number of samples is limited by the RAM-memory size. Although some microcomputers can have a large RAM (e.g. 16 Mbyte), the cube test system must be able to be employed on a general micro-computer which can have just 640 Kbytes of RAM used by DOS and the cube system software. Idea that the data samplings can be held by using the hard disk memory, is difcult to implement, because data transfer time from the sensors to the hard memory is not uniform and too long, compared with sampling cycle. Using a micro-computer with a 80 486 processor, up to 20000 samples from two displacement sensors in the cube test system, could be stored in the RAM memory. Limitation of the RAM size, and number of data for analysis had to be considered, when selecting number of samples. After invoking the sensor drive program, sensors start to transmit measured displacement to the computer. The computer must know when to start recording the transferred data by the sensors. It may be possible with some CNC controllers to communicate with the computer at the start and nish points of the test path by some form of hardware link. However, it is desired to avoid this approach, as there are many types of CNC controllers in use, and may not have such output facility. Hardware synchronisation does not exist between the machine, and the measuring system, and it was therefore necessary to devise a technique to identify the start of the test path, when carrying out the measurement. Before machine performed the test path, data acquisition program was invoked to sample data from the sensors. The rst sampled data was held as a reference position, and continuously compared to new sampled data from the sensors. If difference between rst and new sampled data was larger than 3 um after starting the test path, computer will then begin to store sampled data in the RAM-memory in integer form. After given number of data were sampled, data acquisition from the sensors stopped, and captured data in the RAM-memory then converted to the real-type, and stored in the hard memory in le form. 5. Data analysis For analysing sampled data under various test conditions, a program module was devised for identifying initial set-up alignment of the cube and analysing servo induced errors. In order to analyse effectively sampled data, actual path was divided into four intervals from start to nish point, which are termed as interval IF1, IF2, IR2, IR1 respectively, as indicated in Fig. 6. Criterion point between intervals on the actual path was either turning point, or middle point (Point B in Fig. 6). Turning point on actual measured path, corresponded to square corner point on desired test path, and had to be identied.

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Fig. 6. The intervals IF1, IF2, IR1, IR2 on the square corner test path.

Based on idea that turning point locates where local velocity is minimum in the interval of forward movement on the test path, velocities were derived from measured data by computer program, but calculated velocity curve was not smooth and continuous, containing noise spikes. By a program algorithm employing low pass lter principle, these pulses were eliminated, and positions of local minimum velocity from sampled data were identied. Sampled data from the sensors were absolute positions with respect to reference point, which were determined when sensors were activated by sensor drive program. These absolute sampled data were processed by developed computer program. In case of sampled square corner test data, distance between desired and actual sampled positions d1, d2 as indicated in Fig. 7 at the interval IF1, IF2 was computed as errors, and these errors were plotted on computer screen with some magnication. 6. Application of the cube test system to a CNC machining centre A 3-axis vertical spindle bed type machining centre with a CNC controller (Fig. 8) was tested using developed cube test system. Available machining feed rate was in the range 1 5000 mm/min, and positioning resolution was 1 um. Detailed specications are given in the Appendix. Measurements were undertaken at various feed rates in the range 5004000 mm/min. According to test result with feed rate of 500 mm/min as shown in Fig. 9, movement turning point on actual path did not coincide with corner point (4, 0) on desired path. From measurement data, errors were computed in the intervals, IF1, IF2, IR1, IR2, which were shown in Fig. 6. At low feed rate of operation (500 mm/min), small errors were observed, and the actual path was relatively close to the desired path. Error of 160.4 um occurred in the interval IF2, and 177.6 um in IR1.

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Fig. 7.

Errors during the forward movement.

When operating at a high feed rate (4000 mm/min, 80 per cent of maximum feed rate), errors were large near start, turning and nish points as shown in Fig. 10. In the interval IF1, initial transient was dominant (Error band: 39.3 um). It resulted from acceleration of the machine in minimum time. In the interval IF2 in Fig. 10, identied servo induced feed drive errors were large (1184.5 um), when considering that length of the test path (from point A to B in Fig. 10) is 11.3137 mm. It implied that setting values in the machine controller should be re-adjusted.

7. Adjustment of machine setting values in a CNC machine tool Related to servo performance in the machine control system, adjustable controller parameters and ranges are given in Table 1 [10,11]. Tests were carried out with different combinations of controller parameters. Time constant remained with the smallest value for fast reaction. On the machining centre, time constant remained with minimum available value of 8 msec. First set of measurements (Test A) were carried out under test conditions as shown in Table 1. Figure 11 shows measurement results of Test A1, which were carried out, with the positional gain of 2500 [0.01/sec], velocity gain of 2500, at the feed rate of 500 mm/min. Test results in backward movement, were very similar to that in the forward movement.

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Fig. 8.

The tested CNC Machining centre.

With feed rate of 4000 mm/min, tests (Test A2) were carried out under same settings with Test A1. Figure 12 shows test results and large contouring errors occurred near corner in the forward movement, and the error band in the interval IF2 is 658 um. The test result on backward movement was very similar to that using the forward movement. Therefore forward movement test can represent error features of both moving directions. At high feed rate of machine operation, servo induced feed drive error was highlighted around the corner of the square test path. Hence machine servo characteristics were evaluated, as the error band and overshoot in the interval IF2. Test results of Test A1, A3 and A5 are summarised and plotted in Fig. 13. Abbreviations Maxi 1, Mini 1, Band 1 in Fig. 13 are used and represent maximum and minimum machine errors, and error band in the interval IF1. Figure 14 shows measurement results with Test A1, A3 and A5 in the interval IF2 on the square corner path. The change of the minimum errors was observed as very small. The errors in the interval IF2 were very large, compared with that of low feed rate test as shown in Fig. 13. Measured machine errors at low feed rate were relatively small, compared with high feed rate test, and servo induced feed drive errors were clearly observed in high feed rate test results. Therefore error characteristics at high feed rates were used for error analysis and adjustment of controller setting values.

H.D. Kwon, M. Burdekin / International Journal of Machine Tools & Manufacture 38 (1998) 10451065 1055

Fig. 9.

Test result at 500 mm/min of feed rate.

Band 1, as indicated in Fig. 14, increased from 41.8 to 77.8 um, with increase in positional gain. This error band corresponded to initial transient of test path. Increasing in positional gain, Mini 2 (Fig. 14) decreased from 21.3 to 4.4 um, and Maxi 2 decreased from 679.3 to 206.4 um. Overshoot did not occur with the positional gain of 3500 [0.01/sec], but positional gain of near 4500 [0.01/sec], the overshoot is expected to occur. With different positional gain with xed velocity gain (3000), a second set of measurements (Test B) were carried out under conditions as shown in Table 3 Detailed test results are summarised in Fig. 16 and value changes, such as Band 1, Mini 2 and Maxi 2 were observed. Increasing in positional gain, with xed velocity gain (3000), Band 1 increased from 46 um to 90.2 um, and Mini 2 decreased from 10.1 um to 4 um, and Maxi 2 also decreased from 435.8 um to 176.6 um. From positional gain of 3250 [0.01/sec], overshoot started to occur. Changing positional gain with a xed velocity gain (3200), a third set of measurements (Test C) were carried out under conditions as shown in Table 4. Measurement results such as Band 1, Mini 2 and Maxi 2 are summarised in Fig. 17. Increasing in positional gain, with xed velocity gain (3200), Band 1 increased from 52.1 um to 108 um, and was slightly larger than that in case of positional gain value of 3000 [0.01/sec]. Mini 2 decreased from 9.6 um to 11.8 um, and Maxi 2 also decreased from 393 um to 134.9 um. From position gain value of 3000 [0.01/sec], overshoot started to occur.

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Fig. 10. The test result at 4000 mm/min of feed rate. Table 1 The adjustable controller parameters and adjustable ranges. Adjustable range of the parameter Back-lash compensation factor Velocity gain Positional gain Time constant 0-255 [um] 1-9999 1-9999 [0.01/sec] 8-4000 [msec] Default value X = 8 um, Y = 8 um 1434 3000 8

Changing velocity gain with xed positional gain (3000 [0.01/sec]), a fourth set of measurements (Test D) were carried out under conditions as shown in Table 5. Measurement results, such as Band 1, Mini 2 and Maxi 2, are summarised in Fig. 18. Increasing in velocity gain, with xed positional gain (3000 [0.01/sec]), Band 1 increased from 39.3 to 99.6 um, Mini 2 decreased from 72.1 to 3 um, and Maxi 2 also decreased, from 1256.6 to 173.3 um. From velocity gain value of 3000, overshoot started to occur. Increasing in positional gains, with xed velocity gains (2500, 3000, 3200), Band 1 decreased and initial transient increased. Higher the positional gain in the stable system, error around turning point on actual measured path, was decreasing. However, from a certain positional gain value, overshoot started to occur. Combination of the positional and velocity gains, which resulted in small following errors and overshoot of less than 0.5 um, were found, and plotted in Fig. 18.

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Fig. 11. Square test result of Test A1.

One of these combinations, resulting in minimum transient error, was determined as the optimum values (Fig. 19), i.e. positional gain = 3250 [0.01/sec] and velocity gain = 3000. 8. Conclusions A cube test system which incorporates two linear displacement sensors and a steel cube was developed for assessing servo induce feed drive errors on CNC machine tools. In the test system, square corner test path was used for measurement of servo errors, and near square corner, servo errors were highlighted and effectively evaluated. By applying the developed cube test system, a controller parameter adjustment technique was also developed. With different values, such as velocity and positional gains, servo induced feed drive errors were experimentally evaluated at feed rate in the range 5004000 mm/min. Time constant remained with minimum available value for fast movement. A combination of velocity and positional gains, which resulted in small following error near square corner of the test path and minimum initial transient, was selected as optimum values. Compared with simulation techniques for adjustment of servo parameters, the developed technique using the cube test system is based on real measurement on a CNC machine tool, which includes whole pictures of the servo feed drive system. The developed system also provide real data to simulation of feed drive system and adjusting controller parameters.

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Fig. 12. Square test result of Test A2.

Required equipments for the developed system were relatively simple and adjustment can be carried out within short time through appropriate communication to CNC machine tools. The test system and adjustment technique was shown to be practical and efcient for assessing servo errors and determining servo parameters, and are expected to be widely used by machine builders and users. References
[1] Y. Koren, Design of a digital loop for numerical control, IEEE Transactions on industrial electronics and control instrumentation IECI- 25 (1978) 212217. [2] Y. Koren, Cross-coupled biaxial computer control for manufacturing systems, Journal of Dynamic Systems, Measurement, and Control 102 (1980) 265272. [3] J. Huan, Bahnregelung zur Bahnerzeugung an numerisch gesteuerten Werkzeugmaschinen. Springer-Verlag, (Berlin) 1982. [4] K. Kulkarni, Identication and contouring control of Multiaxial Machine Tool Feed drives, Dissertation Ohio (USA), 1987. [5] O. Masory, Improving contouring accuracy of NC/CNC systems with additional velocity feed forward loop, Journal of Engineering for Industry 108 (1986). [6] G. Pritschow, H. Rudloff, B. Schnurr, Verminderung von Bahnabweichung bei Nachfolgeregelungen am Beispiel einer Nockenwellenschleifmaschine, wt-z. ind. Fertig. 79(Heft 11) (1989). [7] W. Wendt, Bahnregelung von Handhabungsgeraeten und Werkzeugmaschinen, (Springer-Verlag, Berlin) (1987).

H.D. Kwon, M. Burdekin / International Journal of Machine Tools & Manufacture 38 (1998) 10451065 1059

Fig. 13.

Summarised test results in the interval IF1.

[8] M. Burdekin, W. Jywe, Optimising the contouring accuracy of CNC machines using the CONTISURE system. 28-th international MATADOR Conference 1992. [9] W. Jywe, A computer-aided accuracy testing device for machine tools, PhD-Thesis, UMIST, (1992). [10] Fanuc Ltd. FANUC SYSTEM 6M-MODEL B, Operators manual, (1982). [11] Fanuc Ltd. FANUC SYSTEM 6M-MODEL B, Maintenance manual, (1982). [12] M. Weck, M., Handbook of machine tools, Automation and Controls, (3) John Wiley and Sons, (Chichester, New York), (1984).

Appendix Specication of TAKISAWA MAC-V3 machining centre The tested CNC machining centre is equipped with the following specications: Type: TAKISAWA MAC-V3 Machining Center of 3 axis vertical spindle bed type Working travel (mm): 510*400*360 (longitudinal * lateral * spindle head) Distance between the spindle nose and the table top: 140500 mm Maximum permissible load: 200 kg Rapid traverse: X, Y = 1200 mm/min, Z = 1000 mm/min Machining feed rate: 15000 (mm/min)

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Fig. 14. Analysis of test results in the interval IF2. Table 2 Measurement conditions for Test A. Test Test Test Test Test Test Test Test A1 A2 A3 A4 A5 A6 A7 Velocity gain 2500 2500 2500 2500 2500 2500 2500 Positioal gain (0.01/sec) 2500 2500 3000 3000 3500 3500 4000 Feed rate (mm/min) 500 4000 500 4000 500 4000 4000

Control system: FANUC System 6MB Series Simultaneous 3 axis positioning and linear interpolation Resolution: 1 um Spindle: Diameter = =55 mm, Drive motor 7.5 HP, Speed range 6060000 rpm

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Fig. 15.

Test result.

Table 3 Measurement conditions for Test B. Test Test Test Test Test B1 B2 B3 B4 Velocity gain 3000 3000 3000 3000 Positional gain (0.01/sec) 2500 3000 3200 3500 Feed rate (mm/min) 4000 4000 4000 4000

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Fig. 16. Measurement results of Test B.

Table 4 Measurement conditions for Test C. Test Test C1 Test C2 Test C3 Velocity gain 3000 3000 3000 Positional gain (0.01/sec) 2500 3000 3200 Feed rate (mm/min) 4000 4000 4000

H.D. Kwon, M. Burdekin / International Journal of Machine Tools & Manufacture 38 (1998) 10451065 1063

Fig. 17. Measurement results of Test C.

Table 5 Measurement conditions for Test D. Test Test Test Test Test Test Test Test D1 D2 D3 D4 D5 D6 D7 Velocity gain 1434 2000 2500 3000 3171 3200 3500 Positional gain (0.01/sec) 3000 3000 3000 3000 3000 3000 3000 Feed rate (mm/min) 4000 4000 4000 4000 4000 4000 4000

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Fig. 18.

Measurement results of Test D.

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Fig. 19.

Summary of test results.