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CNC/CAM Lecture Notes: Chapter 3 Interpolator

The interpolator plays the role of generating axis movement data from block data by dividing tool movement into individual displacements for each axis. There are two main types of interpolators: hardware interpolators that use electric circuits for fast computation but are difficult to modify, and software interpolators that are more flexible but slower. Common software interpolation methods include the reference pulse method, sampled data method, DDA interpolation, and stairs approximation which determine axis movement in small time intervals to approximate shapes like lines and circles. The sampled data method in particular segments paths into small line segments based on interpolation time and velocity.

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Sutran Erwiyantoro
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135 views

CNC/CAM Lecture Notes: Chapter 3 Interpolator

The interpolator plays the role of generating axis movement data from block data by dividing tool movement into individual displacements for each axis. There are two main types of interpolators: hardware interpolators that use electric circuits for fast computation but are difficult to modify, and software interpolators that are more flexible but slower. Common software interpolation methods include the reference pulse method, sampled data method, DDA interpolation, and stairs approximation which determine axis movement in small time intervals to approximate shapes like lines and circles. The sampled data method in particular segments paths into small line segments based on interpolation time and velocity.

Uploaded by

Sutran Erwiyantoro
Copyright
© © All Rights Reserved
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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CNC/CAM Lecture Notes

Chapter 3 Interpolator
By Yanuar Burhanuddin
Introduction
The interpolator plays the role of generator of axis
movement data from the block data generated by the
interpreter
The one of the key components of CNC accuracy
Two kinds of control methods:
The point-to-point control method: move the axis to the desired
position;
The contour control method: to move the axis along an arbitrary curve.
Tool movement should be divided into components
corresponding to each axis; the locus of the tool is
createdthrough combining the individual displacements for
each axis.
Introduction
Introduction
The requirement of interpolator characteristics
The data from the interpolator should be close to the actual part shape.
The interpolator should consider the limitation of speed due to the
machine structure and the servo specifications while calculating
velocity.
The accumulation of interpolation error should be avoided in order that
the final position should coincide as closely as possible to the position
commanded.
The interpolator classification:
hardware interpolator
Software interpolator
Hardware Interpolator
The hardware interpolator carries out the computation of
interpolation and generates pulses by using an electric circuit.
In the hardware interpolator  high-speed execution, difficult
to adapt new algorithms or modify algorithms.
The typical method for hardware interpolation uses a
DDA(Digital Differential Analyzer) integrator based on
numerical integration  physical: digital circuit
Hardware Interpolator
Hardware Interpolator
The integration processes:
1. Calculate current velocity by velocity summing at the previous time unit
and the velocity increment at the current time unit.
Vk =Vk−1+ ΔVk
2. Calculate the distance increment at the current time unit.
3. Calculate the total displacement by summing the displacement at the
previous time unit and the distance increment at the current time unit.

The above integration process is repeated for every constant


time interval and the iteration frequency is given by
f = 1/Δt
Hardware Interpolator
Hardware Interpolator
Iteration steps for circular interpolation
Iteration DDA Integrator DDA Integrator
step for X-axis for Y-axis
V Q ΔS V Q ΔS
0 15 0 0 0
1 15 15 0 0
2 15 14 1 1 1
3 15 13 1 2 3
4 15 12 1 3 6
5 15 11 1 4 10
6 15 10 1 5 15
7 15 9 1 6 5 1
8 14 7 1 7 12
9 14 5 1 8 4 1
10 13 2 1 9 13
11 13 15 9 6 1
12 12 11 1 10 0 1
13 11 6 1 11 11
14 11 1 1 12 7 1
15 10 11 12 3 1
16 9 4 1 13 0 1
17 8 12 13 13
18 8 4 1 14 11 1
19 7 11 14 9 1
20 6 1 1 15 8 1
21 5 6 15 7 1
22 4 10 15 6 1
23 3 13 15 5 1
24 2 15 15 4 1
25 1 0 15 3 1
Software Interpolator
Two main methods are:
The Reference Pulse Method: Software DDA interpolator,
Stars Approximation interpolator, Direct Search Interpolator

The Reference Word Method (Sampled Data Method):


Euler Interpolator, Improved Euler Interpolator, Taylor
Interpolator, Tustin Interpolator, Improved Tustin
Interpolator
Software Interpolator
Reference pulse method:
reference pulses as an external interrupt signal and the generated
pulses are directly forwarded to the machine drive.
1 pulse denotes 1BLU of axis.
The interrupt frequency determines the speed of the axis.

Sampled-Data Interpolation
The interpolation is executed in two stages.
An input contour is segmented into straight line segments within an
allowable tolerance  rough interpolation.
The approximating line segments are interpolated and the interpolation
result sent to the related axis fine interpolation.
Reference Pulse Method
Sampled Data Method
Methods omparison
DDA Interpolation
The same as the behavior of
hardware DDAs.
The variable L is a linear
displacement
The variables A and B denote the
displacement of X and Y axes
the Q1 and Q2 are initial values
(default is zero)
The variable R is the radius of the
circle.
The variables P1 and P2 give the
center position.
DDA Interpolation

Linier interpolation Circular Interpolation


Stairs Approximation Interpolation
The Stairs Approximation algorithm determines the direction
of the step every BLU interval and sends the pulse to the
related axis  an incremental interpolator

Circular movement case (first quadrant)


The determinator of step direction is Dk 
Dk < 0: This case means that the position (Xk,Yk) is located on the
inside of a circle and, in this case, the step moves in the positive
direction of X-axis.
Dk > 0: This case means that the position (Xk,Yk) is located on the
outside of a circle and, in this case, the step is moved in the negative
direction of the Y-axis.
Dk = 0: One of the above rules can be arbitrarily selected and applied.
Stairs Approximation
Stairs approx. algorithm
Direct search
Improve the weakness of stairs approximation method:
Lot of iterations required for simultaneous movement
Possible error conditions is not considered
Search the direction with the minimum path error
The number of iterations is 30% smaller than that of the Stairs
Approximation algorithm and about 20% smaller than that of the DDA
software algorithm.

Evaluation of the radial error can be replaced by evaluation of Di, j


Di, j = (2R)Ei, j
In order to hold the command velocity Vl (BLU/second), the algorithm
should be repeated at frequency F: .
F = (2√2 /π) V
Method comparison summary
Direct search flowchart
Sampled-data Interpolation (Line)
Sampled-data Interpolation
The fundamental idea of this algorithm is segmentation of the
path by the interpolation time, Tipo.
the line segment ΔL depends on velocity V
Axial increment is transferred to the ring buffer (FIFO buffer)
every interpolation time step and axial increment is used as
input for acceleration/deceleration control.
When the length of the line path, L, is not exactly N times the
displacement per interpolation time ΔL, where N is an integer,
how should the residual length be interpolated?
simply to add all the residual length on the interpolation value at the
last interpolation time.
Sampled-data Interpolation (Circle)
During circular interpolation,
tangential velocity, V should be
held on the circular path.
The velocity of the axes, (Vx,Vy),
is computed by a circular
interpolator, and fed to the closed
loop of position control as a
reference input.
A circular path is approximated by
small line segments. The larger
the number of line segments, the
better the accuracy of
interpolation.
Sampled-data Interpolation (Circle)
In the sampled-data interpolator for a circle, the iteration step
can be expressed using the angle α. The size of this angle α
is a key factor for interpolation.
cos θ(i+1) = Acos θ(i)−Bsin θ(i)
sin θ(i+1) = Asin θ(i)+Bcos θ(i)
Where A = cos α, B = sin α, θ(i+1) = θ(i)+ α
Final position,
X(i+1) = R(i)cos θ(i+1) Y(i+1) = R(i) sin θ(i+1)
Calculation the successive interpolated points by using the
current interpolated point,
X(i+1) = AX(i)−BY(i) Y(i+1) = AY(i)+BX(i)
Sampled-data Interpolation (Circle)
Length of line segments:
DX(i) = X(i+1)−X(i)= (A−1)X(i)−BY(i)
DY(i) = Y(i+1)−Y(i) = (A−1)Y(i)+BX(i)
The velocity of traverse:

DX(i) and DY(i) are the increments along the X- and Y- axes. Vx(i) and
Vy(i) are the velocities for the X- and Y-axes respectively
Note: the velocities are called as reference wors
Two kinds of an error occur when a circle is approximated by line
segments: radial error (ER) and chord height error (EH).
ER is an error from a truncation effect.
EH is not accumulated. EH is computed using Equations
below
Based on the above, α should be determined such that the
value of ER or EH does not exceed a value equivalent to 1
BLU.
Euler algorithm
cos α and sin α are approximated by first-order Taylor series
Expansion with A = 1,B = α

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