6 - Control in Machine Tools

Chapter 7
CONTROL IN
MACHINE
TOOLS
INTRODUCTION
• Any manufacture on a machine tool is achieved through
the change of the shape and the size of a blank (or raw
material) usually by removal, addition and/or plastic
deformation of the material of the blank.
• This demands a pre-determined relative motion between

the tool and the blank.
• The characteristics objective of the control elements

of a machine tool is to attain this pre-determined
relative motion.
REQUIREMENT OF MACHINE TOOL
CONTROL
1. Accuracy
2. Rapid action
3. Mnemonic feature: reduced number of control
elements
4. Control against excessive force, torque etc.: overload
safety devices.
5. Interlocking feature
6. Additional requirements for manual control
7. Reliability
DIFFERENT CONTROL ELEMENTS
MECHANICAL CONTROL ELEMENTS-
DROPPING WORM
CAM CONTROL
CAM CONTROL
 Plate control- When movement is short and
perpendicular to the cam axis. Feed of parting tool.
 Face type-movement is short and perpendicular to cam

axis at an offset.
 Drum type-movement is parallel to the cam axis.

FEEDING A BAR STOCK
SAFETY CONTROL
To avoid erroneous simultaneous engagement of mechanical drives,

Safety control devices are used.
HYDRAULIC AND HYDRO-
MECHANICAL CONTROL
ELEMENTS- DIRECTIONAL VALVE
HYDRAULIC AND HYDRO-
MECHANICAL CONTROL
ELEMENTS- DIRECTIONAL VALVE
 Designed to change the direction or to open and close the

passage of the oil in two or more lines.
 They can reverse the motion or stop them.
 Directional valve can be hand operated, mechanical,

electrical etc
HYDRAULIC TRACER
CONTROL UNIT
HYDRAULIC TRACER
CONTROL UNIT
 Used in automatic lathe to copy the profile of a template.

 For a neutral position of the tracer lever,
m  mo
p1 A1  p2 A2
A1
p2  p1 ,but, A1  2 A2
A2
So, p2  0.5 p1
ELECTRICAL AND ELECTRO-
MECHANICAL CONTROL ELEMENTS
 Push Button Control
 Electrical Limit Switch
 Electric tracer Control

ELECTRICAL LIMIT SWITCH
The limit switch supplies a limit signal when an adjusted limit is

exceeded in either direction, especially when a control valve
has reached a final position
This signal is suitable for reversing control signals, initiating

visual or audible alarms and for connection to central control
or alarm systems.
NUMERICAL CONTROL (NC) OF MACHINE
TOOLS
Numerical control is a method to control the motion of the machine
tool components by means of coded instructions.
NC machine tool consists of
 Machine
tool
 MCU(Machine tool Control unit)
MCU Consists of
a) An Input unit
b) Reading and Parity Check circuits
c) Decoder DPU
d) Interpolator and comparator (Data Processing
e) Position Control Circuit Unit)
f) Velocity Control Circuit
g) Acceleration Circuit CLU
(Control Loop
h) Control for other functions
Unit)
NUMERICAL CONTROL (NC) OF MACHINE
TOOLS
 Control Loop Unit (CLU) uses the Data generated by

DPU to make control signals.
 DPU and CLU are hardwired into the MCU of NC
Machine tool.
 Drawbacks of NC machine tool

 Much time needed to correct any mistake in program.
 Data input tapes damages easily.
 Cutting and feed speed cannot be changed during cutting.
 Mechanical moving parts for tape reading is not suitable for
high speed operation.
CNC MACHINE TOOL
 Due to technological advancement, a dedicated computer

is used as DPU in NC machine tool.
 Fairley complex program can be written with key board
and stored in memory.
 This system is commonly known as Computer Numeric
Control (CNC).
 Advantages of CNC machine Tools:
 Enhanced product quality
 Greater manufacturing flexibility
 Reduced production lead time
 Reduced inspection
 Complex machining
CNC MACHINE TOOL
 Higher effective machining time

 Effect of change of design of a part
 Machine tool damage reduced
 Less material handling
 Reduce skill of operator
 Significant reduction of cost
 Disadvantages of CNC machine Tool

 High Investment
 High skilled programmer and electrician required
 High rigidity and better dynamic characteristics are necessary
to incorporate when building
DIGITAL DISPLACEMENT
MEASUREMENT DEVICE
DIGITAL DISPLACEMENT
MEASUREMENT DEVICE
 A feedback transducer monitors the position of the
moving element of a machine tool and converts a
minimum displacement into discrete numerical values.
 The photo diodes of the scanning element send a signal
every time a mark on the scale is encountered.
 Signals are added in electronic counter, which provide
an accurate measure of distance travelled.
DIGITAL ABSOLUTE MEASUREMENT OF
POSITION
ELECTRICAL STEPPER MOTOR
 It is a synchronous motor specially designed to rotate a

specific number of mechanical degrees for every
electrical pulse received by its controller.
 The relation between degree of spindle rotation and
electrical degree
2
m  e
 Speed, p
1
Nm  n pulse
NProtation are, 1.5, 3, 7.5, 15 degrees
 Typical angle of
That’s all for today

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Chapter 7

• This demands a pre-determined relative motion between

• The characteristics objective of the control elements

 Face type-movement is short and perpendicular to cam

 Drum type-movement is parallel to the cam axis.

To avoid erroneous simultaneous engagement of mechanical drives,

 Designed to change the direction or to open and close the

 They can reverse the motion or stop them.

 Directional valve can be hand operated, mechanical,

 Used in automatic lathe to copy the profile of a template.

 Push Button Control

 Electrical Limit Switch

 Electric tracer Control

The limit switch supplies a limit signal when an adjusted limit is

This signal is suitable for reversing control signals, initiating

 Control Loop Unit (CLU) uses the Data generated by

 Drawbacks of NC machine tool

 Due to technological advancement, a dedicated computer

 Higher effective machining time

 Disadvantages of CNC machine Tool

 It is a synchronous motor specially designed to rotate a

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