数控系统仿真软件开发

In CNC machining, the motion controller executes in real-time to generate trajectory points. when abnormal situations occur, the controller changes its execution to deal with it, protect machine components and machining parts. In this paper, a feed rate reset method which across multiple segments is proposed and integrated in micro-line trajectory planning routine. In trajectory planning process, to make sure CNC machine not exceed its mechanical limits, look-ahead method is applied to readjust corner velocity. To optimize trajectory, two corner transition methods are chosen based on machining time and the smoothness of the velocity profile, and the controller intelligently choose one of them based on the current machining situation. These methods are tested in simulation environment and actual machining.

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The CNC feed system is one of the most important mechatronics assemblies in CNC machine tools. That is why it is of great importance, in the education of future engineers, to pay special attention to analysis of CNC feed systems through the modeling of its components and the simulation of its control structure. This paper presents an educational laboratory setup – a simulator of CNC machine tools, modeling of the drive system of the laboratory setup, and control of CNC feeding system within the MATLAB/Simulink software package. Also, the control simulation of the execution of some program instructions of the G code was presented, as well as the connection of the Simulink model with the microcontroller of the CNC machine tool simulator.

This research focuses on the development of a simulation and control system for Computer Numerical Control (CNC) designed specifically for small and medium-sized companies in the Peruvian textile industry. The goal is to create a CNC system that optimizes production processes without the need for expensive equipment. This system simulation allows generating cutting paths for multiple fabric pieces belonging to a post, thus optimizing production time and ensuring the safety of the operator. Additionally, the aim is to provide a technological solution for the artisans fabric cutting area. The project is carried out using MATLAB software to simulate different parameters and obtain results of cutting speed and time performed by the CNC machine, based on the size and shape of the piece (in this case, a t-shirt). It has been established that the optimal cutting speed and time for the design presented in this article should be less than 1 cm/s to achieve proper trajectory precision. Otherwise, the pieces may take on a different shape. In summary, this study focuses on developing a CNC simulation and control system accessible to small and medium-sized textile companies in Peru, in order to improve production efficiency and ensure precision in fabric cutting, all through the use of technological tools and MATLAB simulation.

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Abstract: Applying UG NX software to model virtual CNC lathes and CNC milling machines in a 1:1 ratio, which is consistent with the actual structure of CNC machine tools. After modeling, importing 3dMAX software for editing and rendering, and then importing Unity 3D for scene building, using C # language to complete interactive and animation functions. The developed virtual simulation system for CNC turning and CNC milling machines has the following six functions modules: structure introduction, model observation, operation and running, disassembly and assembly process, working principle, typical workpiece cutting. Present the professional skill level standards for 1+X CNC turning and milling workers in mixed reality technology, combined with the real equipment of school, to achieve dimensional, realistic, and interactive upgrades. The application of this system can combine virtual and real, inspire students' interest in learning, guide students to engage in interactive learning, and solve traditional teaching problems such as more students, less equipment, and inconsistent requirements between machine tool CNC systems and 1+X certificates.

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The use of control in CNC machines provides a new approach to solving multiple operations in the labor market. This research shows a motor control system of a CNC machine with endless screw, which is capable of making trajectories for the cutting of multiple pieces of leather in simulation in order to optimize the production time of the cut, and the safety of the collaborator, also promote a technological solution for the area of artisanal leather cutting. The project was carried out in the simulated MATLAB software with different parameters giving results of the speed and time of the cutting carried out by the CNC machine according to the size and shape of the part. It was found that the speed and optimal time for cutting the 3 designs presented in this article must be less than 1 mm/s to obtain precise trajectories otherwise the pieces are altered.

With the rapid development of the Internet of Things and intelligent sensing technology, the real-time collected CNC machine tool operating data presents the characteristics of massive quantity, variety, and low density. The purpose of this paper is to study the design of computer simulation operating system for CNC machine tools based on deep learning. Firstly, it summarizes the working process of CNC machine tools and CNC system, and introduces the design and implementation of the training model system module based on deep learning in this article. Secondly, the overall framework design of the virtual simulation system of CNC machine tools was launched, and the data of the simulation operating system based on SAE depth in the network training and the performance analysis of the computer simulation operating system of CNC machine tools were analyzed. The experimental results showed that with the increase of the learning rate, the error the curve becomes unstable and the convergence process becomes more and more difficult. When the learning rate reaches 0.06, the curve no longer converges.

This article presents a planar positioning system for portable computer numerical control (CNC) milling applications. The system incorporates a rotary laser beacon and fixed photodetectors arranged around the workspace. To mitigate errors induced by fluctuations in rotational speed, the system employs encoder-based angular quantization. A circle-intersection algorithm is used to compute positions precisely from measured angular differences. Simulation and experimental results reveal that encoder resolution significantly impacts quantization accuracy. The system achieves submillimeter static positioning accuracy and maintains dynamic accuracy within a 1-mm margin at speeds up to 20 mm/s. A geometric calibration method allows for photodetector coordinate estimation without the need for physical measurement. Robust accuracy is demonstrated across a <inline-formula> <tex-math notation="LaTeX">$1000\times 1000$ </tex-math></inline-formula> mm<inline-formula> <tex-math notation="LaTeX">${}^{\mathbf {2}}$ </tex-math></inline-formula> workspace. This lightweight and compact approach offers a practical localization solution for desktop-scale CNC platforms, supporting both static and dynamic woodworking operations.

This research paper focuses on the use of a thermal model of a CNC machine monitoring system that has been developed using open-source tools. By integrating these tools, predictive maintenance capabilities can be developed, leading to increased machine reliability. The methodology involves the implementation of a thermal model designed with Simulink software. The thermal model has been implemented into a developed monitoring system based on open-source tools, which allows access to real-time data of the CNC machine. The thermal model’s correctness has been verified with the machine operation using the data obtained from the CNC machine monitoring system. The use of open-source tools provides flexibility and adaptability in tailoring the thermal model to specific requirements and gaining key insights into the thermal behavior of the machine. The final section of the publication presents a comparison of simulated and measured outputs.

By studying the structure and functional characteristics of five-axis linkage CNC machine tool, design five-axis CNC machine tool with X, Y, Z linear motion axes, B and C rotation axes. The virtual simulation system of miniature five-axis machine tool is built based on the VERICT, and an impeller part was simulated and processed as an example. Check whether the state of each moving axis in the machine tool movement is correct, and judge the rationality of the structure design of the machine tool based on the error information such as interference and collision in the processing. It is proved by simulation that the machine can realize five-axis linkage machining within the design range and meet the design requirements.

In order to meet the demanding requirements of real time and accuracy for complex trajectory control in multi-axes CNC processing (CNC), an adaptive tool path control system based on deep learning was developed. Model the structure of the control system and coordinate transformation, design the error forecast structure of the neural network, construct the high fidelity simulation platform, and carry on the typical surface processing tasks, show that the model can reduce the average trajectory error by 53.5%, 49.0% and 48.6% in the X, Y and Z axes. The system response time is reduced by 27.5%, and the overshoot is reduced by 58.7%. Resource assessment shows that the average model inference time is 3.82 ms, while the GPU utilization remains below 60%, meeting the industrial real time control requirements. This method is more accurate, responsive, and robust than traditional control strategies.

In CNC machining, non-uniform rational B-spline (NURBS) curve is commonly used to describe the tool path for machining complex curves and surfaces. In order to improve the machining accuracy of NURBS curve, it is necessary to control the feedrate under geometric and kinematic constraints throughout the machining process. This paper proposes a segmental adaptive feedrate planning algorithm with low allowable feedrate at critical sub-curves and high allowable feedrate at regular sub-curves, which makes a balance between interpolation precision and efficiency. To solve the remaining distance problem caused by the contradiction between continuous feedrate planning and periodic interpolation as well as the nonlinear relationship between arc length and parameters, this paper calculates step-length using displacement-time function on every interpolation period and proposes a step-length correcting algorithm at the intersection of two adjacent sub-curves. The simulation results show that smooth motion under the chord-error and kinematic constraints can be obtained within curves with sharp curvature variation throughout the interpolation process, which validate the advantages of the proposed algorithm.

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This paper presents a control system algorithm for a five-axis parallel mechanism system (PMS) CNC milling machine based on a 6-DOF Stewart platform parallel manipulator with a universal-prismatic-spherical (UPS) configuration. The control system reads the G-Code commands as standard CNC machine language, then extract data points and interpolates them to generate the robot trajectory patterns as motion references. Then, the control system uses the modified inverse kinematic equation to determine the length of each link to move the end effector to track the trajectory patterns from the previous G-code extraction process. The inverse kinematic equation is modified especially for the five-axis PMS CNC milling machine by including machine-offset and tools-offset parameters so it will be easier for the control system to implement the kinematic equation. As expected, the system simulation results successfully followed the G-Code program moving commands. The average error of the length control system is 0,1 mm, while the average error of the length change rate control system is 1,8 mm/s. The maximum error is 26.9 mm was caused by the system's inability to follow the motion profile in transient. It can be concluded that 6-DOF Stewart platform parallel structures,which provide better performance than serial structures, can be implemented as a new concept for the motion mechanism of five-axis CNC milling machines. The five-axis PMS CNC milling machine also promises better performance than conventional five-axis gantry structures CNC.

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Abstract The mathematical models of tool path smoothing and feedrate scheduling in Computer Numerical Control (CNC) system are critical for high-precision manufacture. Inthe existing studies, G2/G3 (curvature-continuous/-smooth) trajectory smoothing, and jerk-limited/-continuous feedrate scheduling schemes have been developed. Nonetheless, there are exist some requirements that cannot be satisfied simultaneously, including confined chord error, G01 points interpolated, analytical curvature extremum, real-time performance, kinematic time-optimality, and the smoothness of tool-path and feedrate profile. Recently the scholars found the potentials of the tool path with high-order geometric continuity and the feedrate with high-order kinematic constraints, respectively in increasing the smoothness of tool path and reducing the impact caused by axis actuators during the process. Aiming to reduce the vibration and guarantee high machining efficiency, this work proposes G4 (curvature-variation-smooth) interpolative trajectory model with confined chord error and analytical curvature extrema for trajectory smoothing, and employs jerk-smooth (jerk-differentiable) feedrate mode to perform time-optimal feedrate scheduling. Finally, a real-time tool path processing strategy under various geometric and kinematic constraints is developed. The simulation shows approximation error, curvature extrema, and feedrate fluctuation are reduced compared with G2 transition and G3 interpolation schemes. The experimental results demonstrate advantages of the proposed method in vibration damping, surface quality, compared with the previous works.

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This work aimed to develop both a real implementation and a digital twin for a small CNC machining center. The X-, Y-, and Z-axes feed systems were realized as closed-loop motion loops with DC servo motors and encoders. Motion control was provided by Arduino boards and Pololu motor drivers. A simulation study of the step response parameters was carried out, and then the positioning regime was studied, followed by the two-axis simultaneous motion regime (circular interpolation). This study, based on a hybrid simulation diagram realized in Simulink–Simscape, allowed a preliminary tuning of the PID (proportional integral derivative) controllers. Next, the CAE (computer-aided engineering) simulation diagram was complemented with the CAM (computer-aided manufacturing) simulation interface, the two together forming an integrated digital twin system. To validate the contouring performance of the proposed CNC system, a circular groove with an outer diameter of 31 mm and an inner diameter of 29 mm was machined using a 1 mm cylindrical end mill. The trajectory followed the simulated 30 mm circular path. Two sets of controller parameters were applied. Dimensional accuracy was verified using a GOM Atos Core 200 optical scanner and evaluated in GOM Inspect Suite 2020. The results demonstrated good agreement between simulation and physical execution, validating the PID tuning and system accuracy.

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CNC machine tool is the basic equipment for the development of high-tech industry and high-tech industry. Feed servo system is an important part of CNC system. The matching of drive control parameters is related to the performance of NC system. Servo drive system is an important part of CNC system. Under the same mechanical properties, the matching degree of servo parameters and mechanical properties determines the machining accuracy and quality of the machine tool. Therefore, how to match parameters quickly and effectively has always been the focus of research. A fuzzy adaptive PID controller combining fuzzy control and PID control is designed and applied to the control of NC servo system. The controller has good control performance. The simulation data show that the fuzzy adaptive PID controller has good accuracy and strong robustness.

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Traditional industrial robots' force control systems exhibit limited practicality and cost-effectiveness in manufacturing complex parts. Therefore, this paper proposes an open CNC force control simulation system based on the “PLC + CNC force control technical table (FCTT)”, integrating both hardware and software components. The hardware includes PLC and CNC force control technology, drivers and servo systems, sensor systems, and system control circuits. The software is implemented in C++ with a modular design, while the upper and lower computers communicate primarily via a standard PCI bus. The corresponding CNC machine control technology receives application program commands from the upper computer. Then, it performs motion control according to the corresponding CNC force, driving the servo system to complete the corresponding motion control commands. This system solves the problem of query speed in the force control system, improving its responsiveness and reliability. The design of complex curved parts was validated using this system, and the results showed that the CNC force control system proposed in this paper improved by about 10% compared to traditional systems in terms of CNC force accuracy, rotation accuracy, surface roughness, and matching between virtual and actual values, demonstrating significant advantages.

Traditional CNC machine tool feed system models suffer from low simulation accuracy and limited generalizability. These issues arise from simplified process replication and rigid optimization methods based on mechanical knowledge. To address these challenges, this study proposes a new hybrid mechanism data-driven digital twin (DT) modeling framework. Firstly, a nonlinear coupling characterization method was developed by combining fuzzy proportional integral (PI) control with mechanical system dynamics. This method achieves real-time adaptive parameter updating of the feeding system, and compared with traditional models, the maximum error is reduced by 32.79%. To further address the inherent simplification characteristics of the mechanism model, a WOA-CNN-LSTM-Attention algorithm was independently constructed for compensation, and experimental verification through physical machine operation confirmed that the maximum error was reduced from 0.0576mm to 0.0121mm. Finally, an online recognition system with a recursive least squares multiplication with a forgetting factor was used to achieve fast parameter convergence: tracking for 0.005 seconds in simple cases and 0.01 seconds in complex cases, achieving real-time DT synchronization. This study provides a systematic solution for building stable and efficient DT systems in precision manufacturing applications.

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It is of great significance to study the deep integration of manufacturing technology and new-generation information communication technology under vibration interference of machine tools to improve the intelligence level of CNC machine tools. In this paper, a numerical control manufacturing workshop affected by vibration in discrete manufacturing is taken as the research background, and a solution for a digital workshop operation simulation platform based on the industrial internet is proposed. By constructing the simulation environment of the operation process of the digital factory, the generation and transmission of manufacturing information in the digital factory are simulated. The application architecture of the machining workshop based on a numerical control simulation platform is proposed, and the business process of the numerical control machining workshop is analyzed. Then, the key technologies of NC machine tool modeling, synchronous mapping of data and model, data integration, and fusion are studied. Through the integration and implementation of the NC machine tool simulation platform in the machining workshop, the top-down data instructions can be issued accurately, and the bottom-up feedback information can be confirmed in time. Finally, the system is applied to the electronic information and ship machining workshop to verify the effectiveness of the system framework and method proposed in this paper.

The impeller is a very important part of the fan. When the wind passes through the impeller, it drives the impeller to rotate, which drives the generator to rotate and converts the wind energy into electrical energy. Impeller processing relative to some simple parts, more complex, parts processing accuracy is high, the processing difficulty is mainly the blade, the blade is easy to deform, the main processing method is the combination of turning and five-axis milling. In this paper, the structure of the impeller is analyzed, the process of the parts is analyzed, the special fixture of the impeller is designed, the numerical control simulation of the impeller is carried out on the simulation software, and the simulation accuracy of the impeller machining UG tool route is analyzed in the simulation software, the results show that the design scheme is reliable.

At present, the development of numerical control processing technology has entered a new period and has gradually developed in the direction of artificial intelligence. Along with the development of science and technology in recent years, the present stage of our country has made a significant breakthrough in the application of numerical control processing technology. Hence, learning to master CNC machining technology is necessary. Numerical control simulation software is used to NC machining the bearing bracket (five-axis), and numerical control simulation software SinuTrain is used to NC programming the parts and simulation verification of the machining process. SinuTrain is a CNC training software that functions exactly like the controller itself. The use of this software for bearing bracket (five-axis) numerical control simulation and programming, can make us master the use of this software, and can also help us understand the mechanical processing process and programming technology.

As Numerical Control (NC) machine being used widely and increases efficiency dramatically, it is important to improve the quality of NC code. Though NC simulation tools help eliminate defects of tool path and NC code, it still lacks Key Performance Indicator (KPI) to ensure the application quality of these tools in process of NC life-cycle. This paper proposed initial study of KPI in the application of NC simulation tools.

This paper introduces the method and process of parametric modeling and numerical control programming simulation processing of cylindrical cam by using ug8.5 software, improves the design, manufacturing efficiency and precision of cylindrical cam, and realizes the serial design of cylindrical cam. It has been proved by practice that the performance of cylindrical cam is stable and efficient, which greatly shortens the machining cycle of cam and improves the efficiency.

Digital Twin has become a frontier research topic in recent years and the important development direction of intelligent manufacturing. For numerical control machining, a Digital Twin system can be used as an intelligent monitoring and analysis center by reflecting the real machining process in a virtual environment. The machining simulation is the key technology to realize this kind of application. However, existing machining simulation systems are designed for off-line situation that cannot be used directly in Digital Twin environment. The challenges for machining simulation are analyzed and explained in this article: (1) complete process data representation in simulation system; (2) executing in cooperating with computer numerical control system; (3) more efficient simulation algorithm. In order to meet these challenges, a new machining simulation system is proposed. STEP-NC standard is used to save complete process data exported from the computer-aided manufacturing system and synchronization algorithm is developed based on the communication data of computer numerical control system. Most importantly, an optimized tri-dexel-based machining simulation algorithm is developed to perform high efficiency that can follow the real machining process. Finally, a Digital Twin system for NC machining is presented that has been tested and verified in a workshop located in COMAC (Commercial Aircraft Corporation of China Ltd).

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Thermal error compensation via a numeric control (NC) system is a proven option for upgrading the precision of machine tools. The main advantage is the generally cost-effective application, as no changes to the machine design are necessary. Since modern machine tools are equipped with standard numeric controls along with additional functions and integrated temperature sensors in the machine, compensation methods such as a characteristic diagram (CD) based compensation can be implemented. To increase the applicability and reliability of this CD regression method, a hybrid model approach with a virtual thermo-elastic finite element (FE) machine model and a real-time computable structural model of a machine tool was developed. The structural model uses model order reduction to calculate the current load case in real-time using continuously recorded machine data (motor current, axis position, temperatures). It acts as a virtual monitoring application to check, whether the current machine condition still matches the current CD based prediction. If the current load case is not suitable to the active CDs or any other stored CDs, the generation of new CDs is automatically triggered. In this article, the integration of the hybrid compensation method using an FE model and a structural model of a machine tool is methodically demonstrated. The main focus is on the integration of different software and hardware architectures and their interaction.

: There are many mature numerical control simulation systems on the market at present, but they are basically similar in shape, and only simple geometric simulation is carried out on personal computer (PC), which leads to the lack of realism in the simulation process. In this paper, three-dimensional modelling software is used to model the numerical control machine-tool-workpiece system, and real materials are added to enhance the sense of reality, so as to transform and get the triangular mesh model. Moreover, this paper presents a tool envelope generation algorithm based on mesh model, which can calculate a polygon intersection algorithm based on two-dimensional operation according to the tool trajectory, and determine the spatial position between the tool and the triangular mesh contained in the workpiece. The experimental results show that the algorithm proposed in this paper has low time complexity and meets the basic cutting requirements. At the same time, the virtual machining method of automatic numerical control machine tools based on dynamic cutting algorithm proposed in this paper can effectively improve the machining effect of intelligent numerical control machine tools.

This paper focusses on the dynamic modeling of the machine tool including its Computer Numeric Control (CNC), and its interaction with the machining process. To properly simulate modern machine tools in machining condition, which show close interaction between the dynamic behavior of the mechanical structure, drives, and the CNC, we use an integrated methodology that combines control and MBS capabilities in a nonlinear FEA solver called SAMCEF Mecano. To fully capture the dynamic behavior of the machine, force interactions between the cutting tool and the workpiece are also considered. A strong coupling between the mechatronic model of the machine tool and a machining simulation tool is implemented. A specialized cutting force element has been developed. It considers the dynamics of the tool tip combined with the tool workpiece engagement to generate cutting forces. The use of such digital twin model is demonstrated considering some industrial machining operations.

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The primary goal of this study is to develop a wearable system for providing CNC machine operators with visual and tactile perception of triaxial cutting forces, thereby assisting operators in industrial environments to enhance work efficiency and prevent mechanical failures. To achieve this goal, we successfully integrated a virtual machining tool simulator with the remote-control wearable system (RCWS). Using the ‘King Path’ milling parameters, we employed the simulation software developed by the AIM-HI team to calculate static and dynamic cutting forces, converting this data into vibrational commands for the RCWS to generate corresponding tactile feedback. Furthermore, we conducted extensive experiments, testing various data conversion methods, including three sampling techniques and two data compression strategies, aiming to provide accurate tactile feedback related to cutting forces under different operating conditions.

Collision detection of two objects plays an essential role for the machine tool automation. Although the collision detection of two objects has been studied in applications like virtual reality, the collision detection for the machine tool requires high precision to avoid overcut damage to the high-cost machine tools. The current collision detection for machine tools is under the soft-ware based computer numerical control (CNC), the low computation capability of which refrains the CNC based approach from real-time collision detection. In this paper, we consider the design of application specific integrated circuit (ASIC) to enhance the collision detection for machine tool automation. Because the bounded objects are represented by meshed triangles, we consider the separating axis theorem (SAT) based detection algorithm. Furthermore, by considering high precision required by machine tool applications, the proposed algorithm includes collision detection of either non-coplanar or coplanar triangles. Following the collision detection algorithm, we design hardware architecture with parallel processing to provide higher throughput rate over the architecture reported in our conference paper. The VLSI implementation results under the TSMC TN40G (45nm) CMOS technology reveal that our architecture requires 1,212K gates and provides detection throughput 38.46M per second for collision detection of two triangles, while operating at 500 MHz. For two objects represented by 400 and 400 meshed triangles, respectively, our hardware architecture can provide collision detection in 0.96 ms, which is smaller than the 1 ms required for real-time processing of collision detection of two objects.

Virtual commissioning (VC) is an established method for the efficient qualification of machine tool control software. Despite the potential to reduce the time-to-market and increase product quality, the creation of simulation models for VC still remains an elaborate task. The reason for this mainly results from the lack of data interoperability between engineering and simulation tools. To address this problem, we introduce a process for automatic behavior simulation model generation that covers the inter- and intra-company exchange of data in a heterogeneous toolchain. The workflow combines information of supplier components with ECAD engineering data represented through open standards like the Asset Administration Shell (AAS) and the Functional Mockup Interface (FMI). The desired level of integration between different data models is reached through a knowledge graph leveraging the Resource Description Framework (RDF) serialization of the AAS. In addition, a domain ontology for VC is introduced that semantically enriches the AAS data for simulation model generation. The presented concept is successfully validated with engineering data of a machine tool for sheet metal processing. It is shown, that a simulation model can be generated from a circuit diagram with minimum user interaction.

This electronic With the rapid development of global knowledge economy and science & technology, virtual manufacturing technology based on virtual reality and simulation technology came into being. The Virtual Machine Tool (VMT), as the execution unit of virtual manufacturing, is a key technology and prerequisite for virtual manufacturing. This article uses UG software to complete the construction of the geometric model of the three-axis CNC machine tool, and the NC machining program of the machined parts is generated based on UG CAM. By acquiring the actual machine structure, import the geometric model established in UG into VERICUT to create the kinematic model of the virtual machine tool. Taking a certain type of flange as the simulation processing object, and use the NC program generated in UG CAM to processing simulation in VERICUT. This verifies the correctness of the established model and NC program. Through optimizing the NC machining parameters, the collision or interference between machine tools and parts in actual processing can be avoided.

This paper presents a method to automate the validation tests of a manufacturing machine software with virtual commissioning elements. The work is applied to a welding tool that serves as a brace to keep a mechanical part immobilized during the welding operations. The proposed method consists in three parts: a simulation model of the mechanical components behavior, an environment to run the controlling system and a supervisor software that runs automatically the test scenarios and records the behavior of the controlling system. The analysis of the results will demonstrate that the controlling system is able to perform the right reaction in either nominal or defective scenarios.

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The article describes the proposed method of automated construction of virtual simulators for the subsystem of personnel training of the automated control systems of production. Its distinctive feature is the work with the customer based on the provision of functional videos from production, as well as the formalization of the design and development process in the form of structures for the process of creating software and visual modules taking into account the specifics of the development of virtual reality simulators. An ontological model has been developed for the construction of virtual simulators for training machine tool operators in the automated control systems of production, which uses the identified basic concepts and relationships between them in the subject area of work of machine tool operators. Its implementation is based on the Protege software environment. The following diagrams are proposed: functional and contextual IDEF0 of the functioning of virtual simulators for training in working on universal metal-cutting machines: milling and turning. The architecture of a virtual simulator for use in the subsystem of training personnel of automated control systems of production, as well as a structural diagram of the formation of practice-oriented skills in working on metal-cutting machines using virtual simulators are described.

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ABSTRACT This study proposes a reconfigurable open architecture control system for the Computer Numerical Control (CNC) woodworking educational machine tool called “EMCO F1 CNC”. On this machine physical hardware reconfiguration (spindle position can be vertical and horizontal) is possible. The idea was to develop a control system that would follow the configuration changes of the machine tool. The educational character of the machine and its reconfigurability demand possibilities for machining programme simulations in order to determine optimal workpiece position in the workspace and programme verification. Those are the reasons for developing a virtual machine tool integrated with the control system as a digital twin. The study presents a novel methodology for the development of control systems, merging the concept of “virtual commissioning” with iterative error-driven processes. The objective was to develop a dynamic control system capable of promptly adjusting to kinematics changes in real time. In a wood machining experiment, a test workpiece for machine tools for both machine configurations verified the operation of the developed control system.

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ABSTRACT Additive Manufacturing (AM) enables the creation of complex structures through a layer-by-layer material deposition process, offering significant advantages over traditional subtractive manufacturing. Among the various AM technologies, Material Extrusion (MEX), also known as Fused Deposition Modelling (FDM), is widely used due to its low cost and simplicity. This paper presents the development of an algorithm to reconstruct the sliced geometry from G-code in MEX processes, addressing the need for accurate representation and analysis of printed parts. The implemented algorithm (by MATLAB) interprets G-code commands to recreate the 3D structure of the part, allowing to view and verify the nozzle path, optimise printing parameters, and check the quality. Furthermore, the algorithm facilitates comparative analysis with the original 3D model, identifies potential issues, and implements the mechanical properties prediction by converting the G-code into a fine STL file. The algorithm’s output provides valuable insights into the internal structure, showing material distribution and void presence, supporting further research and industrial applications. This advancement significantly contributes to the digital process chain in AM, aligning with the goals of Industry 5.0 by promoting an integration from design to process control.

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In order to solve the problem of energy consumption prediction in the fused deposition process, an energy consumption prediction method is proposed by associating G-code files with fused deposition hardware. This method systematically studies the energy consumption in the process of fused deposition 3D printing by analyzing the relationship between G code files and fused deposition 3D printers. Starting from the energy consumption mechanism, a prediction model of fused deposition energy consumption for G code files is proposed. By obtaining the specific parameters of the fused deposition processing equipment and the selected experimental model, the experimental process parameter level is designed, and the orthogonal experiment is carried out to predict the energy consumption of the fusion processing in detail. The verification shows that the method can not only predict an accuracy rate of more than 90%, but also effectively predict the optimal process parameter value, which fully proves that the prediction method has high prediction accuracy and good practicability, and can be used for model processing. Provide tool support for energy consumption prediction before processing, saving production costs.

ABSTRACT G code is the input of the CNC system, and its quality affects the machining accuracy and efficiency. However, the G code generated by CAM has some defect points, which will seriously affect the processing quality and efficiency. To solve this problem, this paper proposes a method to screen and optimize the defect points of the G01 format G code of three-axis machining. First, a rough screening method based on the geometric characteristics of the trajectory is constructed. Second, a precise screening method through trend trajectories and box plot to screen out defect points is constructed. Finally, the NURBS curve is used to restore and discretize trajectories to obtain new points of G code. Two cases and experiments are used to verify the optimization effect. The experiments results show that after screening and optimization, the geometric characteristics of the two G codes, such as curvature and the difference between adjacent line segments, are obviously improved. The curves of setpoints speed and acceleration are smoother, the setpoints jerk is reduced, and the vibration is weakened. The processing time of the two G codes is shortened by 4.07% and 9.85% when the feed speed is 3000 mm/min and 2000 mm/min, respectively.

This paper describes the design of a verified tool for analyzing tool paths defined in the RS-274 language for 3D printing systems. We describe how the analyzer was designed to allow a mixture of verification and code-extraction techniques to be combined for constructing a correct toolpath analyzer written in the OCaml language. We show how we moved from a fully hand-written OCaml program to one incorporating verified components, highlighting architectural decisions that were made to facilitate this process. Finally, we share a set of architectural lessons that are generally applicable to other software with a similar goal of integration of verified components.

This study proposed a dynamic parameters’ identification method for the feeding system of computer numerical control machine tools based on internal sensor. A simplified control model and linear identification model of the feeding system were established, in which the input and output signals are from sensors embedded in computer numerical control machine tools, and the dynamic parameters of the feeding system, including the equivalent inertia, equivalent damping, worktable damping, and the overall stiffness of the mechanical system, were solved by the least square method. Using the high-order Taylor expansion, the nonlinear Stribeck friction model was linearized and the parameters of the Stribeck friction model were obtained by the same way. To verify the validity and effectiveness of the identification method, identification experiments, circular motion testing, and simulations were conducted. The results obtained were stable and suggested that inertia and damping identification experiments converged fast. Stiffness identification experiments showed some deviation from simulation due to the influences of geometric error and nonlinear of stiffness. However, the identification results were still of reference significance and the method is convenient, effective, and suited for industrial condition.

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This paper provides a comprehensive overview of the development, technical architecture, and practical applications of the LOLA 30 CNC system, a landmark achievement in domestic industrial innovation in the field of numerical control. Developed in the early 1980s by the LOLA Institute, the system is examined within its historical context, with particular attention to its architectural features and its broader impact on industrial autonomy and engineering education. Special emphasis is placed on its modular design, integration with the PA512 programmable logic controller, and representative use cases. The paper also presents a comparative analysis between the LOLA 30 CNC and the modern LOLA ROSA CNC system, which is based on open-architecture hardware and software. Key technological advancements of the new system, particularly in terms of reconfigurability and distributability, are highlighted.

With the transformation of manufacturing mode and the development of computer technology, the numerical control system has been developed from the traditional closed to the open and intelligent. As the top-level design of numerical control technology, numerical control standard is the strategic support to guide and lead numerical control products to the high-end. However, the related technical standard system and index system of the numerical control system are still incomplete. Through the research and analysis of the numerical control system software index and combined with engineering practice, this paper proposes the real-time performance index of the numerical control system and tests and analyzes the real-time performance of the numerical control system based on x86 and ARM architecture. This will be helpful for the objective evaluation of the performance and software support capability of the real-time system and will be a useful supplement to the evaluation of the open CNC system.

After the advance of NC technology to CNC technology there are attempts to bring openness in the control to bring modularity, flexibility and accuracy in the system to replace proprietary controllers. To experiment the same a portable open architecture-based CNC machine is developed for engraving application. Open source software’s are used to identify the contour, generate CNC g-code and microcontrollers to execute the motion control. The mechanical structure is developed to meet the requirement of low cost without sacrificing the accuracy. Besides the accuracy of the profile to be machined, feed rate is another criterion which should be achieved as it is intended in the program. The 3 axis CNC structure is developed and tested satisfactorily for the targeted performance.

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An advanced flexible programming methodology for CNC woodworking machines was developed. As the research starting base, a three-axis CNC woodworking machine was used. The developed methodology is proposed for programming, simulation, postprocessing, and machining by woodworking machine. This flexible programming method integrates the standard programming based on CAD, CAD/CAM systems, and STEP-NC protocol through different output files, enabling data interoperability during the realization of the machining tasks. The control system for the machine is configured based on the open-architecture software LinuxCNC to verify the flexible programming method and the results obtained. Programming verification was realized by simulation on a configured virtual machine in different programming environments and finally on a virtual machine integrated with the control system. The results obtained from the study were evaluated comparatively.

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As a distributed computing system, a CNC system needs to be operated reliably, dependably, and safely. How to design reliable and dependable software and perform effective verification for CNC systems becomes an important research problem. In this paper, we propose a new modeling method called TTM/ATRTTL (timed transition models/all-time real-time temporal logics) for specifying CNC systems. TTM/ATRTTL provides full supports for specifying hard real time and feedback that are needed for modeling CNC systems. We also propose a verification framework with verification rules and theorems and implement it with STeP and SF2STeP. The proposed verification framework can check reliability, dependability, and safety of systems specified by our TTM/ATRTTL method. We apply our modeling and verification techniques on an open architecture CNC (OAC) system and conduct comprehensive studies on modeling and verifying a system controller that is the key part of OAC. The results show that our method can effectively model and verify CNC systems and generate CNC software that can satisfy system requirements in reliability, dependability, and safety.

The closed design of the motion control system limits its use in multi-axis real-time industrial scenarios. In order to solve this problem, an open motion control system software framework based on Xenomai is designed. Following the principles of layered architecture and modular design, the control system employs a multi-tasking approach. It implements the functions of motion task path description, interpolation calculator, and kinematic solver in the motion control layer through open interfaces. Different types of devices are organized and managed by a device factory. Then, a motion control interface is designed to enable programmable motion control for different devices, and the operational workflow of the motion control system is discussed. Finally, experimental validation is carried out with CNC, SCARA robot, and six-axis industrial robot. The experimental results show that the open multi-axis motion control system based on Xenomai meets the requirements of smooth operation as well as high control accuracy, and has good versatility and scalability.

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As a distributed computing system, a CNC system needs to be operated reliably, dependably and safely. How to design reliable and dependable software and perform effective verification for CNC systems becomes an important research problem. In this paper, we propose a new modeling method called TTM/ATRTTL (Timed Transition Models/All-Time Real-Time Temporal Logics) for specifying CNCsystems. TTM/ATRTTL provides full supports for specifying hard real-time and feedback that are needed for modeling CNC systems. We also propose a verification framework with verification rules and theorems and implement it with STeP and SF2STeP. The proposed verification framework can check reliability, dependability and safety of systems specified by our TTM/ATRTTL method. We apply our modeling and verification techniques on an open architecture CNC (OAC) system and conduct comprehensive studies on modeling and verifying a logical controller that is the key part of OAC. The results show that our method can effectively model and verify CNC systems and generate CNC software that can satisfy system requirements in reliability, dependability and safety.

At present, the focus of CNC technology is mainly towards open CNC systems and cloud manufacturing. But the motion control of the CNC system is still mainly composed of interpolation and motion execution. In order to improve the accuracy and quality of interpolation, the applied algorithms are becoming more and more complex. When encountering complex trajectories, minor modifications require complex calculations. To solve this problem, a new CNC system architecture is proposed, that is, adding processing functions after interpolation. Put the minor modification of the trajectory after the interpolation. The article first introduces the CNC architecture with offline interpolation post-processing (OIPP). Then the Interpolation Byte Stream (IBS) format used to represent the interpolation data is introduced. Since the IBS format has the dual characteristics of geometry and string, geometric transformation and text processing both can be used in processing operation. On the basis of the software program and the matching motion controller, the WEDM-CNC system with post-interpolation processing function is implemented. The interpolated data transmission in the developed system adopts a dual-pointer structure, which can effectively control the data transmission. Finally, the feasibility of the new CNC system was verified through machining experiments. Experiments show that offline interpolation post-processing can modify the interpolated data with high precision and flexibility.

According to research progress and applying technology of CNC control system architecture, this paper discusses three kinds of CNC control systems: Open CNC system, embedded CNC system and PLC CNC system, and a new architecture is proposed. The paper illuminates that integrated motion control system architecture is a new concept of CNC, by which it has high precision and low cost. In this paper, a grinding machining controller using this structure is described and verified by software.

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The STEP file is the “standard for the exchange of product model data,” which is usually used to exchange geometric data in boundary representation (B-rep) between different computer-aided design (CAD) platforms. These data can be fully utilized and integrated into a larger manufacturing organization, such as a computer-aided manufacturing (CAM) environment for computer numerical control (CNC) machining applications based on ISO 6983. The 3D models of 2D machining profiles were created in CAD software and saved as STEP files. The data structure was analyzed by comparing the geometric entities of the CAD model and the STEP file. The algorithm was created using the hypertext preprocessor (PHP) programming language and produced a computer interface system to convert STEP files into G-code format. The machining blocks with profile machining features were simulated using a CNC simulator and PC-based open architecture control (OAC) software. The G-code was validated on a three-axis CNC milling machine, and the result was compared to the CAD model to confirm the machining profile. The integrated interface system I2S demonstrates its ability to interpret all 2D profiles and generate machining tool paths and G-code, allowing data flow between CAD and CAM environments and shortening product development cycles.

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Abstract This study presents a novel feed rate-adaptive predictive interpolation algorithm that combines Pythagorean-hodograph (PH) curves with non-uniform rational b-splines (NURBS) to improve real-time toolpath generation in high-speed CNC machining. Unlike traditional NURBS interpolators, which are prone to feed rate fluctuations and poor curvature handling, the proposed method incorporates a curvature-aware predictive module that dynamically adjusts the feed rate based on local geometry and system dynamics. Key innovations include sharp corner detection, PH-based smoothing, and jerk-limited feed rate profiling. Simulation and experimental results show that the proposed algorithm significantly reduces path-following errors (on average by more than 60 % RMS error reduction) while ensuring smoother, bounded-acceleration trajectories. The algorithm consistently maintains geometric accuracy across different toolpath orientations, making it a robust solution for precision manufacturing tasks that require both real-time responsiveness and high accuracy.

With the rapid development of Computerized Numerical Control (CNC) systems, traditional industrial communication protocols fail to meet the requirements for high real-time performance and reliability. To address these challenges, an open five-axis CNC system is designed and implemented based on the gLink-II bus protocol. This system features a layered architecture that integrates the Windows operating system with a Real-Time Operating System (RTOS) kernel, along with a multithreaded data interaction structure based on a circular buffer to enhance real-time data transmission performance and improve system responsiveness. In the direct linear interpolation control for five-axis machining, an acceleration and deceleration planning method is introduced, taking into account the kinematic constraints of the rotary axes. This method optimizes velocity and acceleration control. The experimental results show that the system achieves a maximum response error of less than 0.2 milliseconds and an interpolation period of less than 0.5 milliseconds in five-axis coordinated control. The system is capable of efficiently performing data processing and task scheduling, ensuring the stability of the CNC machining process.

In a typical computer numerically controlled (CNC) machine, the servodrive system is an important component that directly affects the accuracy of the machine. Its function is to generate and convert command signals to machine motion; and to eliminate errors that are generated during the axis motion. By noting that the errors generated are accumulative, therefore any error that is generated in real time because of lack of accurate axis motion or interpolator malfunction will have a profound effect on the quality of parts produced. This paper is focused on controller design aspect of the feeddrive unit and a physical model of the feedrive system is used to do the simulation study. Controller design is based on fuzzy set theory which as opposed to conventional approaches does not require in depth understanding of dynamics of the system. In this regard, the elements of the controller are developed and used to study its performance. Axis motion is attained by controlling position based on the control output which uses error and its derivative in fuzzy domain about a predefined trajectory. Simulation results demonstrating satisfactory performance of the feedrive system in tracking the desired trajectory are reported

Static configurations and slow adaption to changing requirements characterize today’s production systems. In order to cope with variable external influences, these systems need to become more flexible. One building block towards meeting this requirement from the software perspective is employing quality-preserving processes to develop and update automation applications. While this condition applies to classical automation applications, it is increased if Software-defined Manufacturing (SDM) is applied. Containers can be used to deploy software through orchestration. Orchestration covers initial deployment and the roll-out of new software versions. This makes it in theory possible to deploy automation applications, such as computerized numerical control (CNC) software. However, available tools from information technology cannot be used to orchestrate and update automation applications, as real-time requirements must be considered. This work presents an approach that supports orchestration, specifically the deployment and update process, of real-time containers safeguarded by real-time capable simulation coupled with the control system during the operation phase. It shows how to achieve the right timing for real-time software updates and how to prevent causing damage by observation and safeguarding through information obtained from the real-time simulation. Using real-time simulation in the operating phase, container-based control and real-time orchestration become safer and more applicable in industrial manufacturing systems.

To address frequent dynamic changes and highprecision monitoring demands in automated machine tool lines, this paper proposes a digital twin(DT) solution integrating SolidWorks modeling, Unity WebGL simulation, and PLC realtime data. By building a high-precision 3D model library, developing a parametric interface, and enabling millisecond-level data sync, it achieves real-time virtual-physical mapping for CNC process monitoring.

In order to solve the problem of nonlinear error for a dual rotary table five-axis CNC machine tool due to the linkage of rotary and translational axes, the simulation of motion nonlinear error compensation for a multi-axis linkage CNC machine tool is proposed. The adjacent points in the tool position file are selected as the tool position points for building the model, and then the nonlinear error model resolved by the harmonic function is established according to the error distribution in the classical post-processing. The nonlinear error between the two tool position points is quickly predicted by the analytical expression of this model, and the real-time error compensation of the intermediate interpolation points is realized. Finally, MALTLAB simulation analysis is performed on the tool position file of an impeller part machining to verify the effectiveness of the proposed algorithm. The experimental results show that it can be seen from the distribution curve of the nonlinear error that it is about 10% after compensation as before compensation, thus verifying the effectiveness of the nonlinear error compensation mechanism. The correctness of the nonlinear error analysis and compensation method and the effectiveness of post-processing are verified.

This paper proposes a novel corner smoothing method with a Finite Impulse Response (FIR) filtering algorithm to generate a smooth trajectory for CNC machine tools. Basic point-to-point (P2P) interpolation for linear toolpath causes motion stops at each corner and excites structure vibration. Instead of inserting blending spline curves and solving feedrate planning between linear segments, non-stop feed motion is achieved in real-time by using the approach. Based on kinematic equations and pulse commands of motion axes, the length of FIR filtering is determined to respect corner tolerance and kinematic constraints of the drives simultaneously. Rather than adding the dwell time in filter-based feedrate planning, two-axis motion is realized by evaluating corner speed and matching the same length of FIR filters. Simulation studies and experiments results are provided to validate the effectiveness of the presented technique and improve cycle time and contouring performance.

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Smooth and controlled speed regulation is crucial for multi-axis systems like machine tools and robot arms. Planning the highest possible feedrate within smoothness and axial drive constraints necessitates velocity control methods. However, most methods need repeated calculations or preparation, and the complexity grows quickly with the level of smoothness needed, making it hard to achieve both high smoothness and real-time performance at the same time. This paper proposes a convolution-based velocity-control method. The algorithm is lightweight and straightforward, with complexity independent of the required smoothness order. This is achieved by applying convolution to an original low-order smooth velocity, converting it to arbitrary-order smooth velocity. The smooth order depends solely on the convolution kernel, not the algorithm flow. The method completes smooth velocity control in a single convolution, eliminating the need for iterations. Keys for the method are 1) the design principle of the convolution kernel according to the required smoothness and 2) the control of the trajectory error induced by the convolution. The paper presents the velocity-control scheme and applies it to jounce-bounded feedrate scheduling for parametric curve CNC interpolation. Experimental results confirm high-smoothness and real-time capacity are simultaneously ensured. Note to Practitioners—This work addresses the challenge of achieving simultaneously high-smoothness and high real-time capability velocity control in multi-axis systems like CNC machines and robotic arms. Traditional methods often compromise between motion smoothness and computational efficiency, especially for complex paths. Our solution replaces iterative optimization with a lightweight convolution applied directly to axis velocities. The convolution kernel—designed once per system—instantly converts low-smoothness motion into high-smoothness one without path resampling or heavy computation. This method can be of considerable interest to readers working on high-speed robotic and CNC systems.

The article discusses the approach to the implementation of cutting simulation in the CNC system. Simulation of cutting before starting the actual machining of the product allows you to avoid many errors associated with the positioning, reorientation of the tool, check the correctness of the tool’s approach to the workpiece, etc. This becomes especially relevant in multi-axis machining [1-4]. The advantages of presenting a product model using a sparse voxel octree are considered.

The accuracy of motion control of CNC machine tools directly affects the quality of industrial development. Traditional CNC machine tools have a series of problems such as low control accuracy and slow adjustment speed. Image processing technology is used to improve the motion effect of CNC machine tools. Through image acquisition, image analysis and motion control, the starting point of machining is defined, and the operation is carried out according to the requirements to improve the efficiency of tool operation. Image analysis algorithm is used to control the starting point coordinates of the tool, and the tool is moved to the top to achieve horizontal alignment. This method can not only ensure that the system has a faster control speed, but also ensure that the accuracy of the control is significantly improved.

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With the increasing demand for dynamic performance in CNC machine tool feed systems, existing design methods are facing significant challenges. Kinematic-based static design methods do not account for dynamic conditions during actual machining, while dynamic design methods based on natural frequency struggle to directly address users’ time-domain accuracy requirements. To address this issue, this paper proposes an integrated design method of “Motion Process, Electromechanical and Control”, which directly focuses on time-domain accuracy. The method takes the feed system’s acceleration and deceleration capability as the design basis, with the time-domain design objectives being a combination of position error, velocity error, and velocity fluctuation. After isolating the effects of servo control parameters, the paper investigates the influence mechanism of electromechanical matching under different motion processes on the time-domain accuracy of the feed system. The relationship between time-domain accuracy indicators and the physical components of the feed system is explored, and corresponding analytical and design methods are established. This research provides a new theoretical foundation for the design of CNC machine tool feed systems.

The problem of real-time motion control systems for complex objects is investigated. A condition for the feasibility of control is formed depending on the duration of the control cycle, the complexity of the object and the speed of the system. Keywords: motion control, industrial robot, machine tool, mechatronic system, control cycle, memory-centric architecture. andarmo@yandex.ru

The EtherCAT fieldbus system is widely applied in different types of computerized numerical control (CNC) machine tools due to its outstanding communication performance. In the field of ultra-precision CNC, some machine tools employ controllers that integrate EtherCAT master functionality to achieve real-time communication with other devices; however, the open-source IgH EtherCAT master has rarely been applied to the CNC systems of ultra-precision machine tools. The feasibility of using the IgH EtherCAT master to meet the communication performance requirements of ultra-precision machine tools remains uncertain; therefore, it is necessary to validate the control effect on precision axes under the application of the IgH EtherCAT master. In this work, EtherCAT applications were developed on a personal computer (PC) to alter it to a bus-type controller with the IgH EtherCAT master function. To provide the EtherCAT master with real-time and accurate motion data of the axes, an interpolation algorithm tailored for control experiments was designed, and a G-code data processing method was proposed. Moreover, precision aerostatic linear axes and servo drivers were chosen as EtherCAT slaves for single-axis motion and dual-axis linkage control experiments. The experimental results showed that the motion controller based on IgH can effectively control the precision axes to execute ultra-precision linear and circular interpolation motion.

In this paper, Iterative Learning Control (ILC) combined with a Proportional Derivative (PD) regulator is proposed to deal with the problem of designing a control signal for motion control systems. The main idea in iterative learning control is to gradually improve the performance of the system by exploiting data from the previous iterations. The learning control algorithm can obtain a better tracking control performance for the next run and hence outperforms conventional control approaches such as Proportional Integral Derivative (PID) controller and feedforward control. The main area of application for ILC is control of industrial robots and CNC machine tool, printing, and other industrial applications. The learning algorithms can also be used in combination with other control techniques. For example, learning feedforward control is designed in the first iteration. Then iterative learning control is applied to improve performance in the subsequent iterations. In addition, the conventional feedback regulator is designed in combination with iterative control to deal with uncertainty. Simulation results demonstrate the potential benefits, sensitivity and robustness of the proposed method.

The article presents the application of Mamdani Fuzzy Logic Inference System to optimize the operation of a Computerized Numerical Control (CNC) machine for given dynamic parameters. These parameters are maximum speed, acceleration and JERK. The JERK parameter determines the rate of change of acceleration. The parameters are defined for each working axis of the machine. In order to check the correctness of the solution proposed in the paper, the learning and testing process was conducted on specially designed database including different trajectories generated for machining with different machine dynamics parameters. The approach presented in the paper using elements of fuzzy logic to optimize the operation of the CNC machine proved to be very good. The authors, in cooperation with industry, will develop the aforementioned solution leading to implementations and further scientific publications.

In order to reduce the effect of nonlinear friction and time-varying factors on the servo system of a computer numerical control (CNC) machine tool and improve its motion control accuracy, this paper uses an adaptive sliding mode control (ASMC) method based on model reference adaptive control (MRAC). The method adopts ASMC in the control outer loop and obtains the optimal control parameters by making the sliding mode control (SMC) law continuous and adaptively estimating the control parameters. At the same time, MRAC is used in the control inner loop to enhance the “invariance” of the controlled object so that the switching gain of SMC can satisfy the disturbance matching condition even under lesser conditions. Simulation and experimental results show that compared with the traditional SMC, the ASMC based on MRAC proposed in this paper effectively reduces the influence of nonlinear friction on the system performance, and the reduction in following error reaches 71.2%, which significantly improves the motion control accuracy of the control system. The spectral analysis of the following errors shows that the maximum magnitude reduction rate of the high-frequency chattering is 89.02%, which significantly reduces the effect of the high-frequency chattering and effectively improves the stability performance of the control system.

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EtherCAT is a real‐time Ethernet protocol and has been widely used in the field of motion control owing to its high speed (100 or 1000 Mbps), low processor occupancy, and good synchronization performance in slaves. However, the master–slave synchronization method is blank in the EtherCAT protocol. The study proposes a novel master–slave synchronization method that relies on the stable sync0 of reference slave by adjusting the trigger moment of master interpolation period to settle packet loss caused by EtherCAT master–slave un‐synchronization, adaptively and dynamically. Furthermore, the proposed method improved EtherCAT to a whole new level, indicating that the EtherCAT master no longer depended on the real‐time operating system (RTOS). In addition, a synchronization predictive compensation mechanism was adopted to eliminate the compensation lag defect of existing synchronization methods. Compared with conventional studies, the synchronization method improved compensation efficiency, settled inaccurate compensation with evaluation derived from different working frequencies, and eliminated accumulative error in clock. Finally, the proposed method added almost no computation and communication load and only required eight or 16 bytes to modify the EtherCAT frame coding in the interpolation period. Experiments were carried out on machine tools to demonstrate the advantage of the proposed method in improving the synchronization performance, with an average communication jitter of only 32–71 ns.

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The helical contour motion accuracy of feed drive axes is important for thread milling operations in computer numerical control (CNC) machine tools. However, the motion dynamics and external disturbances significantly affect the contour motion results, while the feed drive axes perform helical motions in thread milling operations. Although existing iterative learning contour control (ILCC) methods can improve contour motion accuracy, the problems of data recording and processing on memory usage and computational burden in control systems, wasted materials, and increased costs in thread manufacturing still limit the practical applications of ILCC. Therefore, considering the similar motion dynamics and external disturbances of the feed drive axes during the pitch cycle motions of a helical path, this study developed a pitch cycle-based iterative learning contour control (PCB-ILCC) method to address the control system and thread manufacturing problems caused by the use of ILCC. For PCB-ILCC, this study adopted contour error vector estimation by referring to the interpolated positions on the pitch cycle of the helical path to simplify the computational complexity and designed the ILCC using the cycle learning method to easily implement the ILCC structure. Thus, this study developed a permanent magnet synchronous motor (PMSM) driving control utilizing the robust control method to mitigate the problems of motion dynamics and external disturbances on the feed drive axes. Thread milling experiments performed on a five-axis CNC machining center demonstrated the feasibility of the PCB-ILCC and validated that it can significantly improve the helical contour motion accuracy of the feed drive axes and achieve an 80% contour error reduction rate in comparison with the proportional–proportional–integral control, which is extensively used in commercialized PMSM drivers and CNC controllers.

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The five axis CNC laser machining machine is widely used in the processing industry with high efficiency and precision and other advantages. Based on the basic principle of kinematics theory on the multi-body system, this paper describes the homogeneous coordinate transformation law of the five-axis laser machining machine tool based on GSN control card, and analyzes the solution of the motion trajectory and converts it into the incremental data of the position of each axis in the coordinate system of the machine tool, which solves the correctness, universality and automation of the numerical control system. It provides a powerful help for the five axis CNC laser machining machine based on GSN control card.

Contouring error is a critical performance metric for five-axis computer numerical control (CNC) machine tools, primarily arising from system response delays and dynamic coupling among different axes. To effectively suppress contouring error, a novel iterative contouring error compensation method based on motion synchronization control is proposed in this article. First, the motion synchronization points for each axis at identical delay times are determined through numerical calculations. Then, the reference trajectory is iteratively compensated based on these synchronization points and a designed disturbance function approximator. This method takes effect directly in the machine tool coordinate system, avoiding the contouring error estimation and achieving higher compensation accuracy. Comparative experiments on a five-axis CNC machine tool show that the proposed scheme can effectively enhance contouring accuracy, particularly for complex trajectories with high curvatures and sharp corners. Furthermore, in side milling operations, where tool tip position remains basically unchanged while the tool orientation varies, the proposed scheme remains effective, while existing methods tend to fail.

CNC machining is the leading subtractive manufacturing technology. Although it is in use since decades, it is far from fully solved and still a rich source for challenging problems in geometric computing. We demonstrate this at hand of 5-axis machining of freeform surfaces, where the degrees of freedom in selecting and moving the cutting tool allow one to adapt the tool motion optimally to the surface to be produced. We aim at a high-quality surface finish, thereby reducing the need for hard-to-control post-machining processes such as grinding and polishing. Our work is based on a careful geometric analysis of curvature-adapted machining via so-called second order line contact between tool and target surface. On the geometric side, this leads to a new continuous transition between "dual" classical results in surface theory concerning osculating circles of surface curves and osculating cones of tangentially circumscribed developable surfaces. Practically, it serves as an effective basis for tool motion planning. Unlike previous approaches to curvature-adapted machining, we solve locally optimal tool positioning and motion planning within a single optimization framework and achieve curvature adaptation even for convex surfaces. This is possible with a toroidal cutter that contains a negatively curved cutting area. The effectiveness of our approach is verified at hand of digital models, simulations and machined parts, including a comparison to results generated with commercial software.

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In state of the art computerized numerically controlled (CNC) machines toolpaths are often defined as polynomial Non-Uniform Rational B-Spline (NURBS) curves. This article investigates three main types of interpolation algorithms for NURBS toolpaths. These are Taylor series interpolation (TSI), predictor-corrector interpolation (PCI) and feedrate correction polynomial interpolation (FCPI). Interpolation accuracy of each method is investigated for an example NURBS toolpath. Interpolation computation time is also investigated for each method. Results are presented that compare the accuracy and computation efficiency of each method. It is shown that the Predictor-Corrector interpolation method achieves the best accuracy of the investigated methods without significant increase in computation time.

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High demands in a modern industry require computerized numerical control machines to accurately track the desired workpiece contour in a minimum motion time for productivity. Generally, minimum motion time and accuracy are contradictory; therefore, the machine slows down tracking in the workpieces with strict geometric constraints. This study presents time-optimal trajectory generation of the workpieces, focusing on straight-line, circle, and spline contour segments by considering fitting errors as geometric constraints. For machining purposes, the given workpiece is divided into several G-code segments represented by the piecewise continuous functions for trajectory generation. In this study, the cubic B-spline function represents each segment trajectory, and the optimal control problem is formulated. The effectiveness is investigated considering different geometric constraints, and the motion time of the resulting trajectories are compared and discussed.