數(shù)控車床系統(tǒng)XY工作臺(tái)與控制系統(tǒng)設(shè)計(jì)

數(shù)控車床系統(tǒng)XY工作臺(tái)與控制系統(tǒng)設(shè)計(jì),數(shù)控車床系統(tǒng)XY工作臺(tái)與控制系統(tǒng)設(shè)計(jì),數(shù)控車床,系統(tǒng),xy,工作臺(tái),控制系統(tǒng),設(shè)計(jì) 目 錄 摘 要 1 前 言 2 一、畢業(yè)設(shè)計(jì)的目的、意義 4 二、畢業(yè)設(shè)計(jì)的內(nèi)容 4 （一）畢業(yè)設(shè)計(jì)題目：?jiǎn)纹瑱C(jī)控制步進(jìn)電機(jī)驅(qū)動(dòng)的多用XY工作臺(tái)。 4 三、數(shù)控系統(tǒng)總體方案的確定 4 （一）系統(tǒng)運(yùn)動(dòng)方式的確定 4 （二）伺服系統(tǒng)的選擇 4 （三）計(jì)算機(jī)系統(tǒng)的選擇 5 （四） X—Y工作臺(tái)的傳動(dòng)方式 5 四、機(jī)械部分設(shè)計(jì) 5 （一）確定系統(tǒng)脈沖當(dāng)量 5 （二）工作臺(tái)外形尺寸及重量初步估算 6 （三）滾動(dòng)導(dǎo)軌副的計(jì)算、選擇 7 （四）滾珠絲杠計(jì)算、選擇 8 （五）齒輪計(jì)算、設(shè)計(jì) 11 （六）步進(jìn)電機(jī)慣性負(fù)載的計(jì)算 12 （七）步進(jìn)電機(jī)的選用 13 五、數(shù)控系統(tǒng)硬件電路設(shè)計(jì) 15 （一）數(shù)控系統(tǒng)的硬件電路由以下幾部分組成： 15 （二）主控制器ＣＰＵ的選擇 15 （三）存儲(chǔ)器擴(kuò)展電路設(shè)計(jì) 15 （四）步進(jìn)電機(jī)驅(qū)動(dòng)電路設(shè)計(jì) 16 （五）其它輔助電路設(shè)計(jì) 17 六、系統(tǒng)控制軟件的設(shè)計(jì) 18 （一）系統(tǒng)控制軟件的主要內(nèi)容 18 （二）系統(tǒng)控制功能分析 18 （三）系統(tǒng)管理程序控制 19 （四）自動(dòng)加工程序設(shè)計(jì) 19 結(jié)束語 20 參考資料 21 黃河科技學(xué)院畢業(yè)設(shè)計(jì)（文獻(xiàn)翻譯） 第10 頁 單位代碼 0 2 學(xué) 號(hào) 080105655 分 類 號(hào) TH6 密 級(jí) 秘密 畢業(yè)設(shè)計(jì) 文獻(xiàn)翻譯 院（系）名稱 工學(xué)院機(jī)械系 專業(yè)名稱 機(jī)械設(shè)計(jì)制造及其自動(dòng)化 學(xué)生姓名 金賀 指導(dǎo)教師 薛東彬 2012年 3 月 10 日  針對(duì)不同的數(shù)控機(jī)床一個(gè)基于互聯(lián)網(wǎng)的機(jī)床檢查計(jì)劃 Dong-ttoon Kim 情報(bào)和精密機(jī)械部門，韓國機(jī)械和材料研究所,大田305 - 343,韓國 Sun-Ho Kim 機(jī)電工程專業(yè)本科工程,東義大學(xué)，Busan 614 - 714釜山、韓國 Kwang-SIK KOH 電氣工程和計(jì)算機(jī)科學(xué)學(xué)院，慶北國立大學(xué)，大邱廣域市702-701，韓國 摘要 本文提出了一個(gè)基于互聯(lián)網(wǎng)的機(jī)床檢查與數(shù)字控制機(jī)床(CNC)技術(shù)。根據(jù)其體系結(jié)構(gòu)的不同，數(shù)控機(jī)床分為兩種類型：一種是封閉式控制結(jié)構(gòu)（CAC），它是傳統(tǒng)的數(shù)控機(jī)床；一種是開放式控制結(jié)構(gòu)（OAC），這是最近推出的PC-based控制器。由于CAC有一個(gè)封閉的架構(gòu)，所以它依賴于數(shù)控機(jī)床供應(yīng)商制定的規(guī)格。而因?yàn)檫@一點(diǎn)，它的應(yīng)用程序很難在數(shù)控領(lǐng)域?yàn)橛脩羲鶎?shí)現(xiàn)。近日，傳統(tǒng)的數(shù)控機(jī)床已被基于PC的開放式數(shù)控機(jī)床所取代。然而，現(xiàn)在還有很多傳統(tǒng)的數(shù)控機(jī)床在OAC配備不足的車間工作。對(duì)于CAC和OAC數(shù)控機(jī)床基于互聯(lián)網(wǎng)的檢查，一個(gè)合適的系統(tǒng)環(huán)境是必要的。通過這項(xiàng)研究，對(duì)包括CAC和OAC在內(nèi)的各種CNC在專業(yè)化生產(chǎn)系統(tǒng)進(jìn)行全球化管理，對(duì)各種CNC基于互聯(lián)網(wǎng)的檢查設(shè)計(jì)一個(gè)合適的環(huán)境，并對(duì)CAC和OAC檢查方法作比較。這項(xiàng)研究成果可作為一個(gè)數(shù)控機(jī)床集成制造系統(tǒng)的全球監(jiān)測(cè)和遠(yuǎn)程控制的基本模型。在本研究中定義的檢查點(diǎn)分為兩類：結(jié)構(gòu)性點(diǎn)和操作點(diǎn)。前者包括軸承的振動(dòng)，主軸單元的溫度，和其他期刊管理點(diǎn)，而后者則包括油檢查，夾具鎖/開鎖，加工開/關(guān)狀態(tài)。 關(guān)鍵詞：基于Internet的檢查方法，變式數(shù)控，CAC，0AC 1導(dǎo)言 電腦和互聯(lián)網(wǎng)的廣泛使用，導(dǎo)致一個(gè)基于Internet的數(shù)控機(jī)床的控制和監(jiān)測(cè)的全球化管理在專業(yè)化生產(chǎn)系統(tǒng)的需求不斷增加。在過去，利用可編程邏輯控制器（PLC）的接觸點(diǎn)，監(jiān)測(cè)做為數(shù)控機(jī)床和制造系統(tǒng)外圍設(shè)備的I / O信號(hào)。 但是，這個(gè)程序已經(jīng)被限制到CNC內(nèi)部信息的監(jiān)測(cè)。它很難執(zhí)行用戶在數(shù)控領(lǐng)域定義的程序，這個(gè)程序包括檢查有關(guān)CNC的各種監(jiān)測(cè)數(shù)據(jù)，外圍設(shè)備和其他外部單位（Rober and Shin, 1995；Lee et.al.,2004）。而所需的用戶自定義程序是數(shù)控機(jī)床監(jiān)測(cè)與遠(yuǎn)程站點(diǎn)的通信應(yīng)用程序模塊。近日，基于PC的開放式結(jié)構(gòu)數(shù)控機(jī)床取代了傳統(tǒng)的數(shù)控機(jī)床，從而提供了一個(gè)方便的環(huán)境來實(shí)現(xiàn)用戶定義的用于遠(yuǎn)程監(jiān)視和控制的數(shù)控程序（Rober and Shin, 1995；Kwon et.al.,2000；Hong et.al.,2003）。然而，很多傳統(tǒng)的數(shù)控機(jī)床在OAC配備不足的車間工作。為了做到對(duì)這種變式數(shù)控機(jī)床遠(yuǎn)程檢查，應(yīng)對(duì)每個(gè)CAC和OAC構(gòu)建合適的環(huán)境。 現(xiàn)在，我們簡(jiǎn)要的概述下相關(guān)的研究。關(guān)于機(jī)床的開放式數(shù)控制造系統(tǒng)管理的研究，已經(jīng)快速的實(shí)現(xiàn)了在柔性制造系統(tǒng)和自動(dòng)配置（Wright，1995）和動(dòng)態(tài)重新配置（Oldknow and Yellowley，2001）的研究。一個(gè)開關(guān)函數(shù)發(fā)生器的研究解決了在開放式結(jié)構(gòu)機(jī)床的維修機(jī)制（Kim et al.，2002）。 機(jī)床的遠(yuǎn)程控制和監(jiān)測(cè)客戶端 - 服務(wù)器環(huán)境也一直被研究（Oldknow and Yellowley，2003）。這種關(guān)于遠(yuǎn)程服務(wù)的代表性例子是由CNC供應(yīng)商開發(fā)的工廠窗口和遠(yuǎn)程系統(tǒng)（Kim et al.，2000;Kang and Kang，1999）。然而，這些系統(tǒng)的特點(diǎn)是當(dāng)?shù)氐挠颦h(huán)境提高基本的技術(shù)支持。此外，這些研究還包括基于互聯(lián)網(wǎng)的機(jī)床管理，CNC故障診斷的實(shí)現(xiàn)和基本的遠(yuǎn)程服務(wù)（Kim et al.，2003）。在柔性制造系統(tǒng)中基于Web的監(jiān)控也進(jìn)行了研究（Jung et al.，2001）。此外，還研究了維護(hù)數(shù)控機(jī)床的公共交換電信電話網(wǎng)（PSTN）和數(shù)字I / O模塊（Hyun et al.，1998）。 然而，這些研究都集中在CAC機(jī)除外的OAC機(jī)上，而研究的大多數(shù)的服務(wù)功能是通過電話線或外部網(wǎng)絡(luò)（如Internet）傳輸?shù)谋O(jiān)測(cè)數(shù)據(jù)。盡管是基于互聯(lián)的應(yīng)用程序，仍要安裝一個(gè)開發(fā)商依賴的特殊的客戶端，因?yàn)榇蠖鄶?shù)情況下是基于客戶-服務(wù)器的配置。在某些特殊情況下，一個(gè)額外的內(nèi)核是必需的。此外，優(yōu)越的數(shù)控廠商，如西門子的第三方支持通過互聯(lián)網(wǎng)的網(wǎng)絡(luò)服務(wù)。然而，在這情況下，非常困難的是服務(wù)的功能往往不適合車間修改功能。在國內(nèi)，甚至有部分?jǐn)?shù)控廠商無法服務(wù)一般商用的基于互聯(lián)網(wǎng)的檢查服務(wù)，如通過lnternet的監(jiān)測(cè)。出現(xiàn)這種情況是因?yàn)榇蟛糠值倪\(yùn)營商和數(shù)控廠商都集中在國內(nèi)數(shù)控市場(chǎng)的穩(wěn)定性和原創(chuàng)能力上面。也就是說，大部分的數(shù)控廠商都害怕數(shù)控機(jī)床因過載而崩潰或因故障造成額外軟件安裝或升級(jí)，所以他們支持遠(yuǎn)程服務(wù)功能。總之，雖然對(duì)OAC有一些研究，但是少有滿意的設(shè)計(jì)，而對(duì)CAC的研究更是非常缺乏。尤其是，基于互聯(lián)網(wǎng)的檢查與CAC和OAC的變種數(shù)控機(jī)床沒有得到充分的研究報(bào)告，由于不便開發(fā)環(huán)境和較差的軟件可移植性。 本文調(diào)查申請(qǐng)的方法是基于互聯(lián)網(wǎng)的檢查技術(shù)，對(duì)OAC和CAC兩個(gè)變式數(shù)控機(jī)床進(jìn)行比較。通過這項(xiàng)研究建議通過基于Internet檢查變式數(shù)控機(jī)床的有效計(jì)劃。首先，遠(yuǎn)程檢查和控制與CAC的機(jī)床和零部件相關(guān)的數(shù)字信號(hào)，通過使用I / O的嵌入式模塊介紹網(wǎng)頁；其次，本文認(rèn)為模擬和數(shù)字遠(yuǎn)程檢查OAC的機(jī)器通過實(shí)施相關(guān)的信號(hào)用戶定義的應(yīng)用程序能夠接口與外部服務(wù)器的數(shù)控域，并通過數(shù)據(jù)采集單元（DAU），能夠獲得與連接的數(shù)據(jù)機(jī)及周邊設(shè)備的聯(lián)系點(diǎn)。 CAC有一個(gè)封閉的架構(gòu)，它是依賴數(shù)控協(xié)力廠商規(guī)范。由于這一點(diǎn)，就已經(jīng)很困難，為用戶實(shí)施在數(shù)控應(yīng)用程序。因此，一個(gè)特殊的，額外的模塊需要基于互聯(lián)網(wǎng)的應(yīng)用程序（塞納科技，2002年）。對(duì)于這一點(diǎn)，一個(gè)網(wǎng)絡(luò)的I / O嵌入式模塊適用于本研究基于互聯(lián)網(wǎng)的檢查。模塊直接連接到TCP/ IP網(wǎng)絡(luò)與遠(yuǎn)程通信網(wǎng)站。為了獲得監(jiān)測(cè)數(shù)據(jù)數(shù)控機(jī)床，模塊的I / O信號(hào)在數(shù)控被分配到PLC的I / O信號(hào)。另一方面，OAC有一個(gè)基于PC的開放式架構(gòu)，運(yùn)作獨(dú)立于數(shù)控供應(yīng)商的規(guī)范并沒有額外的模塊是必要的，用于連接遠(yuǎn)程站點(diǎn)。正因?yàn)槿绱耍粋€(gè)簡(jiǎn)單的DAU，這是不直接連接到OAC的主要電路板，而不是直接影響到數(shù)控穩(wěn)定，用于信號(hào)傳感和數(shù)據(jù)通過RS232/422行收購無需額外通信設(shè)備模塊?；贗nternet的遠(yuǎn)程機(jī)器檢查與OAC，用戶定義的守護(hù)進(jìn)程的工具通信和應(yīng)用程序Web服務(wù)的形式實(shí)現(xiàn)OAC和內(nèi)部功能內(nèi)外部服務(wù)器?；ヂ?lián)網(wǎng)通信之間進(jìn)行數(shù)控領(lǐng)域的守護(hù)程序外部服務(wù)器和網(wǎng)絡(luò)腳本程序。 2基于Internet檢查OAC的方法 在OAC的情況，不需要網(wǎng)絡(luò)支持附加設(shè)備模塊，OAC有一個(gè)方便的結(jié)構(gòu)，可以實(shí)現(xiàn)網(wǎng)絡(luò)應(yīng)用程序。檢查和獲得機(jī)床I / O信號(hào)的數(shù)據(jù)，只需要信號(hào)處理板或外部的DAU數(shù)據(jù)采集。由于大多數(shù)OAC是基于單板計(jì)算機(jī)上的DAU一個(gè)緊湊的結(jié)構(gòu)，比板型（Advantech，2002）更有效可以簡(jiǎn)單地連接I / O信號(hào)。試圖通過監(jiān)測(cè)加工狀態(tài)，應(yīng)用程序通過DAU零部件溫度和振動(dòng)的檢查方法，可以通知檢查時(shí)間和零部件的更換時(shí)間。通過這個(gè)應(yīng)用，數(shù)控機(jī)床及周邊設(shè)備的模擬和數(shù)字接觸點(diǎn)監(jiān)測(cè)使用的DAU。在實(shí)驗(yàn)中，使用外部的I / O的DAU模塊，以減少硬件設(shè)備的大小，并盡量減少負(fù)荷?；贗nternet的檢查OAC機(jī)床配置使用的DAU如圖1RS485通訊內(nèi)部通過RS232/485轉(zhuǎn)換規(guī)范。0V至1.5V的范圍內(nèi)分配一個(gè)采樣周期為每秒10次，以獲取模擬傳輸值。為獲取軸承的振動(dòng)和主軸溫度的實(shí)驗(yàn)，傳輸?shù)哪M值在OAC和DAU之間的通信協(xié)議實(shí)時(shí)監(jiān)控，如圖2所示Subsequently，也進(jìn)行檢查開/關(guān)狀態(tài)的石油和鉗的基本實(shí)驗(yàn)，如圖3所示功能的應(yīng)用程序代碼，實(shí)現(xiàn)在OAC數(shù)控域的內(nèi)部功能。 基于Internet的檢查應(yīng)用，通訊發(fā)達(dá)的守護(hù)程序在數(shù)控領(lǐng)域?qū)嵤?，在外部服?wù)器由Web服務(wù)的Web scr.ipt方案實(shí)施，使用vbscrip，JavaScript和活動(dòng)服務(wù)器頁面（ASP），如圖4守護(hù)程序之間的網(wǎng)絡(luò)通信可以在數(shù)控域和外部Web腳本程序。因此，多個(gè)客戶端可以監(jiān)控檢查的數(shù)據(jù)和機(jī)器的狀態(tài)，通過收購數(shù)字和模擬數(shù)據(jù)傳輸從外部數(shù)據(jù)庫的OAC。數(shù)控通信服務(wù)程序采用標(biāo)準(zhǔn)的開放式數(shù)據(jù)庫連接（ODBC）和數(shù)據(jù)處理，利用結(jié)構(gòu)化查詢語言（SQL）查詢。通過這個(gè)過程，檢查數(shù)據(jù)傳輸相關(guān)的表中的信息構(gòu)建在數(shù)據(jù)庫表中。在互聯(lián)網(wǎng)環(huán)境下的遠(yuǎn)程檢查，實(shí)現(xiàn)了通過設(shè)計(jì)的應(yīng)用程序，如圖5所示結(jié)果表明，這種檢查方法是有利的，在其方便的開發(fā)環(huán)境在軟件方面，可以很容易地實(shí)現(xiàn)用戶定義的應(yīng)用程序。 圖1基于互聯(lián)網(wǎng)的檢查OAC的機(jī)器配置使用的DAU 圖2通信協(xié)議之間的OAC的DAU模 圖3模擬輸入（0-1.5V的范圍）的收購和數(shù)字輸入（8位直接投資） 圖4 OAC和應(yīng)用程序之間的接口網(wǎng)站SEVER 圖5 檢查OAC的機(jī)器所使用的DAU和應(yīng)用程序  3基于Internet的檢查計(jì)劃和變式數(shù)控機(jī)床的例子 基于互聯(lián)網(wǎng)的檢查的計(jì)劃變型數(shù)控機(jī)床的建議圖6CAC機(jī)區(qū)旨在檢查通過下載腳本代碼的數(shù)字?jǐn)?shù)據(jù)和嵌入式設(shè)備服務(wù)器的I / O接口機(jī)制。在OAC機(jī)區(qū)檢查所使用的DAU和應(yīng)用程序，如數(shù)據(jù)采集模塊，通信守護(hù)進(jìn)程模塊，和一個(gè)web腳本模塊的模擬數(shù)據(jù)和數(shù)字?jǐn)?shù)據(jù)?；诨ヂ?lián)網(wǎng)的變種數(shù)控機(jī)床的遠(yuǎn)程檢查，通過擬議的計(jì)劃表見圖7 在CAC的機(jī)床的情況下，一個(gè)Java applet被編碼和下載，以檢查機(jī)床的I / O數(shù)據(jù)和通過網(wǎng)絡(luò)瀏覽器向客戶提供檢查結(jié)果。在I / O地址的Java applet代碼和真正的I / O點(diǎn)的機(jī)床之間分配，監(jiān)視和控制遠(yuǎn)程站點(diǎn)。展示的內(nèi)容是對(duì)監(jiān)測(cè)結(jié)果 I / O的接觸點(diǎn)與當(dāng)前加工/關(guān)狀態(tài)。 CAC的機(jī)床運(yùn)作周期的啟動(dòng)按鈕正在網(wǎng)頁瀏覽器上。 在OAC機(jī)床的情況下，收購的DAU監(jiān)測(cè)數(shù)據(jù)傳送到在遠(yuǎn)程站點(diǎn)，外部服務(wù)器和通信守護(hù)進(jìn)程服務(wù)。它通過網(wǎng)絡(luò)瀏覽器激活油傳感器，主軸溫度是0.0007（這是從0至1.5 V范圍內(nèi)的模擬值）。 結(jié)果表明，在前一種情況下，CAC是有利的，它可以很容易地利用網(wǎng)絡(luò)功能的嵌入式設(shè)備，在硬件實(shí)現(xiàn)基于lnternet的檢查系統(tǒng)。然而，用戶定義的應(yīng)用程序和下載數(shù)據(jù)的最大尺寸被限制在512字節(jié)；后者的情況下，在其方便的開發(fā)環(huán)境，可以方便地實(shí)現(xiàn)在數(shù)控領(lǐng)域的許多不同的應(yīng)用程序，無需額外設(shè)備的優(yōu)點(diǎn)。然而，用戶定義的應(yīng)用程序編程工作需要比在前者的情況下實(shí)施通信和網(wǎng)絡(luò)服務(wù)。 圖6基于互聯(lián)網(wǎng)的檢查環(huán)境變異數(shù)控機(jī)床 圖7 例如基于互聯(lián)網(wǎng)的遠(yuǎn)程檢查變種數(shù)控機(jī)床  4結(jié)論 本文提出了一種新的研究基于Internet檢查傳統(tǒng)的CAC和最近推廣的OAC兩種變式數(shù)控機(jī)床。為了實(shí)現(xiàn)基于互聯(lián)網(wǎng)高效的檢查CAC機(jī)，，使用信號(hào)檢測(cè)方法，通過網(wǎng)絡(luò)I / O嵌入式設(shè)備模塊，可以支持互聯(lián)網(wǎng)應(yīng)用環(huán)境，因?yàn)樵贑AC的環(huán)境執(zhí)行用戶定義的應(yīng)用程序，是依賴于數(shù)控廠商規(guī)范了的數(shù)控領(lǐng)域。 為了實(shí)現(xiàn)基于互聯(lián)網(wǎng)檢查OAC機(jī)床，數(shù)字和模擬信號(hào)的檢查方法，它不需要額外的網(wǎng)絡(luò)I / O的互聯(lián)網(wǎng)應(yīng)用的嵌入式設(shè)備，有人建議，因?yàn)閿?shù)控域執(zhí)行用戶定義的應(yīng)用程序很容易因方便OAC的環(huán)境。這種方法只需利用的DAU取得的I / O硬件方面的數(shù)據(jù)和采集到的數(shù)據(jù)傳送到外部服務(wù)器通過在遠(yuǎn)程站點(diǎn)上的網(wǎng)頁瀏覽器的遠(yuǎn)程檢查。 隨后，對(duì)CAC和OAC機(jī)的檢查方法進(jìn)行了比較。通過這項(xiàng)研究，為數(shù)控機(jī)床與數(shù)控變種的CAC和OAC在制造系統(tǒng)，基于互聯(lián)網(wǎng)的變型數(shù)控機(jī)床的檢查，被設(shè)計(jì)為一體的綜合經(jīng)營的一個(gè)合適的環(huán)境，如建筑的全球管理。這項(xiàng)研究的結(jié)果可能是一個(gè)全球監(jiān)測(cè)和遠(yuǎn)程控制在變種數(shù)控機(jī)床集成制造系統(tǒng)的基本模型。 在今后的工作中應(yīng)解決以下問題：首先，研究人員應(yīng)該調(diào)查優(yōu)越的遠(yuǎn)程檢查環(huán)境的設(shè)計(jì)和實(shí)現(xiàn)，可以在嵌入式設(shè)備利用足夠的上下載的代碼；其次，還需要進(jìn)一步研究，可以更簡(jiǎn)單地對(duì)集成和經(jīng)營變式數(shù)控機(jī)床的標(biāo)準(zhǔn)化和優(yōu)化應(yīng)用程序進(jìn)行開發(fā)。 感謝 感謝工業(yè)改造技術(shù)項(xiàng)目（商務(wù)部，工業(yè)和能源）提供的財(cái)政支持。 Journal of Mechanical Science and Technology, Vol. 19, No. 1, pp. 97-105, 2005 97 A Scheme for an Internet-based Checking Method of Machine-Tools with Variant CNC Architecture Dong-ttoon Kim* Department of Intelligence and Precision Machines, Korea Institute of Machinery and Materials, Daejeon 305-343, Korea Sun-Ho Kim Mechatronics Engineering Major, College of Engineering, Dong-Eui University, Busan 614-714, Korea Kwang-Sik Koh School of Electrical Engineering and Computer Science, Kyungpook National University, Daegu 702-701, Korea This paper proposes an Internet-based checking technique for machine-tools with variant Computerized Numerical Controller (CNC). According to its architecture, CNC is classified into one of two types : Closed Architecture Controller (CAC), which is the conventional CNC, or Open Architecture Controller (OAC), which is a recently introduced PC-based controller. Since CAC has a closed architecture, it is dependent on CNC vender specification. Because of this, it has been very difficult for users to implement application programs in the CNC domain. Recently, the conventional CNC of machine-tools has been replaced by a PC-based open architecture CNC. However, now many conventional CAC machines are being operated together with OAC machines in inadequately equipped shop floors. For Internet-based checking for variant CNC machines with CAC and OAC, a suitable systematic environment is necessary. Through this research, for the global management of variant CNC machines both a CAC and an OAC in the manufacturing system, a suitable environment for Internet-based checking of variant CNC machines was designed, and the checking methods for CAC and OAC machines were compared. The results of this research may serve as a base model for global monitoring and remote control in an integrated manufacturing system with variant CNC machines. Checking points defined in this research are classified into two categories: structured point and opera- tional point. The former includes the vibration of bearing, temperature of spindle unit, and other points of periodical management, while the latter includes oil checking, clamp locking/ unlocking, and machining on/off status. Key Words : Internet-Based Checking Method, Variant CNC, CAC, 0AC I. Introduction Widespread use of computers and the Internet * Corresponding Author, E-mail : kdh680 kimm.re.kr TEL : -t-82-42-868-7148; FAX : -t-82-42-868-7150 9 Department of Intelligence and Precision Machines, Korea Institute of Machinery and Materials, Daejeon 305-343, Korea 9 (Manuscript Received June 11, 2004; Revised October 25, 2004) have led to a continuously increasing demand for Internet-based control and monitoring of CNC machines for distributed global management in manufacturing systems. In the past, the contact points of Programmable Logic Controller (PLC) were utilized for the monitoring of I/O signals associated with CNC machines and peripheral equipment in manufacturing systems. However, this solution has been limited to the monitoring of CNC internal information. It has Copyright (C) 2005 NuriMedia Co., Ltd. 98 Dong-Hoon Kim, Sun-Ho Kim and Kwang-Sik Koh been difficult to check various monitoring data regarding the CNC, peripheral equipment, and other external units by implementing user-defin- ed programs to the CNC domain (Rober and Shin, 1995 ; Lee et. al., 2004). The required user- defined programs are application modules for the monitoring of CNC machines and for com- munication with a remote site. Recently, a conve- nient environment able to implement user-defin- ed programs to a CNC domain for remote moni- toring and control has been provided, since the conventional CNC of machine-tools has been replaced by a PC-based open architecture CNC (Rober and Shin, 1995 ; Kwon et. al., 2000 ; Hong et. al., 2003). However, many conventional CAC machines are now being operated in inadequately equipped shop floors. In order to do a remote check on such variant CNC machines, a suitable environment for each case of the CAC and the OAC should be constructed. We will now briefly outline the related re- search. Regarding research on the management of machine-tools with open architecture CNC in manufacturing systems, there have been studies on rapid part realization in flexible factory sys- tems (Wright, 1995) and on automatic configura- tion and dynamic reconfiguration (Oldknow and Yellowley, 2001). A study on switching function generators addressed the maintenance mechanism of machine-tools with open architecture CNC (Kim et al., 2002). Remote control and monitoring of machine tools by client-server environments has also been investigated (Oldknow and Yellowley, 2001; Kim et al., 2003). The representative examples for such remote services are factory windows and remote systems that are developed by a com- mercial CNC vendor (Kim et al., 2000 ; Kang and Kang, 1999). However, these systems are char- acterized by basic technical support in local domain environments. Besides of this, as for re- search on Internet-based management of mac- hine-tools, CNC-implemented fault diagnosis and basic remote services were reported (Kim et al., 2003). Web-based monitoring has been stu- died in a flexible manufacturing system (Jung et al., 2001). Furthermore, Public Switched Tele- Copyright (C) 2005 NuriMedia Co., Ltd. phone Network (PSTN) and digital I/O modules were utilized for research on the maintenance of CNC machines (Hyun et al., 1998). However, these researches have focused on only OAC machines except CAC machines and the most service function is to transmit moni- toring data via telephone line or external net- work such as Internet. Although in the case of Internet-based application, a special client-ter- minal program, which is dependent of developer, has to be installed because the most cases are based on client-server configuration. In some special cases, an additional kernel is optionally required. Besides, the third-party of superior CNC vendor such as Siemens supports partially the web services via Internet. However, in this case, the service functions are not often suitable to the shop-floor and the modification of the functions is very difficult. In domestic case, even representative CNC vendor can not service gen- erally and commercially the Internet-based chec- king services such as conditions monitoring via lnternet. The cause of such actual circumstance mentioned above is because most operators and CNC vendors have focused on the stability and original ability of CNC in domestic CNC market. That is, most CNC vendors are afraid of the breakdown of CNC machine-tools due to over- load and faults resulting from additional soft- ware installation or upgrade for the purpose of supporting the functions such as remote services. In short, although there are some researches av- ailable for machines with OAC, satisfied applica- tion cases are rare yet and the studies on machines with CAC have been very deficient. Especially, research on Internet-based checking for variant CNC machines with a CAC and an OAC has not been sufficiently reported due to the inconvenient development environment and inferior software- portability. This paper investigates methods for applying Internet-based checking techniques to variant CNC machines with OAC and CAC, and the two types of CNC are compared. And an efficient scheme for Internet-based checking for variant CNC machines is suggested through this study. First, remote checking and control of the digital A Scheme for an lnternet-based Checking Method of Machine-Tools with Variant CNC Architecture 99 signals associated with CAC machines and com- ponent parts by using a web I/O embedded mo- dule are introduced. Second, this paper consi- ders the remote checking of analog and digital signals associated with OAC machines by imple- menting user-defined application programs able to interface with an external server to the CNC domain, and by using a Data Acquisition Unit (DAU) able to acquire data connected with the contact points of machines and peripheral equi- pments. CAC has a closed architecture which is depen- dent on CNC vender specification. Because of this, it has been very difficult for users to imple- ment an application program in CNC. Therefore, a special, additional module is required for Internet-based application (Sena Technologies, 2002). For this, a web I/O embedded module was applied for Internet-based checking in this re- search. The module is directly attached to the TCP/IP network for communication with a re- mote site. In order to obtain the monitoring data of CNC machines, the I/O signals of the module were assigned to PLC I/O signals within CNC. On the other hand, OAC has a PC-based open architecture that operates independent of CNC vendor specification and no additional module is necessary for connection with a remote site. Because of this, a simple DAU, which is not directly attached to OAC main-board and not directly affects to CNC stability, is used for signal sensing and data acquisition via RS232/422 line without additional communication device mo- dule. For Internet-based remote checking of ma- chine-tools with OAC, a user-defined daemon for communication and application programs for web services were implemented in the form of internal function within OAC and an external server. Internet communication is performed be- tween the daemon program of the CNC domain and web script programs of the external server. 2. Structure of Variant CNC Machines and Remote Checking Directions As mentioned above, the implementation of a Copyright (C) 2005 NuriMedia Co., Ltd. user-defined application program is much more difficult in the CAC than in the OAC due to the inconvenient development environment of the CAC. Because the CAC is fully dependent on the CNC vendor, as shown in Fig. 1 (a), the CAC cannot support the application of user-functions that can connect with the network and remotely check CNC machines in the CNC domain. How- ever, as shown in Fig. 1 (b), it is convenient for users to implement the application programs for remote checking in the OAC domain because the OAC has an open architecture based on a PC. For Internet-based remote checking of these two CNC machines that are operated together in a manufacturing system, a suitable system environ- ment must be constructed according to the struc- ture characters of the variant CNC. The conven- tional CAC with closed architecture can effi- ciently use the network-supported unit with em- bedded web server functions because connecting the I/O signals of the applied unit with the I/O signals of CNC machines is possible. This method has an relatively simple system architecture for users, but its fatal flaw is that it cannot manage multiple CNC machines simultaneously with a single server and web script program ; this meth- od, using web-server functions embedded in the device, requires that an individual Internet Pro- tocol (IP) address be associated with each ma- chine. For the recently popularized OAC with a (a) CNC with closed architecture controller (b) CNC with open architecture controller Fig. 1 Structure of variant CNC machines 100 Dong-Hoon Kim, Sun-Ho Kim and Kwang-Sik Koh PC-based open architecture environment, instead of using network-supported units that require additional unique IP addresses, a suitable method is as follows. First, a DAU is utilized in order to acquire I/O data. Then the application program for data acquisition is implemented in order to check I/O contact signals through the DAU, and the interface daemon program, that can transmit the acquired data from a CNC domain to an external server, is implemented in the CNC do- main. A particularly outstanding merit of this system is that a lot of CNC machines can be monitored and managed simultaneously without an additional device with embedded web-server functions. This method also has good expansi- bility. 3. Definition of Checking Points As shown in Table 1, the checking points defined in this research are classified into two categories : structured point and operational point. The former includes the vibration of bear- ing, and the temperature of the spindle unit and other specific units, while the latter includes oil checking, clamp locking/unlocking, and other digital checking points associated with machine operations. Table 1 Definition of checking point Structured Conditions Operational Conditions Vibration of bearings Machining On Temperature of spindle Machining Off Vibration of bearing2 Fault (No Ready) Temperature of spindle2 Oil checking Vibration of bearing3 Clamp lock/unlock Temperature of spindle3 Sub unit on/off 4. Internet-Based Checking Method for CAC Machines This section describes the application of an Internet-based checking method for CAC mac- Fig. 2 hines. In remote monitoring of checked results Copyright (C) 2005 NuriMedia Co., Ltd. and related information with CAC machines, the application program implementation and the program running environment in the CNC do- main are more limited than in an OAC environ- ment that can easily implement software func- tions. Because an additional device module is necessary, we utilized the I/O module with em- bedded minimum operating system and web ser- ver functions, as shown in Fig. 2. By applying this module, the control and monitoring of CNC machines were remotely performed in the experi- ment. The applied device module supports a total of 32 I/O contact points in order to interface with external devices. The contact points were connected with the PLC I/O signals of the CAC machine. Through these points, the machine sta- tus such as cycle start, stop, emergency stop, and machining on/off status can actually be moni- tored in a web environment. The procedure for the application test is as follows. The icons associated with the I/O device module are first designed in default html source by using the supplied device utility, and then the icons properties are assigned to specific I/O addresses. Next, network-supported java class is inserted in default html source and the source codes are compiled by the utility compiler. After that, coded web script files are transferred to the specific file index format so that they can be interpreted by the device module engine (Sena CAC Machine .q D PLC/PMC Z 176 I,. N ooo ooo _ Digital tlO Connection (Digital I/0 Interface Method) .: l Browser Ethernet cable I Hub/SwitCh t Internet-based checking configuration using embedded web I/O device for CAC machine A Scheme for an Internet-based Checking Method of Machine-Tools with Variant CNC Architecture 101 Technologies, 2002). The transferred file, that is in the form of a specific format, is a single image file format that is downloaded to flash memory, as shown in Fig. 3. In order to assign the phy- sical I/O device addresses in application source codes, the real I/O addresses are mapped with the icon properties in web script sources such as html, vbscript, and javascript, as shown in Fig. 4. Fig. 5 shows that the status of the CAC ma- chine is now checked as machining-on when the cycle-start button is selected through a web browser. And through additional analog checking experiment for structured conditions, bearing vi- bration and spindle temperature were monitored in real time. The remote checking model of the CAC machine and its implementation method are relatively simple and convenient, but a database and large-scale script files cannot be loaded. In I User-defined application modules I Cnneetor to Interact Power Supply 16po Sensor nput Conttc Point Fig. 3 Interface between embedded web I/O device and application program detail, a maximum 512 Kbytes application script program can be downloaded to the web I/O embedded device module. However, this method can be very efficient in applications as it uses an I/O board independent of other systems. Here, for remote checking, web script was coded by using java applet and was downloaded to the web I/O embedded device module. For interfacing with the I/O of the CNC machine, I/O contact points were directly connected with each other between the embedded web I/O device and the machine I/ O signals. Test results confirmed that the applica- tion system environment can be easily designed by using this checking method. Table 2 Hardware specification of used web I/O device Item Content CPU 8-bit Microprocessor 512 KB Flesh Memory Memory (User Web File/Parameter App.) Network 10-base T Ethernet (IEEE802.3) Connection External 16 point Digital Input, Connection 16 point Digital Output Internet Protocol HTTP/TCP/UDP/IP/Ethernet Board (Vendor) Dependency, Utility software IP Setting/Web Page Uploading Icons and html implementation by using device utility .1 Icons Property Setting for I/O Address Connection Building Source to Device I Dependent Format I ; Downloading File to Flash Memory I of Embedded Device Server 1 IP Connection of Device and Web . t/O Testing Fig. 4 Address setting and testing of web I/O device Copyright (C) 2005 NuriMedia Co., Ltd. Xltad,i, 808 : ,p Q Fig. 5 Checking for CAC machine by using em- bedded device server 102 Dong-Hoon Kim, Sun-Ho Kim and Kwang-Sik Koh 5. Internet-Based Checking Method for OAC Machines In the case of the OAC, an additional device module for network support is not required, as the OAC has a convenient structure that can implement network application programs. To check and acquire machine I/O signal data, only a signal processing board or external DAU for data acquisition is needed. As most OAC is based on a single board computer with a compact ar- chitecture, a DAU that can simply Connect I/O signals is more efficient than the board type (Advantech, 2002). The application of a checking method that can notify the checking time and the replacement time of component parts was tried by monitoring of machining status, temperature, and vibration of component parts through the DAU. Through this application, the analog and digital contact points of CNC machines and peripheral units were monitored by using the DAU. In the experiment, an external I/O DAU module was used in order to reduce hardware device sizes and minimize the load. The Internet-based checking configuration using DAU for an OAC machine is shown in Fig. 6. RS485 communication was internally performed through RS232/485 con- version specification. A range of 0V to 1.5V was assigned and a sampling period was assigned as 10 times per second in order to acquire analog transferred values. For the experiment for acqui- ring bearing vibration and spindle temperature, 00007Analog Input Field (MS-SOL Server 7.0) ling SOL Links / ODBC Dtiv (Structured Quer Lan! OAC l!rrm I (PC-base Open Architecture Controller) -DAU (Data Acquisition Unit) . I Model NO: ADAM 4000 Sedes Prolor Digital Input 8 bit oooo coDe Sensors Analog Input 0-1,5V Range I Temperature Inspection I Fig. 9 Interface between OAC and application pro- gram of web sever tion programs, as shown in Fig. 10. Results show that this checking method is advantageous in that its convenient development environment in terms of software can easily implement user-defined application programs. 6. Scheme and Example of Internet- Based Checking for Variant CNC Machines The scheme for Internet-based checking for variant CNC machines is suggested in Fig. 11. The CAC machine area is designed to check digital data by using downloaded script codes and the I/O interface mechanism of the embedded . . . . Digital I a ElIbedded Web II0 Module . ; Closed ArcNter Controller ;._J PenttmCF;U Envlrot=lnent Open Achitecture Colltroller Environment Fig. 11 Internet-based checking environment for variant CNC machines . m o I Remote Digital Input Monitoring r ol Sam4 , : r o= sas Real DI Vals r ol s.r7 / ii r DISB / XH Status= = 0 O!LlCf Fig. 10 I Current AD ? Monitoring?) -Real D Values Checking for OAC machine by using DAU and application program Kill CAC Machine OAC Machine /M,ch,o,oo- ; ,o0 oit / elaine S