Architecture for machining process and production monitoring based in open computer numerical control

This paper proposes an architecture for machining process and production monitoring to be applied in machine tools with open Computer numerical control (CNC). A brief description of the advantages of using open CNC for machining process and production monitoring is presented with an emphasis on the CNC architecture using a personal computer (PC)-based human-machine interface. The proposed architecture uses the CNC data and sensors to gather information about the machining process and production. It allows the development of different levels of monitoring systems with mininium investment, minimum need for sensor installation, and low intrusiveness to the process. Successful examples of the utilization of this architecture in a laboratory environment are briefly described. As a Conclusion, it is shown that a wide range of monitoring solutions can be implemented in production processes using the proposed architecture.

EGCL: an extended G-Code Language with flow control, functions and mnemonic variables

In the context of computer numerical control (CNC) and computer aided manufacturing (CAM), the capabilities of programming languages such as symbolic and intuitive programming, program portability and geometrical portfolio have special importance -- They allow to save time and to avoid errors during part programming and permit code re-usage -- Our updated literature review indicates that the current state of art presents voids in parametric programming, program portability and programming flexibility -- In response to this situation, this article presents a compiler implementation for EGCL (Extended G-code Language), a new, enriched CNC programming language which allows the use of descriptive variable names, geometrical functions and flow-control statements (if-then-else, while) -- Our compiler produces low-level generic, elementary ISO-compliant Gcode, thus allowing for flexibility in the choice of the executing CNC machine and in portability -- Our results show that readable variable names and flow control statements allow a simplified and intuitive part programming and permit re-usage of the programs -- Future work includes allowing the programmer to define own functions in terms of EGCL, in contrast to the current status of having them as library built-in functions

Arte reversa: aplicando a engenharia reversa na arte

This study aimed to examine the reverse engineering and respond to a concern about the possible application of this concept in art, breaking down barriers and breaking paradigms. Using 3D scanning, the art of computer aided design and manufacturing – CAD/CAM, machining by computer numerical control - CNC, engineering, and applying this methodology in the arts especially in sculpture, it is possible to dematerialize a artwork, virtualizes it in 3D programs, make speeches, and process a new work, a new art elsewhere. By the example of surgeries at a distance, the artist, or technical author could produce their works, and materialize them anywhere. In other words, do the reverse gear. It discusses the relationship between art and technology, the role of the author, the viewer, which can interfere with the interactivity that case by stating that art, exists only in the look and feel of the viewer.

Self-tuning algorithm for dsp-based motion control in cnc applications

This thesis describes the development of an adaptive control algorithm for Computerized Numerical Control (CNC) machines implemented in a multi-axis motion control board based on the TMS320C31 DSP chip. The adaptive process involves two stages: Plant Modeling and Inverse Control Application. The first stage builds a non-recursive model of the CNC system (plant) using the Least-Mean-Square (LMS) algorithm. The second stage consists of the definition of a recursive structure (the controller) that implements an inverse model of the plant by using the coefficients of the model in an algorithm called Forward-Time Calculation (FTC). In this way, when the inverse controller is implemented in series with the plant, it will pre-compensate for the modification that the original plant introduces in the input signal. The performance of this solution was verified at three different levels: Software simulation, implementation in a set of isolated motor-encoder pairs and implementation in a real CNC machine. The use of the adaptive inverse controller effectively improved the step response of the system in all three levels. In the simulation, an ideal response was obtained. In the motor-encoder test, the rise time was reduced by as much as 80%, without overshoot, in some cases. Even with the larger mass of the actual CNC machine, decrease of the rise time and elimination of the overshoot were obtained in most cases. These results lead to the conclusion that the adaptive inverse controller is a viable approach to position control in CNC machinery.

Máquina-ferramenta CNC para gravação: desenvolvimento de protótipo de baixo-custo

Dissertação de mestrado em Engenharia Mecatrónica

Difusão de tecnologia CAD e CNC como ferramenta básica de criação e produção em pequena escala, acessível à comunidade

The high competitiveness and the search for newtechnologies that differentiate the product from the project,require the use of new digital tools. The computer aideddesign - Computed Aided Design (CAD), with electronicmodeling, simulation, structural analysis and production,performed in a virtual environment through the applicationof specific software, are available but their use is stilllimited. There are various software available in languagesand extensions to industrial production which, from 3Dmodeling, they can manage through Computer NumericalControl - Computed Numerical Control (CNC) machiningcenters, laminating, stamping, mold making and otherprocesses productive. This project aims to encouragecreativity and entrepreneurship in the community throughthe provision of technology computer aided design - CAD,with a view to implementation of machining technology.

Mechanistic approach to predict real machining time for milling free-form geometries applying high feed rate

An accurate estimate of machining time is very important for predicting delivery time, manufacturing costs, and also to help production process planning. Most commercial CAM software systems estimate the machining time in milling operations simply by dividing the entire tool path length by the programmed feed rate. This time estimate differs drastically from the real process time because the feed rate is not always constant due to machine and computer numerical controlled (CNC) limitations. This study presents a practical mechanistic method for milling time estimation when machining free-form geometries. The method considers a variable called machine response time (MRT) which characterizes the real CNC machine`s capacity to move in high feed rates in free-form geometries. MRT is a global performance feature which can be obtained for any type of CNC machine configuration by carrying out a simple test. For validating the methodology, a workpiece was used to generate NC programs for five different types of CNC machines. A practical industrial case study was also carried out to validate the method. The results indicated that MRT, and consequently, the real machining time, depends on the CNC machine`s potential: furthermore, the greater MRT, the larger the difference between predicted milling time and real milling time. The proposed method achieved an error range from 0.3% to 12% of the real machining time, whereas the CAM estimation achieved from 211% to 1244% error. The MRT-based process is also suggested as an instrument for helping in machine tool benchmarking.

Brain computer interface control via functional connectivity dynamics

The dynamics of inter-regional communication within the brain during cognitive processing – referred to as functional connectivity – are investigated as a control feature for a brain computer interface. EMDPL is used to map phase synchronization levels between all channel pair combinations in the EEG. This results in complex networks of channel connectivity at all time–frequency locations. The mean clustering coefficient is then used as a descriptive feature encapsulating information about inter-channel connectivity. Hidden Markov models are applied to characterize and classify dynamics of the resulting complex networks. Highly accurate levels of classification are achieved when this technique is applied to classify EEG recorded during real and imagined single finger taps. These results are compared to traditional features used in the classification of a finger tap BCI demonstrating that functional connectivity dynamics provide additional information and improved BCI control accuracies.

Análise do processo de fresamento de MDF em centro de usinagem CNC

Pós-graduação em Engenharia Mecânica - FEG

A Survey on FPGA-Based Sensor Systems: Towards Intelligent and Reconfigurable Low-Power Sensors for Computer Vision, Control and Signal Processing

The current trend in the evolution of sensor systems seeks ways to provide more accuracy and resolution, while at the same time decreasing the size and power consumption. The use of Field Programmable Gate Arrays (FPGAs) provides specific reprogrammable hardware technology that can be properly exploited to obtain a reconfigurable sensor system. This adaptation capability enables the implementation of complex applications using the partial reconfigurability at a very low-power consumption. For highly demanding tasks FPGAs have been favored due to the high efficiency provided by their architectural flexibility (parallelism, on-chip memory, etc.), reconfigurability and superb performance in the development of algorithms. FPGAs have improved the performance of sensor systems and have triggered a clear increase in their use in new fields of application. A new generation of smarter, reconfigurable and lower power consumption sensors is being developed in Spain based on FPGAs. In this paper, a review of these developments is presented, describing as well the FPGA technologies employed by the different research groups and providing an overview of future research within this field.

Dynamic visual servo control of a 4-axis joint tool to track image trajectories during machining complex shapes

A large part of the new generation of computer numerical control systems has adopted an architecture based on robotic systems. This architecture improves the implementation of many manufacturing processes in terms of flexibility, efficiency, accuracy and velocity. This paper presents a 4-axis robot tool based on a joint structure whose primary use is to perform complex machining shapes in some non-contact processes. A new dynamic visual controller is proposed in order to control the 4-axis joint structure, where image information is used in the control loop to guide the robot tool in the machining task. In addition, this controller eliminates the chaotic joint behavior which appears during tracking of the quasi-repetitive trajectories required in machining processes. Moreover, this robot tool can be coupled to a manipulator robot in order to form a multi-robot platform for complex manufacturing tasks. Therefore, the robot tool could perform a machining task using a piece grasped from the workspace by a manipulator robot. This manipulator robot could be guided by using visual information given by the robot tool, thereby obtaining an intelligent multi-robot platform controlled by only one camera.

Signal processing and information fusing algorithms for the synthesis of an alternative electromyogram/eye gaze tracking computer cursor control system

This research pursued the conceptualization and real-time verification of a system that allows a computer user to control the cursor of a computer interface without using his/her hands. The target user groups for this system are individuals who are unable to use their hands due to spinal dysfunction or other afflictions, and individuals who must use their hands for higher priority tasks while still requiring interaction with a computer. ^ The system receives two forms of input from the user: Electromyogram (EMG) signals from muscles in the face and point-of-gaze coordinates produced by an Eye Gaze Tracking (EGT) system. In order to produce reliable cursor control from the two forms of user input, the development of this EMG/EGT system addressed three key requirements: an algorithm was created to accurately translate EMG signals due to facial movements into cursor actions, a separate algorithm was created that recognized an eye gaze fixation and provided an estimate of the associated eye gaze position, and an information fusion protocol was devised to efficiently integrate the outputs of these algorithms. ^ Experiments were conducted to compare the performance of EMG/EGT cursor control to EGT-only control and mouse control. These experiments took the form of two different types of point-and-click trials. The data produced by these experiments were evaluated using statistical analysis, Fitts' Law analysis and target re-entry (TRE) analysis. ^ The experimental results revealed that though EMG/EGT control was slower than EGT-only and mouse control, it provided effective hands-free control of the cursor without a spatial accuracy limitation, and it also facilitated a reliable click operation. This combination of qualities is not possessed by either EGT-only or mouse control, making EMG/EGT cursor control a unique and practical alternative for a user's cursor control needs. ^

HaptOSM – Creating tactile maps for the blind and visually impaired

This paper describes the latest accomplishments on the current research that is based on the master’s thesis “Ein System zur Erstellung taktiler Karten für blinde und sehbehinderte Menschen” (German for “A system creating tactile maps for blind and visually impaired people”) (Hänßgen, 2012). The system consists of two parts. The first part is new software especially designed and developed for creating tactile maps addressing the needs of blind and visually impaired people on tactile information. The second is an embossing device based on a modified CNC (computer numerical control) router. By using OpenStreetMap-data, the developed system is capable of embossing tactile maps into Braille paper and writing film.