Theory and Design of CNC Systems Part 12 ppt

A General Communication Area is the area in shared memory where states, sitions, and control flags are exchanged between the IRP task and the IPO task.Emergency Stop, Axis Position, Erro

the requester retrieves the data generated by the requested service, an ment signal is transmitted to the receiver, and the process of accessing the sharedmemory is terminated.

acknowledge-In general, this method is used for safe sending of long data such as programfiles, system parameters, and PLC programs to the NCK/PLC modules from the MMImodule For example, in the case of file transfer between MMI and NCK, NCK sendsMMI a request asking to send a part program to MMI and then MMI transmits theprogram file to NCK via the shared memory

Write Answer

Acknowledge Read Answer

Request

Acknowledge

Recognize Interpret Request

Fig 10.12 Request/Answer method

The typical data structure of shared memory for communicating data in OperationMode can be realized as shown in Fig 10.13

10.3.5.1 Inter-task Communication in NCK

Data exchange between IPR, IPO, and POS tasks in the NCK module can be designed

by using shared memory, as shown in Fig 10.14

A General Communication Area is the area in shared memory where states, sitions, and control flags are exchanged between the IRP task and the IPO task.Emergency Stop, Axis Position, Error Handling Diagnosis, Debug Information, andWatchdog Information are transmitted via the General Communication Area

po-A Block Record Buffer is also defined, and is the area used for transmitting dataabout NC blocks to the IPO task, the IPR can only write the data to it, the IPO canonly read data from it It is defined as an area of shared memory and has a ring buffer

1

2

10 - 11

Active G-Code No (Group 1) Active G-Code No (Group 2)

Active Block No.

Fig 10.13 Typical data structure of shared memory

IPR - IPO communication area

POS - IPOcommunication area

IPO taskGeneral communication Block record buffer

Fig 10.14 Data exchange in NCK module

structure Interpolation Type, Start and End Position, Corrections, Axis components,Path Parameters, Path Velocity, Dwell time, and Spindle Information are stored inthe Block Record Buffer

The POS-IPO communication area is the area for exchanging data between theIPO task and the POS task It is defined in shared memory and Command Axis Po-sition, Spindle Output, Machine Position, Emergency Stop, Watchdog Information,and Error Message are exchanged via it

10.3.5.2 Communication Between NCK and MMI

Where the MMI and NCK/PLC modules operate on a single OS and single CPU,communication between MMI and NCK can be designed easily However, in the case

of a CNC system where the MMI and NCK modules operate on individual CPUs, abus interface and high-speed serial interface can be used for communication betweenmodules This configuration has a more complex communication mechanism thanSoft-NC Not only should the communication speed necessary for meeting the real-time requirements be considered but also reliability, communication distance, cost,extensibility, and robustness.

The Open System Interface (OSI) seven layers shown in Fig 10.15 has been ically used as the layer architecture for communication software However, the OSIseven-layer method is not appropriate in industry because it may not meet real-timerequirements So, to realize the high-speed communication between MMI and NCK,simplified layers are used based on three layers from among the seven layers of OSI.Field buses such as BACNET and PROFIBUS have been developed based on thesimplified layers

Deleted layers for real-time application

More Efficient, Faster Response, Lower overhead

Fig 10.15 Comparison between OSI 7 and Simplified Layers architectures

The communication software layer architecture to which the above 3-layer tecture is applied is shown in Fig 10.16 It consists of a Hardware Driver for acti-vating the Ethernet Controller and an Interface Level Driver for providing networkservices and interface with application software On the side of NCK, the commu-nication task is designed as application software based on real-time OS The com-munication task of MMI is designed as application software based on Windows 95.Therefore, on the side of MMI, the communication task can be designed easily by

archi-using an Ethernet driver for PC and Windows OS However, in the case of NCK, thecommunication task can be developed only when a real-time OS supports Ethernet.

Fig 10.16 Software layer for communication between MMI and NCK

To manage the communication data efficiently, it is necessary to define the datablock for assembling the related data in shared memory Having defined the blockfor communication data of MMI, as for the block for NCK, it is possible to developeasily application software for each module

10.4 Motion Control System Programming Example

In this section, the example of system programming for implementing a motion trol system in a real-time environment based on the NCK module detailed in Chap-ter 6 will be described As the development environment of the motion control sys-tem, PC hardware with INTEL processor, Windows NT, and RTX (VentureCom)were considered

con-The Acc/Dec-Control-Before-Interpolation-type NCK, which was implemented

in this section, consists of the Rough Interpolation task, the Acc/Dec control task,the Fine Interpolation task and Position Control tasks As mentioned above, it isnecessary not only to implement all tasks but also to execute them successfully forrealization of NCK For this, various API functions and techniques provided by RTXwere used for system programming This section shows only one example of de-signing NCK based on RTX and the system programming of NCK will be describedbased on the implemented code

10.4.1 Design of System Architecture

The implemented ADCAI-type NCK, as shown in Fig 10.17, is composed of mainfunction, timer handlers for the tasks of NCK, event server and handler for handlingthe instruction from MMI, and ring buffers for transmitting the data between tasks

Feed_Override event

Emergency_Stop

Feed_OverrideInterrupt

Fig 10.17 Sample architecture of ADCAI-type NCK

The main function is the function that is called first when the NCK boots up andperforms the following steps:

1 To initialize internal variables required for execution of NCK

2 To create the timer and timer’s handler for each task

3 To create the event server for handling the instruction from MMI

4 To create ring buffers for transmitting data between tasks

The timer handler is used for tasks that are iteratively activated every specifiedtime The event handler is used for handling aperiodic events

Because the rough and fine interpolation tasks, Acc/Dec control task, and positioncontrol task are performed periodically, as shown in Fig 10.17, they were realizedusing a timer MMI instructions, such as cycle start, emergency stop, and feed over-ride, were realized by an event handler (Note, because the emergency stop is a veryurgent instruction, it is realized by unique hardware interrupt This example is only

to show how to implement motion control.)

10.4.2 Creating Tasks

An individual timer for each task is created This timer activates iteratively particularhandler functions every specified time The following shows how to use the timer forcreating the Acc/Dec control task using RTX API

// *********************************************************** //// Description: Create Timer, set start time and period //

// *********************************************************** //hAccDec = RtCreateTimer(

NULL, // Security - NULL is none

0, // stack size - 0 is use default

DoAccDec, // Timer handler

P ACCDEC, // priority

CLOCK 2); // RTX HAL Timer

RtSetTimer(hAccDec, &Start time4, &RTPeriod);

As the function RtCreateTimer() shown in the above code is for generating atimer, it receives data about security option, the size of stack, the name of the timerhandler, priority, and the reference time as arguments “DoAccDec”, the third argu-ment, is the name of the timer handler function And P ACCDEC, the fifth argument,gives the priority of timer handler

It was mentioned that the latency time is the key performance index of RTOS

in Chapter 9 The average latency time of RTX is within some tens of μs (RTXversion 4.3 and P-III 866MHz) The maximum latency time does not exceed several

μs This means that the timer provided by RTX can be used to implement a taskwhose sampling time is 1 ms Actually, regardless of the assigned priority, there

is the non-interrupted job that hinders real-time tasks In the case of RTX, access(reading/writing) to the hard-disk driver belongs in this non-interrupted job category.Therefore, to guarantee the real-time property, it is essential to find a non-interrupted job and avoid executing it together with real-time tasks

10.4.3 Task Synchronization

In order to synchronize the execution of tasks, the start time and the sampling time

of each task must be properly decided The result of the rough interpolation task

is used as the input to the acc/dec control task Further, the result of the acc/deccontrol task is used as input to the fine interpolation task The result of the fineinterpolation task is used as the input to the position control task Therefore, therough interpolation task, acc/dec control task, fine interpolation task, and positioncontrol task must be started in that order This can be represented by Eq 10.1 In

Eq 10.1, T S RIPO , T S ACCDEC , T S FIPO , and T S POSmean the start times of the rough

interpolation task, acc/dec control task, fine interpolation task, and position controltask, respectively Moreover, A ¡ B denotes that task A starts before task B.

T S RIPO < TS ACCDEC < T S FIPO < T S POS (10.1)The implemented NCK can perform continuous mode machining In order toimplement continuous mode machining, the Acc/Dec control task requires the in-terpolation result from two previous blocks Therefore, the start time of the roughinterpolation task and the Acc/Dec control task can be represented as in Eq 10.2:

T S RIPO + 2 ∗ P RIPO < TS ACCDEC (10.2)

where, P RIPOmeans the sampling time (cyclic time) of the rough interpolation task.The fine interpolation task and the position control task were separately imple-mented Once the fine interpolation task has been performed, the position controltask is executed eight times (The sampling times of the fine interpolation task andthe position control task are set to 16 ms and 2 ms, respectively.) According to thedescription, above, the relationship between the sampling time and the start times oftasks is represented by Eq 10.3:

T S FIPO < T S POS < T S FIPO + P POS (10.3)The relationship shown in Eq 10.3 is because data transmission from the fine in-terpolation task to the position control task is done by shared memory instead of aring buffer In general, the ring buffer is used when the difference between the speed

of producing data and the speed of consuming it is not constant In the NCK ule, the data transition between the Acc/Dec control task and the fine interpolationtask is a good example of the use of the ring buffer Whenever the Acc/Dec controltask is carried out once, the Acc/Dec profile for one block is generated However,the fine interpolation task consumes one profile segment corresponding to one sam-pling time A single execution of the Acc/Dec control task generates data that thefine interpolation task can consume during several tens or several hundred time pe-riods Because the data consumption speed of the position control task and the dataproduction speed of the fine interpolation task are equal and fast data access speed isneeded, shared memory was used Because the usage of shared memory instead ofthe ring buffer makes the execution speed of the task predictable, the usage of sharedmemory has a positive influence on the reliability of the implemented NCK module.After the position control task consumes the whole result from the fine inter-polation task, the fine interpolation task interpolates the path segment (preciselyspeaking, the velocity profile) corresponding to the next sampling time According

mod-to Eqs 10.1, 10.2, and 10.3, the start time of tasks is specified as follows:

// ********************************************************** //// Description: Set start time and period for each timer //

// ********************************************************** //// Set reference time

RtGetClockTime(CLOCK 2, &Start time);

// Start rough IPO after 20 milliseconds.

Start time1.QuadPart = Start time.QuadPart + 200000;

// Start ACC/DEC after 54 milliseconds

Start time4.QuadPart = Start time.QuadPart + 200000 + 160000 +

160000 + 20000;

// Start fine IPO after 62 milliseconds

Start time3.QuadPart = Start time.QuadPart + 540000 + 80000;

// Start POS after 79 milliseconds

Start time2.QuadPart = Start time.QuadPart + 630000 + 160000;

// Set repeat for each timer

RTPeriod.QuadPart = 160000; // 16 msec

POSPeriod.QuadPart = 20000; // 2 msec

// Create rough timer and start

hRIPO = RtCreateTimer(

NULL, // Security - NULL is none

0, // stack size - 0 is use default

DoRIPO, // Timer handler

NULL, // NULL context

P RIPO, // priority

CLOCK 2); // RTX HAL Timer

RtSetTimer(hRIPO, &Start time1, &RTPeriod);

In the above example, RtGetClockTime() is the function to get the current timeand the time from RtGetClockTime() is used as the reference time (the referencetime is saved in the variable Start time.) The start time for each task is decided on byadding a particular time to the reference time For example, the rough interpolationtask starts after 20 ms from the reference time The position control task starts after

79 ms from the reference time 20 ms is the allowance time spent to set variablesand create the timer for the rough interpolation task The Acc/Dec control task startsafter the rough interpolation task has been executed twice and the allowance time, 2

The above was applied to the NCK implemented in this book Depending on theprogramming environment and algorithms, the description above varies

10.4.4 Task Priority

Priority is applied not only to a timer’s handler but also to an event handler

Equa-tion 10.4 denotes the priorities of tasks In Eq 10.4, PR RIPO , PR ACCDEC , PR FIPO, and

PR POSdenote the priorities of the rough interpolation task, the Acc/Dec control task,

the fine interpolation task, and the position control task, respectively PR ES means

the priority of the event for the emergency stop instruction PR MMI denotes the ority of the event for other instructions from the MMI except for the emergency stopinstruction

pri-In Eq 10.4, A < B denotes that the priority of task A is lower than that of task B And A <= B denotes that the priority of task A is less than or equal to that of task B.

PR MMI < PR RIPO <= PR ACCDEC < PR FIPO < PR POS < PR ES (10.4)

of consuming data by the fine interpolation task, memory may be used excessively.Excessive usage of the memory may reduce the performance of system To overcomethis problem, each task checks the number of items stored in the buffer If as manyitems exist as the specified number, the task does not work Using this method, thenumber of items does not exceed the specified size and the following code works like

a ring buffer

// *********************************************************** //// Description: Ring buffer structure and handling function //

// *********************************************************** //// Ring buffer structure for communication between IPR and rough IPO

typedef struct CRingIRTag{

int nGCode; // IPO type 0 : G00, 1 : G01, 2 : G02

Vector Start; // Start position (mm)

Vector Cen; // Center of circular IPO (mm)

float dRadius; // Radius of circular IPO (mm)

float dSpindle; // Spindle speed (RPM)

short int nSpindleDir; // CW: 1, CCW: 2, Stop: 0

int nStatus; // block status 0: start, 1: end

// /BLOCKOVERRAPMODEint nBlockNumber; // Index number of block

int nWorkingstepID; // Working step ID

BOOL IsProgramEnd; // TRUE: end of block, FALSE: under machiningstruct CRingIRTag* next;

} CRingIR;

// Head and tail of buffer

typedef struct CIRListTag

// ********************************************************** //void CIRList AddTail(CIRList* list, CRingIR* item)

{

item− >next = NULL;

if(list− >tail == NULL) {

list− >head = item;

list− >tail = item;

}

else{

list− >tail− >next = item;

list− >tail = item;

}

}

// ********************************************************** //// Description: Delete item structure at head of ring buffer //

// ********************************************************** //BOOL CIRList RemoveHead(CIRList* list)

temp = list− >head;

list− >head = list− >head− >next;

// ********************************************************** //void CIRList DeleteAll(CIRList* list)

mod-// ********************************************************** mod-//HANDLE hShm;

RtUnmapSharedMemory(locate); // Unmapping of created memory

RtCloseHandle(hShm); // Close handle of shared memory

When other processes or threads want to use the shared memory generated by theabove code, access to the shared memory is possible by using RtOpenSharedMem-ory() The function RtOpenSharedMemory() has the reason for the access to thememory, the name of the memory, and the variable for storing the memory’s virtualaddress as arguments In the example below, the first argument, SHM MAP WRITE,denotes that the shared memory is opened for writing some data The third argument

“StatusDBName” is the name of the shared memory The fourth argument, locate, isthe name of the variable for storing the memory address The second argument has nomeaning here and is ignored in the function The code below is to show that the posi-tion and velocity of an axis are written in the shared memory After using the sharedmemory, it is necessary to free the virtual address and the handler of the shared mem-ory by using RtUnmapSharedMemory() and RtCloseHandle() In the code below, thedata written in the shared memory is periodically read by MMI every specified timeinterval and is displayed

// *********************************************************** //// Description: Access the previous shared memory //

// *********************************************************** //hShm = RtOpenSharedMemory(SHM MAP WRITE, FALSE,

“StatusDBName”, &locate);

pStatus = (NC Status DB*)locate;

pStatus− >CommandX = CurPos X.dCommand;

pStatus− >CommandY = CurPos Y.dCommand;

pStatus− >CommandZ = CurPos Z.dCommand;

pStatus− >CurrentX = CurPos X.dGmOut;

pStatus− >CurrentY = CurPos Y.dGmOut;

pStatus− >CurrentZ = CurPos Z.dGmOut;

pStatus− >CurrentFeed = ActualFeed;

RtUnmapSharedMemory(locate);

RtCloseHandle(hShm);

10.4.6 Create Event Service

In general, shared memory is used for data transition between processes and an event

is used for sending the on/off signal The instructions for cycle start and emergencystop from MMI to NCK are examples of the usage of an event (Note that, in general,the on/off signal of switches is sent to PLC via a memory map The on/off signals ofswitches are written in a memory map and PLC checks the memory map iterativelyevery specified time period If PLC notes the change of a particular value in thememory map, PLC performs the corresponding task The memory map is used for

sending/receiving massive data amounts between hardware components (e.g., MMI

operation panel, NCK board, and PLC board) However, when the size of the data

is small and all components are implemented in software, an event may replace thememory map.)

Communication between the MMI operation switch and NCK/PLC was mented via an event The usage of an event makes it possible for NCK/PLC to re-spond quickly and handle MMI operation switch without delay It can reduce theburden for PLC or NCK to monitor a memory map iteratively The following codeshows an example for generating an event variable and a handler for handling thecycle start instruction

imple-// *********************************************************** imple-//// Description: Create Event //

// *********************************************************** //// Create event object

hStartEvent = RtCreateEvent(

NULL, //security attribute

FALSE, //manual reset

FALSE, //initial state

”NCKSTARTEVENT” //the event name

);

// Create thread to handle the event

hStartHandler = RtCreateThread(0, 0, StartHandler, NULL,

CREATE SUSPENDED, 0 );

// Priority assignment of thread

if (RtSetThreadPriority(hStartHandler, STARTPRIORITY) == FALSE)

a priority to the generated thread The fourth is to activate the thread RtCreateEvent()

is the RTX API function for creating an event variable (object) and receives the tification of the event object and initial status of the object as arguments “NCK-STRTEVENT”, the fourth argument, denotes the identification of the event objectand FALSE, the third argument, means that when the event object is created, it is innon-signal status

iden-RtCreateThread() is the function for creating a thread and it receives the threadhandler function and the initial status of the thread as arguments StartHandler, thethird argument, denotes the name of the handler function and the fifth argument,CREATE SUSPENDED, means that as soon as the thread is created, the handler

function is suspended The priority of the generated thread is specified by ThreadPriority() As arguments, RtSetThreadPriority() receives the handler of thefunction to which the priority is assigned and the priority that will be assigned Inthe example, hStartHandler denotes the handler of the function to which the priority

RtSet-is assigned and STARTPRIORITY means the priority After assigning the priority tothe handler function, the thread begins

The following is the thread handler for handling the cycle start instruction Thefollowing function is defined by RtCreateThread() As RtWaitForSingleObject() inthe code is the function to wait for that particular event object to be turned true(or on), it plays the role of temporarily stopping execution of the function RtWait-ForSingleObject() receives the handler of the awaited event and the awaited time asarguments In the code, hStartEvent denotes the handler of the awaited event andINFINITE means that RtWatForSingleObject() waits indefinitely for the event untilthe signal of the event is changed to true (or on)

// ********************************************************** //// Description: Handling “Cycle start” thread //

// ********************************************************** //// Function to handle ‘cycle start’ event

ULONG RTFCNDCL StartHandler(void * nContext)

{

DWORD dwEventReturn;

while(1){

// Wait until Cycle start button is pushed

dwEventReturn = RtWaitForSingleObject(hStartEvent, INFINITE);

Sim total count = 0;

in-// *********************************************************** in-//hStartEvent = RtOpenEvent(EVENT MODIFY STATE, TRUE,

in order to prevent their own technology from leaking out and keeping their marketshare.

However, after the middle of the 1980s, a new manufacturing paradigm, wherecomputer network and optimization techniques were applied to manufacturing sys-tems with the progress of computer technology, has appeared together with the re-quirement for advanced control functions for high-speed and high-accuracy machin-ing Closed CNC systems were not adequate for realizing the new manufacturingparadigm The architecture of closed CNC systems could not meet the user’s re-quirements and improvement of CNC systems was possible, not by MTB (MachineTool Builders) but CNC makers The limited resources of CNC makers made it im-possible to meet the new paradigm

Therefore, various efforts to develop open CNC systems have been tried As atypical result of these attempts, PC-NC that was introduced in the early 1990s LikeIBM PC technology, which appeared in the early 1980s, has progressed by third-party developments based on openness, CNC systems have progressed to PC-NCbased on the openness of PC technology However, now, despite low price, openness,and many developers of PC-NC, the lack of reliability and openness to applicationS/W has made it impossible to implement perfectly open systems

which provides the interface to enable a user to operate a machine, edit a part gram, communicate with external systems, and watch the status of the machine, andthe PLC function, which controls auxiliary functions such as tool change, spindlecontrol, and input/output signal control Details of these functions were introduced

pro-in previous chapters The architecture and functionality of a CNC system that is ically used on the shop floor are designed as shown in Fig 10.18

Analog/Digital Input/Output

Communication Interface (SERCOS, CAN bus)

Display Unit (CRT/LCD)

Key Matrix

PLC I/O MPG

System BUS

Module type

- Digital DI/DO

- Counter Module type

- Digital DI/DO

- Counter

- DA Converter CAN I.F Servo/Step Motor Drive I/O Link (CAN)

Fig 10.18 Architecture and functionality of a typical CNC system

A CNC system to execute MMI, NCK, PLC modules has a closed architecturethat has no way to communicate to a third party system Like the architecture of

a typical PC system the main CPU unit that carries out each module consists of amain processor, ROM for storing system programs, RAM for storing applications,

and keyboard and display unit for user interface These are connected using a systembus.

However, unlike a PC, a CNC system has analog/digital input/output devices forcommunication with the machine and communication interface In the past, in CNCsystems, communication between NC equipment and motors and drives was done

by analog signals and the communication interface was very simple Because of theproblem of noise, digital communication has now typically come to be used andSERCOS is a typical digital communication method With the usage of fiber opticalcable, digital communication makes the exchange of various data and the removal ofnoise possible Therefore, it is becoming possible that the CNC system adjusts theparameters of servo drives and motors directly and that the CNC system monitorsthe status of the servo system in real time Improvement of machining accuracy hasbecome possible due to the removal of noise In addition to communication with theservo system, digital communication has been applied to communication with in-put/output devices In order to enable communication with a variety of sensors andmachine components via a single communication line, a standardized communica-tion method is required For this, various kinds of field bus, such as Profi-bus, CANBus and InterBus-S, have been introduced, but one standard method has not yet beenestablished

Because of the closed nature of the architecture, users and MTBs (Machine ToolBuilders) cannot add some functions to the CNC system mentioned above or wouldhave to pay a lot of money to the CNC maker to add them From the position ofthe MTBs, though, this closed nature is a weapon for dominating the market Theproblems that users raised are summarized in Table 10.7 In order to meet the re-quirements of users, it is necessary to develop open systems where the functions can

be reconfigured and extended and standardized communication protocols, hardware,and interfaces are applied

10.5.2 Open CNC Systems

To overcome the drawbacks of the closed CNC system, an open CNC system hasbeen developed In this section, the concept, definition, and architecture of an openCNC system will be addressed

10.5.2.1 Target of Open-CNC Systems

As mentioned in the previous section, the closed architecture makes it difficult to addsensors for process monitoring or machine control Nor does it not provide flexibility

to adapt the CNC system to a variety of machines and a variety of purposes In tion, since in the closed architecture the scalability of the function and the standardinterface for exchanging the data with other systems are not provided, only one kind