SRI KRISHNA COLLEGE OF ENGINEERING AND TECHNOLOGY

DEPARTMENT OF MECHATRONICS ENGINEERING

MODULE 1
Session: Tutorial on NC systems and its
applications

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Problem 1
The worktable of a positioning system is driven by a leadscrew whose pitch is
6mm. The leadscrew is connected to the o/p shaft of a stepper motor through a
gearbox whose ratio is 5:1. The stepper motor has 48 step angles. The table must
move a distance of 250mm from its present position with a linear velocity =
500mm/min. Determine
a) how many pulses are required to move the table the specified distance and
b) the required motor speed and pulse rate to achieve the desired table velocity.

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Problem 2
Two stepping motors are used in an open loop system to drive the lead screws for
x-y positioning. The range of each axis is 500 mm. The shafts of the motors are
connected directly to the lead screws. The pitch of each lead screw is 3.0 mm, and
the number of step angles on the stepping motor is 125.
(a) How closely can the position of the table be controlled, assuming there are no
mechanical errors in the positioning system?
(b) What are the required pulse train frequencies and corresponding rotational
speeds of each stepping motor in order to drive the table at 275 mm/min in a
straight line from point (x = 0, y = 0) to point (x = 130 mm, y = 220 mm)?

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 Problem 3
A component insertion machine takes 2.0 sec to put a component into a printed
circuit (PC) board, once the board has been positioned under the insertion head.
The x-y table that positions the PC board uses a stepper motor directly linked to a
lead screw for each axis. The lead screw has a pitch = 5.0 mm. The motor step
angle = 7.2 degrees and the pulse train frequency = 400 Hz. Two components are
placed on the PC board, one each at positions (25, 25) and (50, 150), where
coordinates = mm. The sequence of positions is (0,0), (25, 25), (50, 150), (0,0).
Time required to unload the completed board and load the next blank onto the
machine table = 5.0 sec. Assume that 0.25 sec. is lost due to acceleration and
deceleration on each move. What is the hourly production rate for this PC board?

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Problem 4
An NC worktable operates by closed loop positioning. The system consists of a
servo motor, leadscrew and optical encoder. The leadscrew has a pitch of 6mm
and is coupled to a motor shaft with a gear ratio of 5:1. The optical encoder
generates 48 pulses/rev of its output shaft. The table must move a distance of
250mm from its present position with a feed rate of = 500mm/min. Determine
a) how many pulses should be received by the control system to verify that the
table has moved exactly 250mm
b) pulse rate of the encoder
c) the drive motor speed that correspond to the specified feed rate.

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Problem 5
A milling operation is performed on a NC machining center. Total travel distance =
300 mm in a direction parallel to one of the axes of the worktable. Cutting speed =
1.25 m/s and chip load = 0.05 mm. The end milling cutter has four teeth and its
diameter = 20.0 mm. The axis uses a dc servomotor whose output shaft is coupled
to a lead screw with pitch = 6.0 mm. The feedback sensing device is an optical
encoder which emits 250 pulses per revolution. Determine
(a) feed rate and time to complete the cut,
(b) rotational speed of the motor and
(c) Pulse rate of the encoder at the feed rate indicated.

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Problem 6
Mechanical inaccuracies in the open-loop positioning system are described with
standard deviation 𝜎=0.005mm. The range of the worktable axis is 1000mm and
there are 16bits in the binary register used by the digital controller to store the
position. Other relevant parameters are ; pitch p = 6mm, gear ratio = 5:1, no. of
step angles in the motor = 48. Determine the
a) Control resolution
b) The accuracy
c) The repeatability of the system

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Problem 7
The positioning table for a component insertion machine uses a stepping motor
and lead screw mechanism. The design specifications require a table speed of 0.5
m/s and an accuracy = 0.02 mm. The pitch of the lead screw = 6.0 mm, and the
gear ratio = 2:1 (2 turns of the motor for each turn of the lead screw). The
mechanical errors in the motor, gear box, lead screw, and table connection are
characterized by a normal distribution with standard deviation = 0.0025 mm.
Determine
(a) the minimum number of step angles in the stepping motor and
(b) frequency of the pulse train required to drive the table at the desired maximum
speed.

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Problem 8
A machinable grade of aluminum is to be milled on an NC machine with a 20 mm
diameter four-tooth end milling cutter. Cutting speed = 120 m/min and feed = 0.008
mm/tooth. Convert these values to rev/min and mm/rev, respectively.

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Problem 9
A turning operation is to be performed on an NC lathe. Cutting speed = 2.5 m/s,
feed = 0.2 mm/rev, and depth = 4.0 mm. Workpiece diameter = 100 mm and its
length = 400 mm. Determine
a) rotational speed of the workbar,
b) feed rate,
c) metal removal rate, and
d) time to travel from one end of the part to the other.

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Problem 10
The two axes of an x-y positioning table are each driven by a stepping motor
connected to a lead screw with a 10:1 gear reduction. The number of step angles
on each stepping motor is 20. Each lead screw has a pitch = 4.5mm and provides
an axis range = 300 mm. There are 16 bits in each binary register used by the
controller to store position data for the two axes.
a) What is the control resolution of each axis?
b) What are the required rotational speeds and corresponding pulse train
frequencies of each stepping motor in order to drive the table at 500 mm/min
in a straight line from point (30,30) to point (100,200)? Ignore acceleration and
deceleration.

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 END

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