Rotary to linear

Axis Drive System

Feed drive System
Ball screw / ball bearing screw / recirculating
ball screw Mechanism
• It consists of a screw spindle, a nut, balls and integrated ball return
mechanism
• The flanged nut is attached to the moving part of CNC machine tool.
• As the screw rotates, the nut translates the moving part along the guide ways
• High mechanical efficiency In ball screws, about 90% or more of the force
used to rotate the screw shaft can be converted to the force to move the ball
nut. Since friction loss is extremely low, the amount of force used to rotate the
screw shaft is as low as one third of that needed for the acme thread lead
screw.
• Low in wear Because of rolling contact, wear is less than that of sliding
contact. Thus, the accuracy is high. Ball screws move smoothly enough under
very slow speed. They run smoothly even under a load.
Ball screw fixing
 Driving Speed and Critical Speed

Driving Speed

Product of nominal diameter of the ball screw (in

mm) times the maximum allowable speed (in rpm).
 Belts
• Round belts
• Round belts are generally made of rubber. This type of belt is generally used for light loads,
such as in a sewing machine or a vacuum cleaner.
• V belts
• V belts are arguably the most widely used belts in industry. V belts have a V shaped
cross-section, which rests against the side of V pulley under tension. The V shaped
cross-section prevents belt from slipping off.
• Flat belts
• Flat belts are also used to transmit power from one shaft to another. They are generally
classified as either small woven endless belts or higher power flat belts. The woven endless
belts are especially useful where minimum vibration is required at the driven pulley due to
semi-elastic material used in construction. The higher power flat belts are often useful
because they eliminate the need to high belt tension used to grip pulleys, which in turn
reduces the load on the shaft bearings.
Timing/toothed belts
• Timing belts are toothed belts that use their teeth for power transmission, as
opposed to friction. This configuration results in no slippage, and therefore,
the driving and driven shafts remain synchronized. It’s more expensive to
manufacture due to complexity of the belt and pulley shapes.
CHOOSING A TIMING BELT PULLEY

• ENVIRONMENTAL CONSIDERATIONS
• SIZING CONSIDERATIONS
• MATERIAL CONSIDERATIONS
 Couplings

• Coupling is a component used to connect a drive shaft and a driven part,

for example, a motor shaft and a ball screw for the purpose of transmitting
the torque.
• Also, Coupling introduces mechanical flexibility providing misalignment for
the shafts. As a result, this coupling flexibility can prevent uneven wear,
vibration, and other mechanical troubles due to misalignment.
The main roles of a coupling include the following:

• Connecting drive shafts of motors, etc. with driven shafts of ball screws etc. to
transmit power.
Providing tolerance for mounting errors (misalignment) between the drive shaft and
the driven shaft

• The offset between the cores of the

driving shaft and the driven shaft is
called misalignment. There are three
different types of misalignment:
lateral, angular, and axial.
• These should be minimized in order
to avoid equipment issues such as
vibration, noise, uneven wear on the
bearing and so on.
Absorbing equipment impacts and vibration
• Jaw type couplings have elastic bodies such as elastomer built in as an
intermediate component to absorb impacts and vibration
Improving equipment performance

• Depending on the type of coupling, it can

also work to improve equipment
performance in addition to the roles
described so far.
One example is "High-Gain Rubber
Type " using high-gain integrally molded
rubber which suppresses servomotor
hunting and improves limit gain, thus
reducing settling time and improving
productivity.
Disk Type
• The flexibility of disc (metal spring) allows misalignments
Jaw Type

• Resin sleeve placed in the middle of the structure provides

cushioning that damps vibration and absorbs shock
Slit Type

• Slitting metal cylinders gives the flexibility to accommodate

varying degrees of misalignments.
Oldham Type

• Sliding of the spacer in the midportion accommodates larger

misalignments.
• Less reaction force contributes to reduction of loads to bearings
or other mechanical components.
• Separable components enable easy assembling.
Cross Joint Type

• Sliding motion of pins and bushes accommodates

misalignments.
Less eccentricity reaction force contributes to reduction of loads
to bearings or other mechanical components.
Rigid Type

• Simply structured coupling without flexibility. High torsional

rigidity
Bellows Type

• Metal bellows accommodate misalignments.

Reliability of constant rotation velocity makes this series the
best choice for encoders.
Serration Type

• Low Cost. Separatable components enable easy assembling

Servosystems
Servo system Fanuc
Analog Vs Digital servo drives
MOTOR SELECTION’s
Why Servo Motors are Used in CNC Machines

• Quality parts start with the machine tool’s motor. Servo motors are
the choice for axes motion control in machine tools built for
high-speed, high-precision work. Factors like superior torque,
high-resolution movement and feedback, and stability help avoid
results like poor surface finish, accelerated tool wear and out-of-spec
contouring.
• 1. The Ability to Use Encoders
• Rotary and angle encoders for servo drives provide detailed and
precision feedback to the control with thousands of times higher
resolution than what’s possible with stepper motors. Absolute and
incremental-style encoders both not only allow for the precise
control motion and speed that’s required of today’s multi-axis
machinery and intricate part geometries, they provide operators with
better visibility to how the operation is performing.
• 2. Superior Load Control
• Servo motors are available in a wide range of configurations, sizes
and capabilities. This makes it possible to find the ideal rigidity match
for the size and load of any machine tool. This is important because
the inertia ratio between the motor and the load is critical to
maintaining position accuracy during reversals and resisting vibration
in heavy cutting milling applications
• 3. Managed Acceleration
• When it comes to accelerating a table or spindle, the relationship
between torque and inertia in the motor itself is a critical one.
Because of their superior capabilities, servo motors offer more
combinations of torque and the motor’s own inertia that allow
builders to dial in acceleration capabilities as needed.
• 4. Controlled Torque Ripple
• Servo motors that are optimized for machine tools limit the
disturbances they themselves can introduce into a machining
operation. Motor torque invariably fluctuates during a revolution of
the shaft, but the right servo motor can limit the influence this has on
the part, namely contouring errors and shaded finishes.
Servo Motor Detail

Actuator

Reduction gear

Position feedback
Potentiometer
(closed loop system)

Small electric DC motor

Industrial Servomotors

High Speed Spindle

(Siemens) DSD Servo
(Baumüller)
High Torque Motor
(Baumüller) Spindle Motor
(Franz Kessler)
DC Servomotor
AC Servomotors - Induction

This is the stator of an induction AC servo, the

winding must have a 90ᵒ phase difference
AC Servomotor - Synchronous
• Also known as brushless servo, the rotor has a permanent magnet
which rotates by a magnetic field created in the stator at synchronous
speed. It has the same stator as the induction AC servo
Servo Control
Servo tuning

• Tuning a servo system involves adjusting the gains in the motion

controller to minimize the servo system’s response time, settling time,
and overshoot
• The goal of servo tuning is to minimize (but not necessarily eliminate)
the error between the commanded position (or speed or torque) and the
actual value achieved
The most common type of control loop, or algorithm, used for servo tuning is a PID loop,
where “P” refers to proportional gain,
“I” refers to integral gain, and
“D” refers to derivative gain.
A gain is essentially a ratio of output to input, and in a servo control loop, the gains determine how — and to what
extent — the controller tries to correct the errors detected by the feedback device.
P Gain
• The amount of proportional gain in the control loop determines how
much restoring force is applied to overcome the error between the
commanded value and the actual value. The proportional gain is
multiplied by the error and generates the contribution to the output for
the next time period. The term “proportional” is used because the
amount of restoring force is directly proportional to the amount of
error at any instant in time
I Gain
• Integral gain is used to “push” the system to zero error at the end of
the move
• The integral gain value increases with time — hence, the term
“integral.” However, because the integral gain increases at the end of
the move, it can cause the system to overshoot or oscillate. And if the
integral gain is too low, the system will have a slow response time.
Integral gain is primarily used when the system is subjected to static
torque loads
D Gain
• Derivative gain is proportional to the rate of change (the derivative) of
the error. It’s often used in conjunction with proportional gain to
reduce overshoot and provide damping. But a derivative gain that is
too high can reduce system response time and cause oscillations
Feed-forward gains for highly dynamic
applications
• The PID gains described above are reactive corrections to the system’s
behavior over time. For highly dynamic applications, or for better
responsiveness, another type of gain — referred to as feed-forward
gain — works outside the feedback loop and provides a proactive
approach to error correction by predicting the commands needed to
achieve zero error (rather than waiting for the error to develop)
• Feed-forward gains are classified as either velocity feed-forward or
acceleration feed-forward
• Velocity feed-forward works during the constant velocity portion of
the move profile. It minimizes following error and improves response
time by multiplying the derivative of the position command (i.e. the
velocity) by the velocity feed-forward gain value.

• Acceleration feed-forward works during the acceleration and

deceleration portions of the move and can eliminate overshoot
caused by velocity feed-forward. Acceleration feed-forward multiplies
the second derivative of the position command (i.e. the acceleration)
by the acceleration feed-forward gain value.
• Velocity controller tuning means finding the correct drive settings and
feedback gain values to achieve a proper Servo stiffness and response
to a velocity setpoint change.
• Position controller tuning means finding the correct drive
settings and feedback gain values to achieve a proper Servo
stiffness and response to a position setpoint change.
• Torque controller tuning means finding the correct gain values
for a torque controller inside the servo drive to achieve a proper
response from a torque setpoint change.
Stepper Motors

Stepper motors are inherently open-loop devices.

They don’t require feedback because each pulse of current
delivered by the drive equals one step of the motor (or a fraction
of a step in the case of microstepping).
Plus with small step sizes (or step angles) the motor’s position can
be determined very precisely without the need for a feedback
device and complicated control schemes.
Step-loss compensation: Reactive position
correction at the end of the move
• The most common type of closed-loop stepper system is based on
step-loss compensation, also referred to as step-loss control or stepper
position maintenance. In this setup, the drive operates in micro -
stepping mode, and an encoder tracks the shaft (or load) position
• If lost steps are detected, based on the commanded position (number
of steps multiplied by step angle) versus the actual position read by the
encoder, the controller commands additional steps so the motor (or
load) reaches the desired position.
Load position control: Continuous, real-time
position correction without complex controls
• Load position control, also referred to as closed-loop microstepping,
continuously monitors the shaft (or load) position and generates an
error signal. The controller uses this error signal to adjust the
commands in real-time, during the entire move profile
• With load position control, the system still operates as a stepper
system in microstepping mode, but the move profile is more precisely
followed, rather than allowing the motor to deviate during the move
and issuing a single position compensation command at the end of the
move
Servo control: Complete control of torque and
position
• The most advanced closed-loop stepper control method is to operate
the motor as a two-phase brushless motor. This method is referred to
as servo stepper or closed-loop stepper control
• With servo control for stepper motors, instead of the drive providing
full current to the motor to produce movement, feedback from an
encoder detects the shaft position, and a control loop (typically a PID
loop) determines the exact torque needed for the shaft to follow the
move profile. In other words, the motor is driven by a torque
command rather than by pulses of current
Because it delivers only the current required to achieve the move profile, the servo control method yields greater
efficiency than other stepper control methods.
And greater efficiency means less heat and longer motor life. Servo control also eliminates resonance issues that
plague other control methods, provides high torque at low speeds, and allows the motor to use its full rated torque
without the limitations of pullout torque.
And although more complex than an open-loop system, implementing servo control for a stepper motor is still less
demanding than implementing a full servo system.
 Servo Vs Stepper

In general, servo motors are the better choice for applications

that require precise and accurate positioning, high speeds,
and/or the ability to withstand changing loads (especially those
that might require higher than the rated motor torque). For
applications that don’t require position feedback and that
operate solely within the design limits of the motor, stepper
motors provide a simpler, more cost-effective solution.
 Typical Machine Tool

feed drives
feed drives
control the position
control thebetween
position between
working piece andpiece
working working
and working
tool tool

main drives
main drives
provide provide
processing power power
processing
 Characteristics of Servo Drives
Feed drives high maximum torque

high efficiency constant maximum torque

axis
small size speed range < 10 000 rpm

rated power < 20 kW

smooth
Spindle drives operation high rated/continuous torque
at low speeds
constant maximum power
main 4 quadrant
speed range < 20 000 rpm
operation
rated power < 100 kW
Desired Spindle Power, Peak and Continuous
Maximum Spindle Load, Axial and Radial
Maximum Spindle
Speed Allowed
Tooling Style, Size and Capacity for ATC
Belt Driven or Integral Motor-Spindle Design

The major components required for a high speed milling spindle design include:

Spindle Style; Belt Driven or Integral Motor-Spindle

Spindle Bearings; Type, Quantity, Mounting, and Lubrication Method
Spindle Motor, Belt-Type, Motor-Spindle, Capacity, Size
Spindle Shaft; Including Tool Retention Drawbar and Tooling System Used
Spindle Housing; Size, Mounting Style, Capacity
DC Shunt motor Drive

Speed Control of DC Shunt Motor

The classification of speed control methods for a DC shunt
motor are similar to those of a DC series motor. These two
methods are:
Armature Control Methods
Field Control Methods
3 Phase AC Induction Motor
AC Spindle Drive
Control Switches
Control Switches
MCCB PRODUCT DETAILS

Brand: L&T Switchgear

Model: DU
Types: DU125D
No. of Poles: 3
Breaking Capacity (kA): 18kA
Rated Current (A): 32-40 A

The Molded Case Circuit Breaker is another type of electrical protection device
₹4,158 that is used when the load current exceeds the limit.
The molded case circuit breaker also provides protection against short circuit
faults, overloads and it can also be used for switching circuits.
Main components
1.GRID UNIT: The arc generated between contact is
extended, it divides and cools, and current is intercepted
certainly.
2. CONTACT: It consists of a fixed contact and a movable
point of contact, and "ON" and "OFF" of the electricity are
carried out.
3. SWITCHING MECHANISM: The mechanism in which each
pole opens and closes contact simultaneously.
4. BASE AND COVER: The synthetic resin cast which has the
intensity and heat resistance which bear the internal
pressure of interception, and arc-proof is used.
5. TERMINAL: It is the portion which connects external
conductor.
6. OVERLOAD TRIP DEVICE: Overload current and earth
leakage current are detected, and a breaker style is
operated.
7. HANDLE: It is equipment which performs
opening-and-closing operation.
8. TRIP BUTTON: It is the button which trips a breaker from
the exterior mechanically.
MCCB SIZING

Molded case circuit breaker sizing is always carried out according to the
expected operating current of the application, as well as the possible fault
currents. The main aspects to consider when selecting an MCCB are the
following:

• The rated working voltage of the MCCB must match the system voltage of
the application.
• The MCCB must be adjustable to the adequate trip value, calculated
according to the current drawn by the load.
• The operating breaking capacity of the MCCB must be higher than the
expected fault currents in the system.
Types of MCCB
• According to the tripping types, the MCCB is divided into six categories.

• TypeB: They are operating at the fault current reaches 3 to 5 times the full load current. It is used for domestic
applications such as resistive load, lighting loads, etc. The available operating time of this beaker is 0.04 to 15 seconds

• TypeC: Type C breaker specially used for inductive loads, such as transformers, welding machines, electromagnets etc. it
has an operating range of 5 to 8 times the full load current with the time delay of 0.04 to 5seconds.

• TypeD: Suitable for heavy starting current applications such as motors, pumps, lifts, etc. It has an operating range of 10 to
15 times with the time duration of 0.04 to 3 seconds

• TypeK: Operates when the current goes to 8 to 10 times its full load current. Operating time for type K MCCB is 0.04 to 5
Seconds. They are the best suitable feeder protection.
• TypeZ: Type Z MCCBs are very sensitive and they can able to allow 1.5 to 3 times the full load current. Type Z is suitable
for electronics load, whereas high-speed tripping required.
MCB
 Tripping Mechanism
Tripping Mechanism
Thermal Tripping Thermal Tripping
Magnetic tripping.
Magnetic tripping.
Types of MCB
Type B
Type C
Type D
Type K

1.Actuator lever – used to manually trip and reset the circuit breaker. Also indicates the status of the circuit breaker (On or
Off/tripped).
2. Actuator mechanism – forces the contacts together or apart.
3. Contacts – allow current when touching and break the current when moved apart.
4. Terminals
5. Bimetallic strip – separates contacts in response to smaller, longer-term overcurrents
6. Calibration screw – allows the manufacturer to precisely adjust the trip current of the device after assembly.
7. Solenoid – separates contacts rapidly in response to high overcurrents
8. Arc divider/extinguisher
Limit switches
Pressure switches
• A pressure switch for sensing fluid pressure contains a capsule,
bellows, Bourdon tube, diaphragm or piston element that deforms or
displaces proportionally to the applied pressure. The resulting motion
is applied, either directly or through amplifying levers, to a set of
switch contacts.
Float Switch