Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application

In precision machining, various classical and advanced feedback position controllers such as cascade, proportional-integral-derivative, and sliding mode controllers have been developed with the aim to meet the precision requirements of the machine tool controller. To-date, most of these position con...

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Main Author:	Mat Seman., Norhidayah
Format:	Thesis
Language:	English English
Published:	2019
Subjects:	T Technology (General) TJ Mechanical engineering and machinery
Online Access:	http://eprints.utem.edu.my/id/eprint/24677/1/Integration%20Of%20G-Code%20With%20Position%20Controller%20Via%20Interpreter%20Design%20Using%20MATLAB%20For%20Milling%20Machine%20Application.pdf http://eprints.utem.edu.my/id/eprint/24677/2/Integration%20Of%20G-Code%20With%20Position%20Controller%20Via%20Interpreter%20Design%20Using%20MATLAB%20For%20Milling%20Machine%20Application.pdf
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id	my-utem-ep.24677
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Jamaludin, Zamberi
topic	T Technology (General) TJ Mechanical engineering and machinery
spellingShingle	T Technology (General) TJ Mechanical engineering and machinery Mat Seman., Norhidayah Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application
description	In precision machining, various classical and advanced feedback position controllers such as cascade, proportional-integral-derivative, and sliding mode controllers have been developed with the aim to meet the precision requirements of the machine tool controller. To-date, most of these position controllers are not well utilized in commercial CNC machine tools. This is due to the limitation of the input reference applied for the position controller structure. Commonly, input reference signals such as step, ramp, sinusoidal, and other waveforms are utilized in testing and verifying the efficiency and performance in design process of position controllers. In most cases, the position controllers rarely utilize geometrical drawing such as CAD/CAM trajectory as input reference without extensive programming or trajectory generation algorithm. Thus, this thesis aims to integrate directly the trajectory in G-code form of *.txt format as input reference for the position controller algorithm designed in MATLAB/Simulink via development of a system interpreter. A user interface of G-code-position controller (GPC) interpreter was designed using uicontrol objects in MATLAB GUI platform and Callbacks were programmed in Scripts Editor. The interpreter functions to extract and interpret the x and y data positions from the generated G-code. The input of the interpreter is the G-code generated from a standard three-dimensional geometrical CAD/CAM part production using CATIA software. Simulation of the interpreter was performed to compute the x and y data positions which were later validated experimentally by applying a cascade P/PI position controller for an XY positioning table of CNC milling machine. The success of the experimental validation proved the consistency of the interpreter to track three different shapes of geometrical objects in milling machining process. In simulation of the three G-code trajectories, the operation time to extract the data was recorded, whereby a 0.92%, 1.09%, and 1.35% efficiencies were achieved from extraction of 8429 data, 9514 data, and 12127 data, respectively. Based on the findings, it is concluded that more extraction time is required with increase in sample data size. The interpreted G-codes of random-curvy-shape, oval-shape, and circular-shape trajectories were validated experimentally on an XY milling machine positioning table resulted in RMSE values of respectively 0.0203mm and 0.0068mm, 0.0063mm and 0.0064mm, and 0.0057mm and 0.0064mm for x and y axes. As a conclusion, the realization of this interpreter has enabled seamless integration between a CAD/CAM trajectory and position controllers thus resulting in a reliable, accurate, and adaptable machining process to any desired specifications put forward by the part manufacturers. As a future recommendation, it is desired that the interpreter is tested and validated in real cutting experiments against the utilization of parts with complex shapes and processes to ensure its robustness and accuracy prior to commercialization.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Mat Seman., Norhidayah
author_facet	Mat Seman., Norhidayah
author_sort	Mat Seman., Norhidayah
title	Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application
title_short	Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application
title_full	Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application
title_fullStr	Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application
title_full_unstemmed	Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application
title_sort	integration of g-code with position controller via interpreter design using matlab for milling machine application
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Manufacturing Engineering
publishDate	2019
url	http://eprints.utem.edu.my/id/eprint/24677/1/Integration%20Of%20G-Code%20With%20Position%20Controller%20Via%20Interpreter%20Design%20Using%20MATLAB%20For%20Milling%20Machine%20Application.pdf http://eprints.utem.edu.my/id/eprint/24677/2/Integration%20Of%20G-Code%20With%20Position%20Controller%20Via%20Interpreter%20Design%20Using%20MATLAB%20For%20Milling%20Machine%20Application.pdf
_version_	1747834086041321472
spelling	my-utem-ep.246772021-10-05T10:57:23Z Integration Of G-Code With Position Controller Via Interpreter Design Using MATLAB For Milling Machine Application 2019 Mat Seman., Norhidayah T Technology (General) TJ Mechanical engineering and machinery In precision machining, various classical and advanced feedback position controllers such as cascade, proportional-integral-derivative, and sliding mode controllers have been developed with the aim to meet the precision requirements of the machine tool controller. To-date, most of these position controllers are not well utilized in commercial CNC machine tools. This is due to the limitation of the input reference applied for the position controller structure. Commonly, input reference signals such as step, ramp, sinusoidal, and other waveforms are utilized in testing and verifying the efficiency and performance in design process of position controllers. In most cases, the position controllers rarely utilize geometrical drawing such as CAD/CAM trajectory as input reference without extensive programming or trajectory generation algorithm. Thus, this thesis aims to integrate directly the trajectory in G-code form of *.txt format as input reference for the position controller algorithm designed in MATLAB/Simulink via development of a system interpreter. A user interface of G-code-position controller (GPC) interpreter was designed using uicontrol objects in MATLAB GUI platform and Callbacks were programmed in Scripts Editor. The interpreter functions to extract and interpret the x and y data positions from the generated G-code. The input of the interpreter is the G-code generated from a standard three-dimensional geometrical CAD/CAM part production using CATIA software. Simulation of the interpreter was performed to compute the x and y data positions which were later validated experimentally by applying a cascade P/PI position controller for an XY positioning table of CNC milling machine. The success of the experimental validation proved the consistency of the interpreter to track three different shapes of geometrical objects in milling machining process. In simulation of the three G-code trajectories, the operation time to extract the data was recorded, whereby a 0.92%, 1.09%, and 1.35% efficiencies were achieved from extraction of 8429 data, 9514 data, and 12127 data, respectively. Based on the findings, it is concluded that more extraction time is required with increase in sample data size. The interpreted G-codes of random-curvy-shape, oval-shape, and circular-shape trajectories were validated experimentally on an XY milling machine positioning table resulted in RMSE values of respectively 0.0203mm and 0.0068mm, 0.0063mm and 0.0064mm, and 0.0057mm and 0.0064mm for x and y axes. As a conclusion, the realization of this interpreter has enabled seamless integration between a CAD/CAM trajectory and position controllers thus resulting in a reliable, accurate, and adaptable machining process to any desired specifications put forward by the part manufacturers. As a future recommendation, it is desired that the interpreter is tested and validated in real cutting experiments against the utilization of parts with complex shapes and processes to ensure its robustness and accuracy prior to commercialization. 2019 Thesis http://eprints.utem.edu.my/id/eprint/24677/ http://eprints.utem.edu.my/id/eprint/24677/1/Integration%20Of%20G-Code%20With%20Position%20Controller%20Via%20Interpreter%20Design%20Using%20MATLAB%20For%20Milling%20Machine%20Application.pdf text en public http://eprints.utem.edu.my/id/eprint/24677/2/Integration%20Of%20G-Code%20With%20Position%20Controller%20Via%20Interpreter%20Design%20Using%20MATLAB%20For%20Milling%20Machine%20Application.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=116883 mphil masters Universiti Teknikal Malaysia Melaka Faculty Of Manufacturing Engineering Jamaludin, Zamberi 1. Abdul Kadir, A. Z., Xu, X. and Ridwan, F., 2011. 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