High Efficiency Application of Zhongda Automation Program on Cylindrical Grinder

**Abstract:** This article presents an in-depth overview of the Delta B series servo system, VE series inverter, and the Zhongda Universal CNC system, with a focus on their application in cylindrical grinding machines. By leveraging the high openness of the Zhongda Universal CNC System, it enables technological innovation that differs from the traditional intuitive input methods used in other CNC machine tools. This open architecture simplifies operations, enhances user experience, and significantly improves processing efficiency. **Keywords:** Servo system, universal CNC, cylindrical grinder, high openness, intuitive input **1. Introduction** Cylindrical grinding machines are essential in finishing the outer diameter of workpieces, ensuring precise dimensions and surface finish. These machines require high precision and consistency in machining, making them ideal for advanced control systems. The Zhongda Universal CNC system offers a highly open platform, allowing customization and flexibility in both hardware and software configurations. Its open architecture includes features such as an accessible display screen, internal PLC, I/O planning, and parameter settings, all of which can be tailored to specific machine tool requirements. This openness allows operators to input fixed processing data without modifying G-code, streamlining the workflow and reducing the complexity of operation. As a result, the system is not only more user-friendly but also increases productivity and reduces errors. **2. Working Principle of Cylindrical Grinders** Cylindrical grinders typically use two servo axes, X and Y, to control the movement of the workpiece and grinding wheel. The workpiece rotates while the grinding wheel spins, with their rotational axes parallel to the X-axis but in opposite directions. Friction between the grinding wheel and the workpiece surface performs the actual machining process. The X and Y axes control the shape and size of the workpiece. Traditional cylindrical grinders often rely on hydraulic systems for Y-axis control, which limits flexibility and precision. However, the integration of CNC technology allows for precise control of position and speed, along with automated dressing of the grinding wheel via NC programs. This greatly expands the range of machinable parts and improves overall performance. **3. CNC External Cylindrical Grinding Machine Solution Based on Delta’s Automation Platform** Each machine tool has unique mechanical and electrical design requirements. The openness of the Zhongda Universal CNC system makes it adaptable to various applications, meeting the specific needs of different manufacturers. Leveraging Delta’s comprehensive automation product line, Zhongda provides cost-effective, efficient, and reliable solutions for machine tool builders and end users. The integrated solution includes the PUTNC-H4C-2 CNC system, Delta ASDA-B servo system, and VE Series Inverter, offering a complete and optimized setup for high-precision cylindrical grinding. **3.1 Technical Features of the PUTNC-H4C-2 CNC System** The PUTNC-H4C-2 CNC system, as shown in Figure 1, is designed for high flexibility and ease of use. It supports up to three servo axes (X, Y, A) and includes an embedded PLC for customized control. Operators can personalize the interface and plan screen content, enhancing usability. Key features include: - Open system architecture with embedded PLC - High-definition LCD display - Support for multiple servo axes - Customizable PLC functions - Expandable I/O options for enhanced connectivity Figures 2 through 5 illustrate the workpiece selection, setting, and wheel dressing screens, showcasing the system's intuitive user interface. **3.2 MCM Parameter Modification** Several key parameters are used to fine-tune the performance of the system. Examples include: - Tool radius compensation (e.g., 00012500;022Tool#1radiuscompensation) - Backlash compensation for X and Y axes - Jog feed rate and speed settings - Encoder resolution and motor rotation direction - Software over-travel limits and home grid direction - Pitch error compensation for lead screws These parameters allow for precise tuning of the machine’s behavior, improving accuracy and reliability. **3.3 Processing Variable Definition** Defining variables is crucial for efficient programming. Variables such as workpiece dimensions, tool offsets, and cutting speeds are set based on the specific machining task, ensuring consistent results across multiple cycles. **3.4 NC Program Example** An example of a new wheel dressing program demonstrates how the system handles complex machining tasks. The program uses G-code commands to define the geometry of the grinding wheel and perform precise dressing. Another example shows how tool radius compensation is applied during workpiece machining, using G40, G41, and G42 commands to ensure accurate cuts. **4. Delta Servo System and Frequency Converter** **4.1 ASDA-A Series AC Servo System** The ASDA-A series AC servo system, introduced in 2003, and the ASDA-B series, launched in 2005, are widely used in industrial applications, especially in CNC machine tools. Key features include: - Three basic control modes: position, speed, and torque - Fast dynamic response with 1 ms servo setting time - PDFF control architecture for improved disturbance rejection - Automatic gain adjustment for easier tuning - Resonance suppression and low-pass filtering - Indexing positioning function for tool magazine control **4.2 VFD-VE Series Vector Control AC Drive** The VFD-VE series, introduced in 2007, is designed for high-speed spindle control. It supports frequency outputs up to 3600Hz and includes advanced control functions such as vector control, torque control, and position control. Additional features include: - High-speed spindle indexing capability - Precise speed control (up to ±0.02%) - Strong low-speed torque (150% at 0.5Hz) - Motor parameter estimation and weak magnetic curve optimization - Mechanical brake control and power failure deceleration - Temperature protection via PTC feedback **5. Conclusion** As the manufacturing industry continues to evolve, automation plays a vital role in improving efficiency, precision, and quality. The Zhongda Universal CNC system, with its high openness and stability, offers significant potential for specialized machining applications. When combined with Delta’s automation products—such as servo systems, inverters, and encoders—it delivers a comprehensive solution that enhances machine tool performance. This integration not only boosts the stability and quality of the machine tools but also improves the efficiency and accuracy of the produced parts. As a result, manufacturers can achieve higher productivity and better product quality, keeping pace with the growing demands of modern manufacturing.

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