Development of CK6130 Small CNC Lathe

At present, economical CNC machine tools remain the most in-demand segment in China's market and account for the highest sales volume of CNC machines. Reusing existing idle, outdated machine tools through numerical control (NC) retrofitting to transform them into high-efficiency, multi-functional, cost-effective CNC machines is an effective way to revitalize existing capital and represents a key path toward low-cost automation. The CK6130 small CNC lathe we developed is a practical implementation of this concept. The CK6130 small CNC lathe consists of two main components: a microcomputer numerical control system and the machine tool itself. During machining, the workpiece’s NC program is first written and then checked for any errors before being transferred to the numerical control unit. The NC device calculates the feed pulse sequence based on the program instructions, which is then distributed by a multi-function NC board. After being amplified by the drive power source, these pulses generate control signals that regulate the spindle speed, start/stop functions, feed system movement direction, speed, and displacement, as well as the selection and operation of tools and cooling/lubrication systems. This ensures that the tool, workpiece, and other auxiliary devices operate precisely according to the NC program, enabling the production of parts with the required shape, size, and precision. Figure 1 shows the overall plan of the CNC machine control system. The microcomputer numerical control system used in this machine is an open-loop, cost-effective system that controls both the X-axis and Z-axis, allowing for two-axis linkage and linear interpolation between coordinates. It is composed of a microcomputer, a stepping motor drive power supply, a stepping motor, a multi-function NC interface board, and a control circuit. Any PC or compatible computer above IBM PC-286 can be used, with the CNC card inserted into its bus slot. The developed CNC software package allows users to input and store the workpiece processing program via the keyboard, with a power-off protection function to ensure data safety. This improves system reliability and enables efficient CNC machining. The stepping motor drive employs a pulse width modulation circuit and smooth subdivision circuit, significantly increasing the torque at high frequencies and enhancing the system's responsiveness. It also reduces vibration at low frequencies, ensuring smoother operation. Additional protection features include over-temperature, over-voltage, over-current, and under-voltage protection. Photoelectric isolation is also used to enhance the system's resistance to interference. The machine body of the CK6130 CNC lathe is upgraded from the traditional C615 lathe. Key improvements include modifications to the feed transmission system, main transmission system, and tool holder structure. Figure 2 illustrates the transformation of the two-axis feed system. For the Z-axis (longitudinal) feed system, the original feed box, carriage box, lead screw, and other components were removed. A stepping motor was installed on the left end of the original screw, along with a reduction gear box. The stepping motor uses one-stage gear reduction, and double-bladed gears are used to eliminate backlash. The original lead screw was replaced with a ball screw, which is pre-tensioned to reduce bending deformation caused by the screw's weight, thus improving stiffness. The stepping motor is connected to the reduction box via a zero-backlash coupling, transmitting drag torque to the ball screw pair to drive the carriage back and forth. For the X-axis (horizontal) feed system, the stepping motor is mounted on the carriage and drives the ball screw through a gear reduction. The main transmission system has been upgraded by installing a photoelectric encoder on the rear end of the spindle, combined with an electromagnetic clutch and sliding gear, transforming the manual gear system of the C615 into an automatic one. This simplifies operation while using a two-speed motor to increase the number of gear stages. Figure 3 shows the tool post workflow diagram. The tool post has been upgraded from a conventional manual indexing type to a 4-position electric tool post, controlled by the NC system. When the tool post receives a signal from the microcomputer, it returns the current tool position information via a Hall element circuit. Once the position matches the microcomputer's requirements, the system sends a signal to lock and execute the tool change. The CK6130 CNC lathe offers several notable features. It uses a general-purpose PC as the CNC system, and the machine body is based on a standard C615 lathe. The programming interface includes a color full-screen display and human-machine dialogue, enabling online CNC programming, program inspection, grammar correction, graphic simulation, and automatic parameter setting. It supports the entire automated machining process, including complex shapes like cylinders, cones, arcs, faces, threads, and compound surfaces. The CNC software is open, with reserved interfaces for scalability and future upgrades, making it an excellent solution for low-cost automation.

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