Introduction
Welcome to Shinden Modern’s blog! This is the first article I’ve written for Shinden Modern. When it came to choosing a topic, I thought about the services we offer as a manufacturer of rapid prototyping. We provide CNC machining, sand casting, low-pressure casting, and 3D printing. The goal of this blog is to share the essence of what we do and why it matters to you. One of our main services at Shinden is providing transparent CNC machined prototypes for display or specific metal parts to test the feasibility of our customers’ designs. As the saying goes, “To do a good job, one must first sharpen their tools.” In this article, I’ll introduce the development of CNC machines so that you, as our reader, you can better understand the evolving needs of the industry and how Shinden meets those needs. Okay, let’s move on.
Early Development of CNC Machines
The Beginnings
The world’s first CNC machine was developed in 1952 at the Massachusetts Institute of Technology (MIT) in the USA. It was a three-axis CNC machine created in collaboration with Parsons Co. and MIT, designed to process helicopter blade profile templates with an accuracy of ±0.0381mm. This invention marked the beginning of numerical control (NC) technology.
The Generations of CNC Development
First Generation: Electronic Tubes NC
In the early days, Numerical Control were controlled by electronic tubes—large vacuum tubes that managed electrical signals based on the flow of electrons in a vacuum.
- Functionality: Electronic tubes act as switches or amplifiers for control numerical control machines.
- Advantages: Vacuum tubes can handle high voltages and currents without damage.
- Disadvantages:
- Size and Space: The numerical control machine required significant space to accommodate the large vacuum tubes.
- Heat Generation: Vacuum tubes generated substantial heat, necessitating cooling solutions.
- Reliability: These tubes were prone to failure and needed regular replacement.
Second Generation: Transistor-Based NC Systems
The introduction of transistors marked a major improvement over vacuum tubes. Transistors allowed for smaller, more reliable, and energy-efficient controls.
- Why Improvement: Transistors offered enhanced reliability and reduced size compared to vacuum tubes. However, these systems were still hardwired and lacked flexibility.
- Application Needs: Industries require faster, more reliable machines capable of performing more complex operations.
Third Generation: Integrated Circuits and Early Microprocessors
The advent of integrated circuits and early microprocessors in the 1960s brought about significant reductions in the size and cost of control units while improving computational capabilities.
- Why Improvement: Integrated circuits and microprocessors allowed for smaller, more cost-effective control units with improved computational power.
- Application Needs: There was a growing need for more complex machining capabilities and the ability to easily update or change programs without extensive rewiring .
Transition to Computer Numerical Control (CNC)
Starting from the 1990s, the adoption of general-purpose CNC systems marked a significant shift towards software-based control. This shift opened new possibilities for flexibility, complexity, and ease of use in manufacturing processes.
Fourth Generation: General-Purpose Microprocessors
By 1970, general-purpose minicomputers had already appeared and were being mass-produced. These were then adapted as the core components of numerical control systems, marking the beginning of the computer numerical control (CNC) stage. In 1971, Intel Corporation in the USA became the first in the world to integrate the arithmetic unit and control unit of a computer onto a single chip using large-scale integrated circuit technology, calling it a microprocessor (or CPU for short).
- Why Improvement: General-purpose microprocessors enabled the development of fully programmable CNC systems, allowing for complex logic and control algorithms to be implemented and easily modified through software.
- Application Needs: The demand was for highly customizable and programmable systems that could easily adapt to different tasks, reduce setup times, and handle complex part geometries.
Transition to Integrated Circuits
The advent of integrated circuits marked a significant leap forward. Integrated circuits are small chips that can perform the functions of thousands to millions of electronic tubes. They use semiconductor materials (like silicon) to miniaturize and massively increase the efficiency of electrical circuits.
- Functionality: Integrated circuits could handle complex calculations and control tasks much more efficiently, allowing for precise control over the machining processes.
- Pros:
- Compact Size: Dramatically reduced the size of control units, making machines more compact and versatile.
- Efficiency and Precision: Enabled more precise control over machining tools, allowing for the creation of complex and detailed parts.
- Reliability: More reliable than tubes, with a longer lifespan and less maintenance required.
- Cons:
- Initial Cost and Complexity: The transition required significant investment in new technology and training for operators.
- Sensitivity: Integrated circuits are sensitive to static electricity and extreme conditions, requiring careful handling.
I provided images illustrating the evolution of CNC machining technology. On the left, you’ll see an old machining tool controlled by vacuum tubes, characterized by its large size and manual operation. On the right, there’s a modern CNC machine driven by small integrated circuits, featuring a digital control panel and the precision it brings to machining tasks. These images visually encapsulate the transformation from manual, cumbersome operations to automated, precise, and efficient processes, made possible by advances in CNC technology.
Fifth Generation: Networked and Integrated Systems
By 1974, microprocessors were applied to numerical control systems. This was because the capabilities of minicomputers were more than sufficient for controlling a single machine tool (at that time, they were used to control multiple machine tools, known as group control), making microprocessors a more economical and reasonable choice. Additionally, the reliability of minicomputers was not ideal. Although early microprocessors did not have high enough speed and functionality, these issues could be resolved through multi-processor structures. Since microprocessors are the core components of general-purpose computers, this stage continued to be known as computer numerical control (CNC).
- Why Improvement: The integration of networking capabilities allowed CNC machines to become part of larger automated systems, facilitating remote monitoring, programming, and coordination among multiple machines.
- Application Needs: The focus was on streamlining production processes, enhancing efficiency, and integrating manufacturing operations for better workflow and data exchange across different machines and systems.
Sixth Generation: Intelligent and Adaptive Control Systems
By 1990, the performance of the PC had developed to a high stage to meet the requirements of the core components of the numerical control system. The CNC system has since entered the PC-based stage.
- Why Improvement: The latest advancements aim to incorporate AI and machine learning for adaptive control, predictive maintenance, and optimized machining processes, allowing CNC systems to adjust in real time to varying conditions.
- Application Needs: The industry requires smart manufacturing solutions that can predict failures, optimize operations for energy efficiency, and automatically adjust to material variations or unexpected changes in production demands.
Conclusion
Each generation of CNC system development has been driven by the need to address specific manufacturing challenges, improve operational efficiency, and meet the evolving demands for precision, flexibility, and automation in industrial production processes. Understanding the history and development of CNC machines highlights the significant advancements that have transformed manufacturing processes. At Shinden Modern, we have 65 sets CNC machines and 103 CNC machine operators for your project, to produce your rapid prototypes with high speed.
References:
