Project timeline

Abstract

This project focused on analyzing and modernizing a legacy micro-machining station, i.e., CNC-machine. During this project, the control architecture was found to be outdated, and with incompatible motion-controller paradigm it was realized that these factors prevented the integration with modern CAM/CAD workflows. Early investigation and research revealed that the machine’s Trajexia-based system relied on a propietary variant of BASIC-language called Trajexia BASIC, which operates on point-by-point manual motion definitions. However, the modern CNC-machines work on G-code, which operates on mathematical functions expressing the shapes and paths. Due to that, a modernization study on the CNC-machine was conducted, resulting in a comprehensive modernization plan. The modernization plan included functional machine model, concepts for a new LinuxCNC-based user interface, a catalogue for future hardware replacement parts and a clear pipeline of the current machine. These form a structured basis for upgrading the machine to be fully G-code compatible with visual instructions and a maintainable system for future research and teaching use. This project report provides a thorough overview of the project's progress and highlights the significant points encountered during the project.

How the project started

The project was introduced by QTT (Quad Tech Turku) on capstone session in September 2025. The initial aim of the capstone project Micro-Machining Station: Programming Motion into Reality was to focus on developing a complete digital-to-physical machining workflow, while using a three axis micro-machining platform. The machining platform consisted of three linear Omron AC servo driven axes X, Y and Z, a Trajexia MC04 motion controller and a toolhead. Generally, the original goal of the project was to transform digital models into real toolpath motions by designing, implementing and integrating both software and hardware components. More precisely, the goal was to create a micro-machining system that allows students and researchers to swap toolheads as needed and that uses easily input G code programs. The initial workflow was proposed to involve a generation of 3D geometry, i.e., STEP file, conversion of the STEP file into G-code, interpretation of that G-code through a custom PC-based software and transmission of the corresponding motion commands to the Trajexia controller which eventually would drive the servo axes X, Y and Z. Altogether, the aim was to develop a user interface (UI) wrapper that manages the full pipeline from file input to real-time machine motion and thus machining. In other words, a completely functional micro-machining environment, that works on G-code.

Initial end goal and proposed workflow

Based on the presentation given by the project stakeholders, the initial primary end goal of the project was to build a functional software pipeline for a micro-machining station that is capable of transforming a digital 3D-model into coordinated machine motion by using G-code. In a simple form, a pipeline that makes a CNC-machine’s toolhead move. Initially, the project workflow was proposed to be divided into the following main tasks:

• 1. STEP file creation in 3D CAD model
• 2. Toolpath/G-code generation using tools such as Fusion 360, SolidCAM or hand-coded
• 3. Translation of G-code into Trajexia commands in PC-based interpreter implemented in Python, C# or other suitable language
• 4. Implementation of communication between the Trajexia motion controller and the interpreter via Ethernet or RS232
• 5. Motion execution on the micro-machining station via Omron servo drivers

The aforementioned workflow was meant to run inside a new UI wrapper developed by the capstone team.

How the project went

The project began by familiarizing with the micro machining station, i.e. CNC-machine, that served as the basis for the capstone assignment. At this early stage, the overall condition of the machine, as well as the lack of documentation, became apparent. It was noted that the machine had originally been constructed using a mixture of components from Cencorp and Omron and included some custom modifications, which resulted in a machine configuration with no complete and accurate manuals available. Because of this, a significant portion of the early work revolved around identifying components, gathering what documentation could be found, and determining how the existing software and hardware communicated. At first, the condition of the machine and its associated control system were examined. An initial mapping of the responsibilities and tasks was outlined as follows: systematic collection of manuals for the different subsystems of the machine, investigation of the machine’s communication interfaces and pathways and its electrical structure and assessment of the embedded PC. Due to the absence of official documentation and accurate manuals, the manufacturers of the machine parts and Trajexia were contacted.

As most of the machine parts’ manuals had been found, including manuals relevant to the servo systems and motion controllers, as well as other peripheral devices, the importance of avoiding premature disassembly of the machine was identified and brought out. Additional tasks were included to clarify the communication protocols used by the machine, the feasibility of replicating or replacing the embedded software, and the need to produce a machine technology map. The contacting of the manufacturers had also proven to be successful at this point, especially regarding the motion controller compatibility and software behavior. It was identified that the current motion controller did not support G-code, but relied on a proprietary variant of BASIC language. Additionally, it was identified that the communication protocol used by the machine was outdated and not widely compatible with modern CNC-systems. Challenges were enhanced by the uniqueness of the machine due to being hand-assembled which had resulted in the absence of documentation for any key subsystems. At that point, the following research steps were set as follows: locating the existing program files, analyzing alternative options, such as Omron Sysmac Studio, for G-code support, further identifying communication protocols, exploring machine modelling and determining the feasibility of using available CAM tools. Following the previous, the project took a significant shift, as it was determined that attempting to operate the machine at that state was not feasible. This was justified by the age, incompatibility and uncertain support status of the existing hardware. It was concluded that a new set of servo drivers and a new motion controller would eventually be required. A compatibility research work for replacement parts was initiated. In addition, requirements for the UI were researched, even though the feasibility of using Omron's Sysmac Studio software was still under investigation. Since Trajexia BASIC-based control system did not support G-code or modern workflows, Omron Sysmac Studio was evaluated as a possible programming and UI solution.

At this point, the team was divided into two subgroups, working on different approaches and tasks. One subgroup focused on the machine modelling in attempt to understand the machine working principles better, revising the machine pipeline and producing initial user documentation. The other subgroup began analyzing the layout and capabilities of the existing UI, researching Omron Sysmac Studio, evaluating the possible compatible replacement hardware and collecting and analyzing the data obtained from manufacturers' responses. Challenges including model inconsistencies, uncertainty in the interoperability of motion controllers, and limitations of available simulation tools were documented. The subgroup responsible for the component compatibility prepared a detailed analysis of the servo motors and servo controllers attached to the machine. Technical specifications such as torque, speed ratings, supply voltage, encoder type, and connector standards were brought from product data and compared with modern alternatives. The data obtained from the manufacturers’ responses was analyzed and synchronized systematically with the work of that subgroup, resulting in the identification of a compatible replacement servo drivers. Similar work was done for motion controllers, where options with varying levels of G-code support were compared. The need to replace the I/O system, which was stated by the manufacturers as well, was also confirmed. This hardware-based analysis provided the necessary basis for future purchase recommendations. The subgroup responsible for machine modelling produced a functioning 3D representation of the machine for deeper analysis and understanding of the machine’s current state. The hardware-compatibility requirements for future upgrades were clarified, and a preliminary end-to-end pipeline was constructed.

How the end goal changed

As the work progressed, the findings gathered from research and investigations formed a clear picture of the machine's limitations, its outdated control architecture, and the scope of work required for restoration. It was revealed from the documentation gathered, the hardware mapping and the feasibility assessments that many of the original assumptions for the machine restoration were no longer realistic, and it was understood and agreed that the project had to evolve from its original objectives and final goal. For this reason, the project shifted into a new phase that focused on structured modernization plan, comprehensive documentation and guides, and a new UI development. These actions were recognized to provide a solid foundation for future work, and guidelines for the team next working on the machine and continue the modernization process with clear direction. All the documentation was set to be gathered on a Docusaurus page. These included user guides, theoretical descriptions, the modernization plan and a detailed description of the current machine pipeline and workflows. The aim of this was to create a space where everything relevant is easily found and could be navigated, so that the new learners and project continuers could readily understand the project and concepts involved. Additionally, research into suitable control solutions progressed. NY PMAC system was investigated due to its stronger G-code support and its compatibility with Omron’s modern software system. Relevant development kits, HMI tools, and configuration environments were reviewed to assess how advanced control features could be integrated into the future system. This study helped to refine the long-term modernization plan and supported decisions regarding the renewal of software frameworks and hardware. A structured user pipeline was drafted, which outlined each stage of the operational workflow.

Nearing the finish line

As the project progressed, clear and concrete final objectives were set. These included the development of a modernized UI incorporating real-time toolpath visualization, 3D visualization, adjustable machine settings and integrated G-code output conforming to the LinuxCNC dialect. Additionally, the Docusaurus website was defined to provide specific documents, including machine profile guides, a catalogue for replacement parts, tutorials and a thorough project report. Effort was dedicated to creating instructional guides and tutorials explaining how to create customized machine profiles for Autodesk Fusion and Cura. The UI design was developed, and multiple layout concepts were generated using tools such as Qt Designer, building upon earlier drafts. The UI draft incorporated real-time axis indicators, visualization panels for both simulated and physical paths, manual jog controls, G-code editing capabilities, I/O panels and adjustable parameters that governed motion constraints and system settings.

How the project ended

In the end, the end goals with corresponding documentation were set as follows:

• 1. Concrete outcomes:
  • 1. A part selection diagram in Lucid chart
  • 2. Diagram of existing parts and electronics
  • 3. Illustrated guides on how to create machine profiles for Autodesk Fusion and Cura
  • 4. A functional machine 3D model of the machine in Autodesk fusion, useful for future testing and finishing the UI
• 2. Documentation:
  • 1. Theoretical information regarding abstractions, to avoid vendor lock-ins
  • 2. Catalogue of suitable replacement parts from Omron
  • 3. Written guides and documentation for the following work of the project