The history of numerical control (NC) began when the automation of machine tools first incorporated concepts of abstractly programmable logic, and it continues today with the ongoing evolution of computer numerical control (CNC) technology.
The first NC machines were built in the 1940s and 1950s, based on existing tools that were modified with motors that moved the controls to follow points fed into the system on punched tape. These early servomechanisms were rapidly augmented with analog and digital computers, creating the modern CNC machine tools that have revolutionized the machining processes.
Earlier forms of automation Cams
The automation of machine tool control began in the 19th century with cams that "played" a machine tool in the way that cams had long been playing musical boxes or operating elaborate cuckoo clocks. Thomas Blanchard built his gun-copying lathes (1820s–30s), and the work of people such as Christopher Miner Spencer developed the turret lathe into the screw machine (1870s). Cam-based automation had already reached a highly advanced state by World War I (1910s).
However, automation via cams is fundamentally different from numerical control because it cannot be abstractly programmed. Cams can encode information, but getting the information from the abstract level (engineering drawing, CAD model, or other design intent) into the cam is a manual process that requires machining or filing. In contrast, numerical control allows information to be transferred from design intent to machine control using abstractions such as numbers and programming languages.
Various forms of abstractly programmable control had existed during the 19th century: those of the Jacquard loom, player pianos, and mechanical computers pioneered by Charles Babbage and others. These developments had the potential for convergence with the automation of machine tool control starting in that century, but the convergence did not happen until many decades later.
Tracer control The application of hydraulics to cam-based automation resulted in tracing machines that used a stylus to trace a template, such as the enormous Pratt & Whitney "Keller Machine", which could copy templates several feet across. Another approach was "record and playback", pioneered at General Motors (GM) in the 1950s, which used a storage system to record the movements of a human machinist, and then play them back on demand. Analogous systems are common even today, notably the "teaching lathe" which gives new machinists a hands-on feel for the process. None of these were numerically programmable, however, and required an experienced machinist at some point in the process, because the "programming" was physical rather than numerical.
Servos and synchros One barrier to complete automation was the required tolerances of the machining process, which are routinely on the order of thousandths of an inch. Although connecting some sort of control to a storage device like punched cards was easy, ensuring that the controls were moved to the correct position with the required accuracy was another issue. The movement of the tool resulted in varying forces on the controls that would mean a linear input would not result in linear tool motion. In other words, a control such as that of the Jacquard loom could not work on machine tools because its movements were not strong enough; the metal being cut "fought back" against it with more force than the control could properly counteract.
The key development in this area was the introduction of the servomechanism, which produced powerful, controlled movement, with highly accurate measurement information. Attaching two servos together produced a synchro, where a remote servo's motions were accurately matched by another. Using a variety of mechanical or electrical systems, the output of the synchros could be read to ensure proper movement had occurred (in other words, forming a closed-loop control system).
The first serious suggestion that synchros could be used for machining control was made by Ernst F. W. Alexanderson, a Swedish immigrant to the U.S. working at General Electric (GE). Alexanderson had worked on the problem of torque amplification that allowed the small output of a mechanical computer to drive very large motors, which GE used as part of a larger gun laying system for US Navy ships. Like machining, gun laying requires very high accuracy – fractions of a degree – and the forces during the motion of the gun turrets was non-linear, especially as the ships pitched in waves.
In November 1931 Alexanderson suggested to the Industrial Engineering Department that the same systems could be used to drive the inputs of machine tools, allowing it to follow the outline of a template without the strong physical contact needed by existing tools like the Keller Machine. He stated that it was a "matter of straight engineering development".. However, the concept was ahead of its time from a business development perspective, and GE did not take the matter seriously until years later, when others had pioneered the field.
Parsons Corp. and Sikorsky The birth of NC is generally credited to John T. Parsons and Frank L. Stulen,The International Biographical Dictionary of Computer Pioneers refers to Parsons as "the father of computerized milling machines", and the Society of Manufacturing Engineers awarded him a citation for "conceptualization of numerical control marked the beginning of the second industrial revolution." working out of Parsons Corp. of Traverse City, Michigan. For this contribution, they were jointly awarded the National Medal of Technology in 1985 for "Revolutioniz[ing] Production Of Cars And Airplanes With Numerical Controls For Machines".
In 1942, Parsons was told that helicopters were going to be the "next big thing" by the former head of Ford Trimotor production, Bill Stout. He called Sikorsky Aircraft to inquire about possible work, and soon got a contract to build the wooden stringers in the rotor blades. At the time, rotor blades (rotary wings) were built in the same fashion that fixed wings were, consisting of a long tubular steel spar with stringers (or more accurately ribs) set on them to provide the aerodynamic shape that was then covered with a stressed skin. The stringers for the rotors were built from a design provided by Sikorsky, which was sent to Parsons as a series of 17 points defining the outline. Parsons then had to "fill in" the dots with a French curve to generate an outline. A wooden jig was built up to form the outside of the outline, and the pieces of wood forming the stringer were placed under pressure against the inside of the jig so they formed the proper curve. A series of trusswork members were then assembled inside this outline to provide strength.
After setting up production at a disused furniture factory and ramping up production, one of the blades failed and it was traced to a problem in the spar. At least some of the problem appeared to stem from spot welding a metal collar on the stringer to the metal spar. The collar was built into the stringer during construction, then slid onto the spar and welded in the proper position. Parsons suggested a new method of attaching the stringers directly to the spar using adhesives, never before tried on an aircraft design.
That development led Parsons to consider the possibility of using stamped metal stringers instead of wood. These would not only be much stronger, but far easier to make as well, as they would eliminate the complex layup and glue and screw fastening on the wood. Duplicating this in a metal punch would require the wooden jig to be replaced by a metal cutting tool made of tool steel. Such a device would not be easy to produce given the complex outline. Looking for ideas, Parsons visited Wright Field to see Frank L. Stulen, the head of the Propeller Lab Rotary Wing Branch. During their conversation, Stulen concluded that Parsons didn't really know what he was talking about. Parsons realized Stulen had reached this conclusion, and hired him on the spot. Stulen started work on 1 April 1946 and hired three new engineers to join him.
Stulen's brother worked at Curtis Wright Propeller, and mentioned that they were using punched card calculators for engineering calculations. Stulen decided to adopt the idea to run stress calculations on the rotors, the first detailed automated calculations on helicopter rotors. When Parsons saw what Stulen was doing with the punched card machines, he asked Stulen if they could be used to generate an outline with 200 points instead of the 17 they were given, and offset each point by the radius of a mill cutting tool. If you cut at each of those points, it would produce a relatively accurate cutout of the stringer. This could cut the tool steel and then easily be filed down to a smooth template for stamping metal stringers.
Stullen had no problem making such a program, and used it to produce large tables of numbers that would be taken onto the machine floor. Here, one operator read the numbers off the charts to two other operators, one on each of the X- and Y- axes. For each pair of numbers the operators would move the cutting head to the indicated spot and then lower the tool to make the cut. This was called the "by-the-numbers method", or more technically, "plunge-cutting positioning". It was a labor-intensive prototype of today's 2.5 axis machining (two-and-a-half-axis machining).
Punch cards and first tries at NC At that point Parsons conceived of a fully automated machine tool. With enough points on the outline, no manual working would be needed to clean it up. However, with manual operation the time saved by having the part more closely match the outline was offset by the time needed to move the controls. If the machine's inputs were attached directly to the card reader, this delay, and any associated manual errors, would be removed and the number of points could be dramatically increased. Such a machine could repeatedly punch out perfectly accurate templates on command. But at the time Parsons had no funds to develop his ideas.
When one of Parsons's salesmen was on a visit to Wright Field, he was told of the problems the newly formed U.S. Air Force was having with new jet-powered designs. He asked if Parsons had anything to help them. Parsons showed Lockheed their idea of an automated mill, but they were uninterested. They decided to use 5-axis template copiers to produce the stringers, cutting from a metal template, and had already ordered the expensive cutting machine. But as Parsons noted:
Now just picture the situation for a minute. Lockheed had contracted to design a machine to make these wings. This machine had five axes of cutter movement, and each of these was tracer controlled using a template. Nobody was using my method of making templates, so just imagine what chance they were going to have of making an accurate airfoil shape with inaccurate templates.
Parson's worries soon came true, and Lockheed's protests that they could fix the problem eventually rang hollow. In 1949 the Air Force arranged funding for Parsons to build his machines on his own. Early work with Snyder Machine & Tool Corp proved the system of directly driving the controls from motors failed to give the accuracy needed to set the machine for a perfectly smooth cut. Since the mechanical controls did not respond in a linear fashion, one could not simply drive it with a given amount of power, because the differing forces meant the same amount of power would not always produce the same amount of motion in the controls. No matter how many points were included, the outline would still be rough. Parsons was confronted by the same problem that had prevented convergence of Jacquard-type controls with machining.
First commercial numerically controlled machine