Gear change

Enabling gear changes and the related reserved use of the M functions M40-45 are realized by the channel parameter P-CHAN-00052 (main_spindle_gear_change).

	Gear changes can only be programmed for the main spindle in DIN syntax [PROG]removed link: [PROG].

Six gears or records are available and can be programmed in combination with the S word and M40-45. After startup of the NC control, the default gear specified in the axis machine record P-AXIS-00079 (getriebe_stufe) is valid.

Moving to the change position

With the rapid traversing speed specified in the axis machine record P-AXIS-00209 (vb_eilgang), the axis is moved to the current gear's change position P-AXIS-00078 (getr_schalt_pos). If the gear does not have a preferred direction, the direction of rotation is chosen with optimization of the travel distance.

The change operation is normally undertaken by the PLC. Adjustments to the new characteristic quantities of the gear are necessary at the NC control end. Two cases must be distinguished:

The measurement system is coupled to the motor's shaft. Depending on the gear, the measuring system resolution must be adapted (factors in the axis machine record: P-AXIS-00233 (wegaufz), P-AXIS-00234 (wegaufn)).
The measurement system is coupled to the gear's shaft. The measuring system's resolution must be retained, and the control dynamics of the gear must be adapted. Factors in the axis machine record: P-AXIS-00128 (multi_gain_n), P-AXIS-00129 (multi_gain_z), P-AXIS-00099 (kv).

Parameterizing the speed ranges

Each of the six gear pseeds covers a specific speed range, which is defined by a minimum P-CHAN-00058 (min_speed) and a maximum P-CHAN-00055 (max_speed) speed (unit: rpm). Overlaps of the speed ranges are allowed. The minimum and maximum speeds of speed ranges not used must be assigned to zero.

Automatic gear selection

When automatic gear selection P-CHAN-00004 (autom_range=1) is used, the gear is determined from the programmed speed S based on the speed table. The M functions M40-M45 are not programmed.

The P-CHAN-00074 (range_way) specifies in which direction the table is searched through for the suitable speed range during gear selection (from speed 1 to 6 ("bottom up") or from speed 6 to 1 ("top down")).

Manual gear selection

Manual gear selection P-CHAN-00004 (autom_range=0) requires programming of the M functions M40-M45 together with the speed S. A message is issued if the speed S is not in the programmed speed range.

Minimizing change operations

Generally, the control system attempts to minimize changes. A gear selection is not realized if a new speed can be run with the current gear.

Configuration example

Definition of M40-M45 and of the synchronisation methods.

m_synch[1] 0x00000001 MOS
m_synch[2] 0x00000002 MVS_SVS
:
m_synch[40] 0x00000002 MVS_SVS 
m_synch[41] 0x00000002 MVS_SVS 
m_synch[42] 0x00000002 MVS_SVS 
m_synch[43] 0x00000002 MVS_SVS 
m_synch[44] 0x00000002 MVS_SVS 
m_synch[45] 0x00000002 MVS_SVS 
m_synch[48] 0x00000008 MNS_SNS
m_synch[49] 0x00000002 MVS_SVS

Enabling the M functions M40-45 and gear changing:

:
main_spindle_gear_change          1   0: OFF   1: ON
:

Parameterizing the spindle gear (search direction and speed ranges):

spindel[0].range_way     0     0:bottom up    1:top down
#
spindel[0].range_table[0].min_speed    50    (M40)
spindel[0].range_table[0].max_speed    560   (M40)
spindel[0].range_table[1].min_speed    400   (M41)
spindel[0].range_table[1].max_speed    800   (M41)
spindel[0].range_table[2].min_speed    700   (M42)
spindel[0].range_table[2].max_speed    3500  (M42)
spindel[0].range_table[3].min_speed    3501  (M43)
spindel[0].range_table[3].max_speed    4000  (M43)
spindel[0].range_table[4].min_speed    3800  (M44)
spindel[0].range_table[4].max_speed    5500  (M44)
spindel[0].range_table[5].min_speed    5400  (M45)
spindel[0].range_table[5].max_speed    7000  (M45)
#

Gear change 2: — Figure 1-11: Defining the speed ranges in accordance with the example

Programming example Automatic gear determination: ON

:
spindel[0].autom_range     1
:

NC-program:

S650 M03    OK, M41⇒SPS
S750        OK, no changing, M41already selected
S950        OK, automatic changing, M42⇒  SPS
S1050       OK, no changing,M42already selected
S750        OK, automatic changing,M41⇒  SPS
S500        OK, no changing,M41already selected
S350        OK, no changing,M41already selected
S8000       Error, speed too high

A programmed gear stage is always checked:

M41 S750    OK, "automatic" changing, M41⇒  SPS
..but
M40 S750    Error, wrong gear stage

Programming example Automatic gear determination: OFF

:
spindel[0].autom_range     0
:

NC-program:

M41 S650 M03    OK,
M41⇒SPS
M41 S750    OK, no changing, M41 already selected
M42 S950    OK, changing, M42⇒SPS
M42 S1050   OK, no changing, M42 already selected
M41 S750    OK, changing,M41⇒SPS
M41 S500    OK, no changing,M41 already selected
M41 S350    OK, no changing, M41 already selected
M41 S200    Error, program different gear stage (M40)
S950        Error, no gear stage (M42) programmed