Gear change

activation

The channel parameter P-CHAN-00052 (main_spindle_gear_change) enables gear changes and the related reserved use of the M functions M40-45.

Gear changes can only be programmed for the main spindle in DIN syntax [PROG//Gear change].

6 gear speeds or data records are available for programming in combination with the S word and M40 - M45 functions. After start-up of the NC controller, the default gear speed specified in the axis machine data record P-AXIS-00079 (getriebe_stufe) is activated.

Approach the change position

The rapid traverse velocity specified in the axis machine data record P-AXIS-00209 (vb_eilgang) moves the axis to the change position of the current gear P-AXIS-00078 (getr_schalt_pos). If the gear has no preferred direction, the direction of rotation is selected to optimise the motion path.

The change operation is normally undertaken by the PLC. Adjustments must be made in the NC controller to adopt the parameters of the new gear. A distinction must be made between two cases here:

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

Parameterise the speed ranges

Each of the 6 gear speeds 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). Speed range overlaps are permitted. The minimum and maximum speeds of the unused speed ranges must be assigned the value 0.

Automatic gear speed selection

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

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

Manual gear speed selection

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

Minimise change operations

Generally, the control system attempts to minimise change operations. A gear speed selection is not executed if a new speed is run at the current gear speed.

Configuration example

Definition of M40 - 45 and 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
:

Parameterise the spindle gear (search direction, 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 1:
Define the speed ranges according to the example

Programming Example

Automatic gear stage determination: ON

:
spindel[0].autom_range        1
:
NC program:
S650 M03      OK, M41→ PLC
S750           OK, no change, M41 already selected
S950          OK, automatic change, M42 → PLC
S1050          OK, no change, M42 already selected
S750          OK, automatic change, M41 → PLC
S500           OK, no change, M41 already selected
S350           OK, no change, M41 already selected
S8000          Error, speed too high
A programmed gear stage is always checked:
M41 S750       OK, "automatic" change, M41 → PLC
..but
M40 S750       Error, wrong gear stage

Programming Example

Determine the automatic gear stage: OFF

:
spindel[0].autom_range       0
:
NC program:
M41 S650 M03  OK, M41 → PLC
M41 S750      OK, no change, M41 already selected
M42 S950      OK, change, M42 → PLC
M42 S1050     OK, no change, M41 already selected
M41 S750      OK, change, M41 → PLC
M41 S500      OK, no change, M41 already selected
M41 S350      OK, no change, M41 already selected
M41 S200 Error, program different gear stage (M40)
S950      Error, no gear stage (M42) programmed