Spindle Gear changing

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22 Apr 2025 07:49 #326874 by dctrytsman
Spindle Gear changing was created by dctrytsman
Can someone please explain how to set up gear changes. My lathe spindle motor is connected to a gearbox that has two gear ratios and the gears are changed by a pneumatic actuator. The gearbox is then connected to the spindle via belts. The spindle has a encoder connected to it via a 1:1 geared belt drive. The feedback part of the system works fine.

How can I connect this to HAL so that the machine automatically selects the correct gear based on the requested spindle speed. I think that the gear change should take place when the spindle speed is very low, but not standing still as the gears wont change smoothly.

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22 Apr 2025 14:09 #326890 by andypugh
Replied by andypugh on topic Spindle Gear changing
I have a similar (but different) system on my lathe. Mine has a 2-speed gearbox with magnetic clutches to change gear. (The differencce here is that mine _can_ change gear at zero speed)

I have a HAL component that controls this, and actually does rev-matching (ie, it will shift when the ratio of the shaft speeds matches the gear ratio)



Gearchoice.comp is here: github.com/andypugh/HalComps

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25 Apr 2025 07:25 #327033 by dctrytsman
Replied by dctrytsman on topic Spindle Gear changing
My spindle has an encoder on and at the moment, regardless of what gear I am in, it will always run at the selected RPM. I tested this, I selected the low gear ratio manually and ran S1000 M3 and it ran 1000RPM. I then did a M5, set the gear to high ratio manually, set S1000 M3 and the spindle ran at 1000RPM.

Unfortunately there is no clutch on the gearbox so I wont be able to change gears while running.

I basically just need a way to change gears automatically when a spindle speed command is given. When a S command is given, the spindle should first stop if it is running, then change to the appropriate gear based on the S command given, then start and run at the commanded speed. If possible, I would like the spindle to stop, then run at a very low rpm , then change gears if needed, then run at the given rpm.

Is there any way to implement this ?

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