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Instead of having the operators stop the robot, have you program do it, then you can reduce the shift time to nearly exactly what it need to make the shift every time. At least that's how I would do it
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It seems to me that when you are shifting "up" (from high torque to high speed) you want to do this "on the fly" to take advantage of the first 1/2 second of excellent acceleration as well as the improved speed of your "high" gear.
I agree, when you are heading into high torque mode from high speed mode, you can (and should) do this at zero speed.
I would think that a hysteresis loop on speed command would cover the programming side.
It still doesn't answer what happens if you get "in between" gears, which still seems to be a potential problem with all the designs that I have seen.
Andrew, Team 356