Customizing Synphase Cards

All Synphase cards are manufactured identically. It is through custom settings of the 29 variables of each individual Synphase card that the firmware knows how to respond as a complete system. Depending on these settings, it is possible for all motors to run at different RPMs while maintaining the same production speed. The hierarchy of phasing can be set up or modified here as well.

As all communications with the Synphase cards is via the serial port interface of a PC, it is assumed that one is available and it has an installed copy of the “Operator’s Interface

During a Production Run, there are usually only 2 things that concern the operator, production speed and differential. Although both of these are accessible in the list of the 29 variables, the operator’s interface of the PC has a separate page for each variable to enhance operator access and reduce chances of inadvertent operator errors.

Rate opens a window that allows the operator to adjust the production speed within limits while providing additional information such as present speed and percentage of change. Using this window to adjust machine speed will cause all motors in the system to change speed in unison while maintaining production.

Differential opens a window that allows the operator to advance or retard the position of a mechanism by temporarily speeding up or slowing down its motor in a controlled manor. Additional information is graphically presented showing master/slave relationships and present set point.

Synphase cards with advance/retard wiring connectors mounted allow the operator to perform this same differential function using momentary push button switches mounted near the mechanism.

Between Production Runs, the machine is typically shut down for Job Change. This could be as short as changing molds or more involved with reconfiguring mechanisms. For instance, the number of fingers on a transfer wheel may be changed from 16 to 20, which would also involve changing the chain from 96 links to 100 links.

Because of the electronic gearbox feature of the Synphase cards, no A/B change gears would be required. However, the appropriate information would have to be input to the proper place. In this example, both the mechanism’s reduction ratio and the number of fingers would have to be entered into the Synphase card responsible for the transfer wheel drive.

A 6 motor drive on an IS machine with each motor containing 29 variables results in 174 possibilities. The job change crew would have to locate and change 2 of these 174 variables. The job change window on the PC brings only the relevant variable into view in an easy to navigate table. This simplifies the task for the setup crew and helps prevent errors. The variables that populate the list can be altered as needed by instrument men.

When the Machine is Initially Installed, or When a Synphase Card
is Replaced
, it is important to do two things. First, because the Synphase cards communicate with the PC via the serial port on a multi-drop 2-wire line, each Synphase card must have a unique address. Second, all 29 variables for each card must be reviewed for proper setting. Most will remain at their factory default settings, but it is critical to change a few in order to attain the advantage of the flex line that Synphase offers.

The 29 variables used to customize a Synphase card are available in the “Synphase Custom Configuration” window. Accessing Synphase Card Variables is a detailed explanation on the mechanics of retrieving present settings, and sending new values to the Synphase cards. Explanations Of Synphase Card Variables provides the reasons certain values are chosen.

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