Programming Synphase For Tandem Operation
Operating while in production

Because of the flexibility in programming the Synphase cards, more than one way exists to drive a tandem machine configuration. TCD Systems has chosen one method as detailed here. If you have any questions or would like to explore another option, we will work with you when you contact us.

In the home window of the Synphase program running on your PC, click on the “Edit Motors” button and clearly identify each mechanism. Organize this area anyway you desire. Shown below is one possible method.

Feeder, Gob Distributor, Machine Drums

Each of cards #1, 2, 3, 5, 6, 7 should be programmed in the “Synphase Custom Configuration” entered by clicking the “Card” button in the home window. All 8 variables regulating production speed (A through H) should be programmed as normal for a single machine. The variable A, bottles per minute, refers to the bottles per minute produced on each machine. The total production from the tandem configuration will be twice that amount.

The difference in card configuration between single machines and tandem machines involves the phasing hierarchy. What mechanism is differentialed to what other mechanism is different because the requirements of production have changed.

Controlling which section of ware produce on the machine closest to the lehr is followed by section 1 ware from away from the lehr and keeping even spacing of the intermingling of ware requires that the machine drums of the furthest away machine be slave to the machine drums closest to the lehr. For the machine nearest the lehr, select I)Rx=0 and I)Tx=1. For the other machine, select I)Rx=1 and I)Tx=2.

Each of the two machines in tandem work independently. Gob distributor #1 must be in position relative to the “load” time of sections on machine #1 and the shear cut of Feeder #1 must be synchronized to “load” a section of the machine nearest the lehr. For both the Feeder and the Gob distributor closest to the lehr, set I)Rx=1 (to slave them to the Machine drums closest to the lehr) and set I)Tx=0 because they are not slaves to anything else.

Likewise, for the furthest machine, set both the Feeder and the Gob distributor to I)Rx=2 (to slave them to the furthest machine) and set I)Tx=0 because they are not slaves to anything else.

Main Conveyor

The main conveyor is handling twice as many bottles in tandem operation as it would be for a single machine. It must have a higher belt speed to accommodate the extra ware. The Synphase card is programmed exactly the same as for single operation. The higher belt speed results from increasing the step (variable “C”). For a discussion on factors concerning larger steps, go to the top of this page. Both I)Rx and I)Tx are left at zero because this is just a flat belt. All positioning of ware on the belt is controlled by 90-degree pusher cam settings and phasing machine drum drives.

Transfer Wheel, Cross Conveyor, Stacker

These mechanisms are set up to respond to individual bottles independent of the machine being single or tandem, and independent of single, double, triple, or quad gob operation. Because the actual number of bottles per minute arriving at the mechanism is twice the amount in variable “A” (bottles per minute), we need a “fudge” factor of 2 in the numerator of each of these cards. As variable “C” is typically unused and set to 1 for the Synphase cards controlling these three mechanisms, enter “2” for variable “C” on each card.

The transfer wheel still phases to the machine nearest the lehr so its I)Rx remains equal to 1. Position on the cross conveyor is meaningless so its I)Rx remains equal to zero. If you prefer to have the stacker slave to the transfer wheel instead of the machine drums of the machine nearest the lehr, change I)Rx of the stacker to equal 3 and also change I)Tx of the transfer wheel to equal 3. Remember, the machine furthest from the lehr has already used differential channel 2.

Operating Synphase - Conveyor Spacing Adjustments of Tandems

With the exception of the differential for the motor driving the machine drums of the furthest machine from the lehr, all motors are operated exactly the same as the standard system.

There are three types of problems that can affect spacing and each has a different solution.

  • One or more of three Synphase controlled axis can be malfunctioning. To check this problem, observe the “Fault” indicator LED on each of the three Synphase control cards. If they are illuminated, the hardware is running fine and the problem is elsewhere.
  • The machine-to-machine differential may need adjustment. Observing all sections of ware identifies this problem. If each lead bottle from each section of ware from the furthest machine is the same distance away from rear bottle immediately in front of it, (ware from the machine closest to the lehr) and the distance from each trailing bottle to bottle immediately behind it is the same for all sections, advancing the differential of the furthest machine will close the gap between all lead bottles. Retarding the differential of the furthest machine will open this gap for all sections.
  • If some lead bottles are too close and some lead bottles are too far from the bottles in front of them, changing the differential will do nothing to correct the problem. Trace the problem back to the section forming that ware and observe the motion of its 90-degree pusher. Either the pusher head is improperly handling the ware, or the cam setting is incorrect.
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Programming Synphase for Tandem.pdf
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