Tank manufacturing machine with toolkit mounted sensor and instrumented punch nose for measuring friction

Abstract

The can body manufacturing machine comprises a punching assembly capable of moving in reciprocating linear motion and a tool kit with a plurality of dies. A sensor is mounted behind the last one of the plurality of molds of the toolkit. During the drawing and thinning process, the stamping assembly presses the cup blank over the dies to deform the cup blank into a can, and the sensor measures the total load during the drawing and thinning process.

Description

Citation of relevant applications

[0001] This application claims the benefit and priority of U.S. Provisional Patent Application No. 63 / 591,587, filed on October 19, 2023, entitled “CAN BODY MAKER WITH TOOL-PACK MOUNTED LOADCELL AND INSTRUMENTED PUNCH NOSE FOR MEASURING FRICTION”, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0002] This application relates to metal processing technology, and more specifically to tank manufacturing systems and methods. Background Technology

[0003] Cylindrical or tubular structures (hereinafter referred to as "cans") are typically formed by first creating a blank from a material (such as metal), and then drawing the blank into a shallow cup. After the initial drawing of the shallow cup, a can-making machine can carry the shallow cup onto one end of a reciprocating punch, guiding it through a series of dies to obtain a can of the desired size and thickness. The can, driven by the punch, can contact a bottom forming tool, thereby forming the bottom of the can (e.g., to have a dome shape). Some systems can incorporate sensors on the body of the punch, but such instrumented punches must replace traditional non-insulated punches, and even in use, the sensors may be affected by vibration noise and sensor fatigue due to the reciprocating motion of the punch. Furthermore, the installation, maintenance, and / or removal of sensors on instrumented punches are not easy. Summary of the Invention

[0004] The embodiments covered by this patent are defined by the following claims, not by the content of this invention. The content of this invention is a high-level generalization of various embodiments and introduces some concepts that will be further described in the following detailed description section. The content of this invention is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used alone to define the scope of the claimed subject matter. This subject matter should be understood by referring to the appropriate portions of the entire specification of this patent, any or all of the drawings, and each claim.

[0005] According to some embodiments, the can manufacturing machine includes a ram assembly that is movable in a reciprocating linear motion along an axis and includes a punch and a plunger. The can manufacturing machine also includes a tool kit having multiple dies, each die including a hole through which a cup-shaped blank is driven during deep drawing and thinning processes. The tool kit includes a sensor mounted along the axis and behind the last of the multiple dies relative to the ram assembly. The sensor includes the hole through which the cup-shaped blank passes after passing the last die, and the sensor can measure the total load during the thinning process.

[0006] According to some embodiments, the can manufacturing machine includes a stamping assembly that is movable in a reciprocating linear motion along an axis and includes a punch and a plunger. The can manufacturing machine also includes a toolkit having multiple thinning dies and sensors located at fixed positions within the toolkit, the sensors being capable of measuring the total load during the deep drawing and thinning processes of the can manufacturing machine.

[0007] According to various embodiments, a deep drawing and thinning method for forming a can includes inducing reciprocating linear motion of a stamping assembly of a can manufacturing machine, such that the reciprocating linear motion drives a cup-shaped blank through a plurality of dies in a toolkit. The method includes using a sensor supported behind the last die of the plurality of dies in the toolkit to measure the total force on the cup-shaped blank.

[0008] The various embodiments described herein may include additional systems, methods, features, and advantages that are not necessarily explicitly disclosed herein, but will be apparent to those skilled in the art upon review of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages are included within this disclosure and protected by the appended claims. Attached Figure Description

[0009] This specification refers to the following figures, in which the same reference numerals are used in different figures to indicate the same or similar parts.

[0010] Figure 1 A tank manufacturing machine based on the actual design is shown.

[0011] Figure 2 It is based on the implementation plan. Figure 1 A perspective view of the sensors in the toolkit of the tank manufacturing machine.

[0012] Figure 3 yes Figure 2 End view of the sensor.

[0013] Figure 4 yes Figure 2A cross-sectional view of the sensor. Detailed Implementation

[0014] This document describes a can manufacturing machine and associated methods including a sensor for measuring the total load during the drawing and thinning processes. In various embodiments, the sensor for measuring the total load is advantageously located in a fixed position within the can manufacturing machine. In some embodiments, the sensor for measuring the total load is mounted within a toolkit of the can manufacturing machine, such as behind the third or last thinning die in the toolkit. Compared to conventional methods of mounting the total load sensor inside the punch, the systems and methods described herein reduce vibration noise and sensor fatigue in the sensor measurement caused by the reciprocating motion of the punch. The systems and methods described herein provide improved accessibility for sensor installation, maintenance, and / or removal. In various embodiments, the systems and methods described herein can allow for the measurement of the total load using a punch without instrumentation. In some embodiments, the total load measured by the sensor can better determine and calculate the frictional forces during the drawing and thinning processes. Various other benefits and advantages can be achieved using the systems and methods described herein, and these benefits and advantages should not be considered limiting.

[0015] Figure 1 An example of a can manufacturing machine 100 according to an actual embodiment is shown. Generally, the can manufacturing machine 100 includes various components for performing a drawing and thinning process in which a can 104 is formed from a cup-shaped blank 102. The cup-shaped blank 102 can be formed from various materials as needed, and in some embodiments, the cup-shaped blank 102 is a metal, such as, but not limited to, aluminum or aluminum alloys, such as 1xxx series aluminum alloys, 2xxx series aluminum alloys, 3xxx series aluminum alloys, 4xxx series aluminum alloys, 5xxx series aluminum alloys, 6xxx series aluminum alloys, 7xxx series aluminum alloys, 8xxx series aluminum alloys, and / or any other aluminum or aluminum alloy as required.

[0016] like Figure 1 As shown, the tank manufacturing machine 100 typically includes a stamping assembly 106, a tool kit 108, and optional components such as a dome machine 110. Optionally, a housing or enclosure 138 is included to at least partially house one or more components of the tank manufacturing machine 100.

[0017] The stamping assembly 106 includes a punch 112 and a punch 114 supported by the punch 112. The punch 112 typically extends along an axis 128, and the punch 114 may be supported at or near one end of the punch 112. The punch 114 typically includes a punch sleeve 116 and a punch nose 118. In some embodiments, the punch sleeve 116 and the punch 118 are separate components, but in other embodiments, the punch sleeve 116 and the punch 118 may be single or integral components. The can manufacturing machine 100 includes an actuator 120 that drives or otherwise causes the piston assembly 106 to reciprocate linearly in a predetermined direction (indicated by arrow 122). Various types of actuators may be used as actuator 120 to cause the reciprocating linear motion of the stamping assembly 106.

[0018] Tool kit 108 includes one or more dies 124, and in some embodiments, tool kit 108 includes multiple dies 124. Each die 124 includes a hole 126 and is arranged along axis 128 such that during the drawing and thinning processes, the stamping assembly 106 drives the cup-shaped blank 102 through the die 124. In the example shown, tool kit 108 includes four dies 124A-D—the initial die 124A can be a re-drawing die, and the subsequent dies 124B-D can be thinning dies. As discussed in detail below, the re-drawing die can deform the cup-shaped blank 102 from a shallower, wider body to a narrower, longer body, and the thinning die can thin the sidewalls of the cup-shaped blank 102 from an initial thickness to a final thickness and elongate the cup-shaped blank 102 to form a can 104. The number of dies 124 shown should not be considered limiting.

[0019] In some embodiments, the can manufacturing machine 100 includes a cup holder 127 aligned with axis 128 for receiving and supporting the cup-shaped blank 102 along axis 128 before it is driven through the tooling kit 108. The can manufacturing machine 100's arching machine 110 can shape the bottom of the can 104 after the tooling kit 108.

[0020] During the drawing and thinning process, the stamping assembly 106 (particularly the punch 114) engages the cup-shaped blank 102 along axis 128 and forces the cup-shaped blank 102 through the toolbox 108. As the cup-shaped blank 102 is forced through the toolbox 108, it is drawn and thinned, deforming from a shallower, wider body into a narrower, longer can 104, with reduced wall thickness. The bottom forming machine 110 can form the bottom of the can 104. The stamping assembly 106 can be driven at any suitable speed to produce a desired number of cans 104 per minute. As some non-limiting examples, the stamping assembly 106 can be driven at a speed of approximately 200 to 450 strokes per minute (e.g., approximately 400 to 450 strokes per minute), where one stroke refers to one cycle of engaging the cup-shaped blank 102, forming, and releasing a can 104. In other words, at a rate of 200 to 450 strokes per minute, the components engage, form, and release the canister at a rate of approximately 200 to 450 strokes per minute.

[0021] During the drawing and thinning processes, the cup-shaped blank 102 is subjected to various forces. The total force or load is the force applied to the cup-shaped blank 102 by the punch 114 (via the stamping assembly 106) during thinning. The total force or load typically represents the sum of the frictional force between the punch 114 and the sidewall of the cup-shaped blank 102 and the punch nose force between the punch 114 and the bottom of the cup-shaped blank 102. In various embodiments, obtaining measurements of two of the three forces can allow the determination of the third force (e.g., obtaining measurements of the total force and the punch nose force can allow the determination of the frictional force).

[0022] In various embodiments, the can manufacturing machine 100 includes a sensor system 130 having a first sensor 132 for measuring total force or load and a second sensor 134 for measuring force at the punch nose. The sensor system 130 may optionally include a controller 136 (e.g., a processor and / or memory) communicatively coupled to the sensors 132, 134, and the controller 136 may determine frictional forces during drawing and thinning based on information from the sensors 132, 134. In other embodiments, the sensor system 130 may not need to include a controller 136, and information from the sensors 132, 134 may be provided to an operator and / or other devices as needed.

[0023] In some embodiments, a second sensor 134 for measuring the force at the punch nose can be disposed on the punch 114. In such an embodiment, the second sensor 134 can move with the stamping assembly 106 during the reciprocating linear motion of the drawing and thinning process.

[0024] refer to Figure 1In various embodiments, a first sensor 132 for measuring the total load may be positioned at a fixed location on or within the can-making machine 100. In such embodiments, while a second sensor 134 may move with the stamping assembly 106, the first sensor 132 typically maintains its position during the drawing and thinning processes. Mounting the first sensor 132 at a fixed location within the can-making machine 100 relative to the stamping assembly 106, particularly behind the last thinning die 124 of the can-making machine 100, allows for the measurement of the total load during the drawing and thinning processes without the need for instrumentation of the stamping assembly 112. Mounting the first sensor 132 at a fixed location further reduces vibration noise in the sensor measurement, allowing for better determination of frictional forces or other information based on the measured data. In various embodiments, a fixed first sensor 132 can reduce sensor fatigue (and extend sensor lifespan) and can increase the ease of installation, maintenance, and / or repair.

[0025] In some embodiments, the first sensor 132 is provided with the toolkit 108, and in some embodiments, the first sensor 132 may be positioned along axis 128 behind the last thinning die in one or more dies 124. In various embodiments, the first sensor 132 may be provided in place of the wear plate conventionally positioned behind the thinning die 124. Figure 1 In the illustrated embodiment, the first sensor 132 is mounted behind the third thinning mold 124 of the tool kit 108. In some embodiments, and discussed in detail below, the first sensor 132 may be aligned with the mold 124 along axis 128, which can minimize and / or eliminate the influence of the first sensor 132 on the precise alignment of the tool kit 108.

[0026] refer to Figures 2 to 4 In various embodiments, the first sensor 132 includes a hole 140, and when the first sensor 132 is assembled into the tool kit 108, the hole 140 can be aligned along axis 128 with a hole 126 in the die 124. In these embodiments, during the deep drawing and thinning process, the cup-shaped blank 102 can pass through the hole 140 of the first sensor 132 after the last die 124.

[0027] In various embodiments, the first sensor 132 typically includes a loading surface portion 142 and a support ring portion 144, which together define a first end 146 and a second end 148 of the first sensor 132. In various embodiments, the loading surface portion 142 defines an aperture 140 of the first sensor 132. The support ring portion 144 may include one or more orifices 150 or other suitable engagement features to facilitate mounting of the first sensor 132 in a tool kit 108. A wiring 152 optionally extends from the first sensor 132, and in some non-limiting embodiments, the wiring 152 may extend off-axis from the first sensor 132, such as... Figure 2 and Figure 3 As shown.

[0028] The first sensor 132, the loading surface portion 142, and the support ring portion 144 can have various relative dimensions as needed. In some embodiments, the width 154 of the loading surface portion 142 can be maximized to maximize the contact area of ​​the first sensor 132. In various alternative embodiments, and as... Figure 4 As best shown, the support ring portion 144 may be recessed at the first end 146 relative to the loading surface portion 142, and the loading surface portion 142 may be recessed at the second end 148 relative to the support ring portion 144. In other embodiments, a first sensor 132 having other shapes, sizes, and / or features may be used to measure the total load.

[0029] The following provides a collection of exemplary embodiments, including at least some embodiments that are explicitly listed as “examples” providing further descriptions of various exemplary embodiments in accordance with the concepts described herein. These examples are not intended to be mutually exclusive, exhaustive, or limiting; and this disclosure is not limited to these exemplary examples, but covers all possible modifications and variations within the scope of the proposed claims and their equivalents.

[0030] Example 1. A can manufacturing machine comprising: a stamping assembly capable of reciprocating linear motion along an axis, the stamping assembly including a punch and a punch; and a tool kit including: a plurality of dies, each of the plurality of dies including a hole, wherein the punch is configured to press a cup-shaped blank through the hole of the plurality of dies to form a can during a deep drawing and thinning process; and a sensor mounted along the axis and behind the last of the plurality of dies relative to the stamping assembly, wherein the sensor includes the hole through which the cup-shaped blank passes after passing the last die, and wherein the sensor is configured to measure the total load during the thinning process.

[0031] Example 2. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor is mounted within the housing of the toolkit.

[0032] Example 3. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor is a first sensor, and wherein the stamping assembly includes a second sensor on the punch, the second sensor being configured to measure the punch nose force during the thinning process.

[0033] Example 4. The can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof further includes a controller configured to determine the frictional force during the thinning process based on the total load from the first sensor and the punch nose force from the second sensor.

[0034] Example 5. A tank manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor includes a loading surface portion and a support ring portion, wherein the loading surface portion defines the orifice.

[0035] Example 6. A tank manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the support ring portion is recessed at a first end of the sensor relative to the loading surface portion, and the loading surface portion is recessed at a second end of the sensor relative to the support ring portion.

[0036] Example 7. A can manufacturing machine comprising: a stamping assembly capable of reciprocating linear motion along an axis, the stamping assembly including a punch and a punch head; and a tool kit including a plurality of thinning dies and a sensor located at a fixed position within the tool kit, wherein the sensor is configured to measure the total load during the drawing and thinning processes of the can manufacturing machine.

[0037] Example 8. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the plurality of molds includes at least three thinning molds, and wherein the sensor is mounted in the tool kit behind the last of the at least three thinning molds.

[0038] Example 9. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor includes an outer diameter and an inner diameter, wherein the inner diameter defines an aperture for receiving a cup-shaped blank during the deep drawing and thinning process.

[0039] Example 10. A tank manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor is centered on the axis.

[0040] Example 11. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor is a first sensor, and wherein the stamping assembly further includes a second sensor for measuring the punch nose force during the thinning process.

[0041] Example 12. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the second sensor is located on the punch nose of the stamping assembly.

[0042] Example 13. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, further comprising a controller configured to determine the frictional force during the thinning process using the total load from the first sensor and the punch nose force from the second sensor.

[0043] Example 14. A can manufacturing machine according to any of the foregoing or subsequent examples or combinations thereof, wherein the second sensor is movable together with the stamping assembly.

[0044] Example 15. A method for drawing and thinning a can, the method comprising: inducing a reciprocating linear motion of a stamping assembly of a can manufacturing machine, the reciprocating linear motion driving a cup-shaped blank through a plurality of dies in a tool kit; and measuring a total force on the cup-shaped blank using a sensor supported behind the last of the plurality of dies in the tool kit.

[0045] Example 16. The method according to any of the foregoing or subsequent examples or combinations thereof, wherein causing reciprocating linear motion includes driving the cup-shaped blank through the hole of the sensor behind the last mold among the plurality of molds in the toolkit.

[0046] Example 17. The method according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor is fixed when the stamping assembly drives the cup-shaped blank through the hole of the sensor.

[0047] Example 18. The method according to any of the foregoing or subsequent examples or combinations thereof further includes using a sensor on the stamping assembly to measure the punch nose force on the cup-shaped blank.

[0048] Example 19. The method according to any of the foregoing or subsequent examples or combinations thereof, wherein the sensor on the stamping assembly is a punch nose sensor of the punch of the stamping assembly.

[0049] Example 20. The method according to any of the foregoing or subsequent examples or combinations thereof further includes determining the frictional force during thinning based on the measured punch nose force and the total force.

[0050] As used herein, the terms “invention” and “the present invention” are intended to refer to all the subject matter of this patent application and the following claims. Statements containing these terms should not be construed as limiting the subject matter described herein or limiting the meaning or scope of the patent claims below.

[0051] In this specification, references are made to alloys identified by AA numbers and other relevant designations such as “Series” or “5xxx”. For information on the most commonly used numerical designation systems for naming and identifying aluminum and its alloys, see the Aluminum Association’s “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Composition Limits for Aluminum Alloys in the Form of Castings and Ingots”.

[0052] As used herein, unless the context clearly indicates otherwise, “an,” “a,” and “the” refer to both singular and plural references.

[0053] The subject matter of embodiments of this disclosure is specifically described herein to satisfy statutory requirements, but such description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in combination with other existing or future technologies. This description should not be construed as implying any particular order or arrangement of the various steps or elements, except where the order or arrangement of the individual steps of an element is clearly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “rear” are intended to refer to the orientation shown and described in one or more of the accompanying drawings to which the component and orientation are referenced.

[0054] The terms “comprising,” “having,” “including,” and “containing” should be interpreted as open-ended terms (i.e., meaning “including but not limited to”) unless otherwise noted. All methods described herein may be performed in any suitable order unless otherwise specified herein or otherwise clearly contradicted by the context. Any and all examples or exemplary language (e.g., “such as”) provided herein are intended only to better illustrate embodiments of the invention and, unless otherwise required, do not limit the scope of the invention. The language in this specification should not be construed as indicating any non-claimed element as necessary for practicing the invention.

[0055] The foregoing aspects are merely possible examples of embodiments, set forth only for the purpose of clearly understanding the principles of this disclosure. Many changes and modifications may be made to the embodiments described above without departing substantially from the spirit and principles of this disclosure. All such modifications and changes are intended to be included within the scope of this disclosure, and all possible claims relating to aspects or combinations of elements or steps are intended to be supported by this disclosure. Furthermore, although specific terminology is used herein and in the appended claims, such specific terminology is used in a general and descriptive sense only and is not intended to limit the described embodiments or the purpose of the appended claims.

Claims

1. A can manufacturing machine, comprising: A stamping assembly capable of reciprocating linear motion along an axis, the stamping assembly including a punch and a punch head; as well as The toolkit includes: A plurality of dies, each of the plurality of dies including a hole, wherein the punch is configured to press a cup-shaped blank through the hole of the plurality of dies during a deep drawing and thinning process to form a can; as well as A sensor is mounted along the axis and behind the last of the plurality of dies relative to the stamping assembly, wherein the sensor includes a hole through which the cup-shaped blank passes after passing the last die, and wherein the sensor is configured to measure the total load during the thinning process.

2. The can manufacturing machine according to claim 1, wherein the sensor is installed inside the housing of the tool kit.

3. The can manufacturing machine of claim 1, wherein the sensor is a first sensor, and wherein the stamping assembly includes a second sensor on the punch, the second sensor being configured to measure the punch nose force during the thinning process.

4. The can manufacturing machine of claim 3, further comprising a controller configured to determine the frictional force during the thinning process based on the total load from the first sensor and the punch nose force from the second sensor.

5. The tank manufacturing machine according to claim 1, wherein the sensor includes a loading surface portion and a support ring portion, wherein the loading surface portion defines the orifice.

6. The tank manufacturing machine according to claim 5, wherein the support ring portion is recessed at the first end of the sensor relative to the loading surface portion, and the loading surface portion is recessed at the second end of the sensor relative to the support ring portion.

7. A can manufacturing machine, comprising: A stamping assembly capable of reciprocating linear motion along an axis, the stamping assembly including a punch and a punch head; as well as The toolkit includes multiple thinning dies and sensors located at fixed positions within the toolkit, wherein the sensors are configured to measure the total load during the deep drawing and thinning processes of the can manufacturing machine.

8. The can manufacturing machine of claim 7, wherein the plurality of molds comprises at least three thinning molds, and wherein the sensor is mounted in the tool kit behind the last of the at least three thinning molds.

9. The can manufacturing machine of claim 7, wherein the sensor includes an outer diameter and an inner diameter, wherein the inner diameter defines an aperture for receiving a cup-shaped blank during the thinning process.

10. The tank manufacturing machine according to claim 7, wherein the sensor is centered on the axis.

11. The can manufacturing machine of claim 7, wherein the sensor is a first sensor, and wherein the stamping assembly further comprises a second sensor for measuring the punch nose force during the thinning process.

12. The can manufacturing machine according to claim 11, wherein the second sensor is located on the punch nose of the stamping assembly.

13. The can manufacturing machine of claim 11, further comprising a controller configured to determine the frictional force during the thinning process using the total load from the first sensor and the punch nose force from the second sensor.

14. The tank manufacturing machine according to claim 11, wherein the second sensor is movable together with the stamping assembly.

15. A method for deep drawing and thinning to form a can, the method comprising: The reciprocating linear motion of the stamping components of the can manufacturing machine drives the cup-shaped blank through multiple dies in the toolkit. as well as The total force on the cup-shaped blank is measured using a sensor supported behind the last of the plurality of molds in the toolkit.

16. The method of claim 15, wherein inducing reciprocating linear motion comprises driving the cup-shaped blank through a hole in the sensor behind the last of the plurality of molds in the toolkit.

17. The method of claim 16, wherein the sensor is fixed when the stamping assembly drives the cup-shaped blank through the hole of the sensor.

18. The method of claim 15, further comprising measuring the punch nose force on the cup-shaped blank using a sensor on the stamping assembly.

19. The method of claim 18, wherein the sensor on the stamping assembly is a punch nose sensor of the punch of the stamping assembly.

20. The method of claim 18, further comprising determining the frictional force during thinning based on the measured punch nose force and the total force.

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