Systems and methods for obtaining forming forces of can end features

Abstract

A can end conversion system (100) for forming features in a can end shell (103) includes a tooling station (102) with a tool assembly (112). The tool assembly (112) may at least partially form a can end feature in the can end shell (103) during a feature forming process. The tooling station (102) additionally includes a force measurement device (124) within the tooling station (102) for measuring loads in the tool assembly (112) during the feature forming process. A method of forming features in a can end shell (103) with a can end conversion system includes receiving the can end shell (103) at the tooling station (102), causing the tool assembly (112) to at least partially form a can end feature in the can end shell (103), and measuring a load in the tool assembly (112) of the tooling station (102) while at least partially forming the can end feature.

Description

SYSTEMS AND METHODS FOR OBTAINING FORMING FORCES OF CAN ENDFEATURESREFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application No. 63 / 508, 136, filed on June 14, 2023, and entitled SYSTEMS AND METHODS FOR OBTAINING FORMING FORCES OF CAN END FEATURES, the content of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] This application relates to metal containers, and more particularly, to systems and methods for forming can end features in a can end shell that can be joined with container bodies to form the metal containers.BACKGROUND

[0003] Metal containers, such as those intended to hold food or beverages (e.g., aluminum beverage cans), generally include a container body having an opening defined in one end, and a closure (referred to as a “container end shell” or a “can end shell”) designed to close the opening of the container body. The container body and the can end shell are typically joined at their peripheries (e.g., by being crimped or rolled together) to form a liquid-tight and gas-tight joint. While some container ends are flat circular discs, container end shells are more commonly provided with raised and contoured or curled peripheral edges that facilitate the joining process.

[0004] A can end shell may be first formed from a metal sheet, such as but not limited to an aluminum or aluminum alloy sheet. Additional can end features may be formed in the can end shell by one or more feature forming processes using suitable tooling, and feature forming processes may include rivet forming, tab forming, paneling, scoring, embossing, tab-securing, etc., and such processes are commonly performed. Feature forming processes are commonly performed by several separate tooling stations that may be incorporated into tooling such as a conversion press. Some conversion presses may include a sensor behind and outside of the entire conversion press, but such sensors are unable to measure or detect forming forces on the can end shell.SUMMARY

[0005] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject matter. The subject matter should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0006] According to certain embodiments, a can end conversion system for forming features in a can end shell includes a tooling station with a tool assembly for at least partially forming a can end feature in the can end shell in a feature forming process. The tooling station also includes a force measurement device within the tooling station for measuring loads in the tool assembly during the feature forming process.

[0007] According to various embodiments, a method of forming features in a can end shell with a can end conversion system includes receiving a can end shell at a tooling station of the can end conversion system. The method includes causing the tool assembly to at least partially form a can end feature in the can end shell and measuring a load in the tool assembly of the tooling station using at least one force measurement device within the tool assembly while at least partially forming the can end feature.

[0008] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0010] FIG. 1 illustrates a can end feature forming system and can end shells according to embodiments.

[0011] FIGS. 2A-B illustrate a station of a can end feature forming system according to embodiments.

[0012] FIG. 3 illustrates a flow chart of a method of can end feature forming according to embodiments.DETAILED DESCRIPTION

[0013] Described herein are can end feature forming systems and associated methods. The can end feature forming systems include at least one tooling station with a tool assembly, and the tool assembly includes one or more force measurement devices within the tool assembly for measuring loads during a forming process. Non-limiting examples of tooling stations with such tool assemblies may include a bubble-forming station, a button-forming station, a rivet-forming station, an embossing station, a down paneling station, a scoring station, a tab-forming station, and / or a tab-staking station. In certain embodiments, a plurality of stations may be provided for performing various can end feature processes, and each station of the plurality of stations may include at least one force measurement device. In certain embodiments, the one or more force measurement devices may be provided on components of the tooling assemblies that are proximate and / or adjacent to a can end shell during a feature forming process using the tool assembly.

[0014] Compared to traditional can end feature forming systems, the systems and methods described herein allow for measurement of forming forces on can end shells during can end feature forming processes and can end shell manufacturing. In certain embodiments, the systems and methods described herein may allow for measurement of forming forces during different steps that occur in the overall can end feature forming processes. Measurement of forming forces in turn may be utilized to determine characteristics of the can end shell and / or the tool assembly itself, such as but not limited to effects of the can end shell feature forming process on metal properties, tooling design, setup, and / or arrangement, tooling wear profile, combinations thereof, and / or other characteristics as desired. In some embodiments, measurement of the forming forces may be used to determine characteristics of the metal, such as but not limited to formability, friction, and / or how changes in the metal interact with the tooling. The measured forming forces and / or additionalinformation determined based on the measured forming forces may be utilized to control various aspects of the can end feature forming system and / or process, such as but not limited to type of metal utilized for the can end shell, loads applied by components of the tooling assemblies, arrangement and / or types of components of the tooling assemblies, etc. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0015] Referring to FIG. 1, a can end conversion system 100 may include one or more tooling stations 102 for forming various features in a can end shell 103. In some examples, can end shell 103 may be various metals as desired, including but not limited to aluminum, aluminum alloys, steel, or other metals as desired. In some examples, metal sheet 101 may be aluminum or an aluminum alloy in the Ixxx series, 2xxx series, 3xxx series, 4xxx series, 5xxx series, 6xxx series, 7xxx series, 8xxx series and / or any other aluminum or aluminum alloy.

[0016] In various embodiments, the tooling stations 102 are arranged to sequentially process can end shells 103 and / or features for can end shells 103 (such as but not limited to tabs). The tooling stations 102 may be arranged to process any number of can end shells 103 at a given time. As nonlimiting examples, the can end conversion system 100 may be a single lane can end conversion system 100 (e.g., a single can end shell is at a given tooling station 102), a two lane can end conversion system 100 (e.g., two can end shells are at a given tooling station 102), a three lane can end conversion systems 100, etc.

[0017] Any number of tooling stations 102 may be utilized as desired, and the tooling stations 102 may be various types of tooling stations and / or provided in various arrangements or sequences as desired. Each tooling station 102 includes a tool assembly having a forming surface for performing various feature forming processes. Non-limiting examples of feature forming processes include button forming, bubble forming, rivet forming, embossing, down panel forming, scoring, coining, doming, tab-forming, and / or a tab-staking, among others. In the example illustrated in FIG. 1, the tooling station 102 A is a bubble forming station for forming a bubble 104 in the can end shell 103, the tooling station 102B is a button forming station for forming a button 106 in the can end shell 103, the tooling station 102C is a scoring station for forming a score 108 in the can end shell 103, and the tooling station 102D is a tab-staking station for staking a tab 110 to the can end shell 103 using a rivet 111. As mentioned, in other embodiments, other toolingstations 102 and / or combinations of tooling stations 102 may be utilized in various sequences with the can end conversion system 100 as desired, such as but not limited to a rivet forming station, a coining station, an embossing station, a down panel station, a doming station, a tab-forming station, and / or other feature forming stations as desired. In one non-limiting example, at least one tooling station 102 is a coining station. In various embodiments, a given tooling station 102 may perform one operation or a plurality of operations. As a non-limiting example, a plurality of rivet progression stations may perform a plurality of forming operations in sequence (and optionally with overlap). As a further non-limiting example, a tooling station may cause stretching during a drawing operation, and close to the end of the drawing a gap between the tools becomes smaller than the metal gauge and the metal is coined. During coining, the metal may compressed in the thickness direction changing the final geometry in a way that may facilitate subsequent forming operations.

[0018] FIGS. 2A-B illustrate an example of one of the tooling stations 102 for the can end conversion system 100 with a tool assembly 112. In FIGS. 2A-B, the tooling assembly 112 may be fixed or otherwise connected to a support 118 and includes one or more tools 116 (e.g., dies, inserts, etc.) having one or more forming surfaces 114. While a single tooling assembly 112 is illustrated with the tooling station 102, in other embodiments, a tooling station 102 may include a plurality of tooling assemblies, such as a lower tooling assembly 112 (as illustrated in FIGS. 2A- B) and an upper tooling assembly 112. In such embodiments, the lower tooling assembly 112 may engage a lower surface 120 of the can end shell 103 during the feature forming process and the upper tooling assembly may engage an upper surface 122 of the can end shell 103 during the feature forming process.

[0019] In FIGS. 2A-B, the tooling station 102 is a bubble forming station and the forming surfaces 114 of the tool assembly 112 may form the bubble 104 in the can end shell 103. In this example, during the bubble forming operation, the tooling station 102 may receive the can end shell 103 (FIG. 2A) and the tool assembly 112 may engage the can end shell 103 such that the bubble 104 is formed in the can end shell 103 (FIG. 2B). As mentioned, in other embodiments, other tooling stations may have other tool assemblies with other components, configurations, and other characteristics as desired. Non-limiting examples of other tooling assemblies for the can end conversion system 100 may include, but are not limited to, those described in U.S. Patent No.5,749,257 to McEldowney, et al., and U.S. Patent No. 4,568,230 to Brown, both of which are hereby incorporated by reference in their entirety.

[0020] In various embodiments, at least one tooling station 102 of the can end conversion system 100 includes one or more force measurement devices 124 within the tool assembly 112. The one or more force measurement devices 124 may measure loads in the tool assembly 112 during the feature forming process performed by the at least one tooling station 102. The one or more force measurement devices 124 may be various suitable types of sensors or other devices suitable for measuring loads. As discussed below, the one or more force measurement devices 124 may measure forming forces on the can end shell during the feature forming process, including at various stages of the feature forming process.

[0021] Any number of force measurement devices 124 may be utilized as desired. As nonlimiting examples, the tool assembly 112 may include a single force measurement device 124 as illustrated in FIGS. 2A-B, two force measurement devices 124, or more than two force measurement devices 124.

[0022] The one or more force measurement devices 124 may be provided on various components of the tool assembly 112 as desired. As a non-limiting example, in FIGS. 2A-B, one force measurement device 124 is provided on the tool 116 with the forming surface 114 and such that the force measurement device 124 is proximate to the can end shell 103 during the feature forming process. In other examples and depending on the type of tooling station 102 and / or tool assembly 112, the one or more force measurement devices 124 may be provided on various components as desired. In embodiments wherein the tooling station 102 includes an upper tool assembly and a lower tool assembly, the one or more force measurement devices 124 may be provided on the upper tool assembly, the lower tool assembly, or both the upper tool assembly and the lower tool assembly. When force measurement devices 124 are provided on both the upper tool assembly and the lower tool assembly of the tooling station 102, the number of force measurement devices 124 on the upper tool assembly need not be the same as the number of force measurement devices 124 on the lower tool assembly.

[0023] In addition to measuring loads, in certain embodiments, the position of the tool assembly 112 and / or the tools 116 of the tool assembly 112 may be measured during the feature forming process. In some embodiments, the position may be measured by the one or more forcemeasurement devices 124, while in other embodiments, other sensors may be included in the tool assembly 112 for measuring the position of the tool assembly 112 and / or the tools 116 of the tool assembly 112.

[0024] In the embodiment illustrated, one or more positions sensors 128 are utilized for detecting and / or monitoring the position of the tool assembly 112 and / or the tool 116 (and thus changes in the position of the tool assembly 112 and / or the tool 116). In various embodiments, directly measuring the position (rather than calculating from tool design and press timing) provides information with improved accuracy. The position sensor 128 may be various types of sensors suitable for measuring position. The number and location of the one or more position sensors 128 should not be considered limiting, and in other embodiments, one or more position sensors 128 may be provided at various locations suitable for measuring the position of the tool assembly 112 and / or the tool 116. In various embodiments, the position of the tool assembly 112 and / or the tool 116 may be utilized to generate a load displacement chart (or otherer suitable output), which may be utilized to relate changes in load with metal formability, tooling design, and / or with specific steps of the forming process. In certain embodiments, knowing the position of the tools 116 (from the position sensors 128) and the corresponding change in load (from the force measurement devices 124) may allow for a determination of the amount of deformation in areas of interest, such as but not limited to areas susceptible to cracking.

[0025] As a non-limiting example, in some embodiments, a tooling station 102, such as but not limited to a coining station, may perform one or more operations, and the position sensors 128 (or other suitable devices) may allow for an identification of the different operations, a start of one operation and completion of another operation, etc., thereby allowing for improved evaluation of the tools 116 and / or processes performed. As an example, a tooling station may cause stretching during a drawing operation and, close to the end of this drawing operation, a gap between the tools becomes smaller than the metal gauge, and the metal is coined. In such examples, the position sensors 128 (or other devices) measuring the position of the tool assembly 112 and / or the tools 116 may allow for an identification of the start of coining based on the detected position and independent of other changes, which may allow for an evaluation of how the initial drawing or stretching contributed to fracture formation. In various embodiments, knowing the position of the tools and the corresponding change in the load may allow for a determination of the amount ofdeformation in critical areas. In certain embodiments, directly measuring the position instead of calculating from tool design and press timing may provide more accurate and reliable information.

[0026] As illustrated in FIGS. 2A-B, the can end conversion system 100 optionally includes a controller 126 (e.g., processor and / or memory) that is communicatively coupled to the one or more force measurement devices 124 (and optionally the position sensors when provided separately). Such communication may be various types of communication as desired, including various wired and / or wireless communication as desired.

[0027] In embodiments with the controller 126, the controller 126 may receive the measured loads from the one or more force measurement devices 124. The controller 126 may also receive the measured positions from the force measurement devices 124 and / or the position sensors when provided separately. In certain embodiments, the controller 126 may generate an output response based on the received loads and / or positions. Output responses may include, but are not limited to, providing the received information to an operator via a user interface and / or a remote device, providing an alert or notification to the operator, and / or controlling one or more components of the tooling station 102 and / or the can end conversion system 100.

[0028] In some embodiments, the controller 126 may produce a graph and / or other output with a relationship between measured loads and measured positions. In certain embodiments, the controller 126 may provide the graph and / or other output of the relationship between the measured loads and measured positions for each stage of the feature forming process for the particular tooling station 102 (e.g., bending, stretching, coining, etc.).

[0029] Referring to FIG. 3, in certain embodiments, the controller 126 may measure or determine forming forces on the can end shell during the feature forming process performed by the tooling station 102 based on the measured loads from the one or more force measurement devices 124. As a non-limiting example, in a block 302, the controller 126 may receive one or more first loads from the one or more force measurement devices 124 during a first process in which the tooling station 102 performs the feature forming process but without the can end shell 103 (e.g., during a calibration process). In various embodiments, block 302 also includes receiving measured first positions from the one or more force measurement devices 124 and / or other positions sensors during the first process.

[0030] In a block 304, the controller 126 may receive second loads from the one or more force measurement devices 124 during a second process in which the feature forming process is performed with the can end shell 103 (e.g., during a can end conversion operation). In various embodiments, block 304 also includes receiving measured second positions from the one or more force measurement devices 124 and / or other positions sensors during the second process.

[0031] In a block 306, the controller 126 may determine the forming forces on the can end shell 103 during the feature forming process based on a difference between the measured second loads (and optionally the measured second positions) and the measured first loads (and optionally the measured first positions). Optionally, the controller 126 may determine forming forces on the can end shell for each state of the feature forming process for the particular tooling station 102.

[0032] The measured loads from the one or more force measurement devices 124 may be utilized to determine characteristics of the can end shell 103, the tooling station 102, and / or the tool assembly 112. Such determinations may be performed by the controller 126, the operator, and / or as otherwise desired. As non-limiting examples, the measured loads and / or measured forming forces may be utilized to determine metal properties of the can end shell 103, effects of various tool assembly 112 designs, setups, or arrangements, combinations thereof, and / or other characteristics as desired.

[0033] In some embodiments, the measured forming forces and / or additional information determined based on the measured forming forces may be utilized to control various aspects of the can end conversion system 100 and / or process. Such control may be performed by the controller 126, the operator, and / or as otherwise desired. Non-limiting examples of control include controlling the type of can end shell 103 supplied, loads applied by components of the tool assemblies 112, arrangement and / or types of components of the tooling stations 102, combinations thereof, and / or other controls as desired. In other embodiments, the measured loads from the one or more force measurement devices 124 may be utilized to perform various other processes and / or controls as desired.

[0034] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an “Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these exampleillustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0035] Illustration 1. A can end conversion system for forming features in a can end shell, the end conversion tool assembly comprising: a tooling station comprising a tool assembly, the tool assembly configured to perform a can end conversion operation; and a force measurement device within the tooling station, wherein the force measurement device is configured to measure loads in the tool assembly during the can end conversion operation.

[0036] Illustration 2. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a first tooling station of a plurality of tooling stations and the force measurement device is a first force measurement device of a plurality of force measurement devices, and wherein each tooling station of the plurality of tooling stations comprises a corresponding force measurement device within the tooling station.

[0037] Illustration 3. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a rivet-forming station.

[0038] Illustration 4. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a paneling station.

[0039] Illustration 5. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a scoring station.

[0040] Illustration 6. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is an embossing station.

[0041] Illustration 7. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a tab-staking station.

[0042] Illustration 8. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a doming station.

[0043] Illustration 9. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a tab-forming station.

[0044] Illustration 10. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tool assembly comprises an upper tool assembly and a lower tool assembly, and wherein the force measurement device is on the upper tool assembly.

[0045] Illustration 11. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tool assembly comprises an upper tool assembly and a lower tool assembly, and wherein the force measurement device is on the lower tool assembly.

[0046] Illustration 12. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the force measurement device is proximate to a forming surface of the tool assembly.

[0047] Illustration 13. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, further comprising a controller communicatively coupled to the force measurement device, wherein the controller is configured to measure forming forces on the can end shell by: receiving a first measured load from the force measurement device during a calibration process without the can end shell; receiving a second measured load from the force measurement device during the can end conversion operation of the tool assembly with the can end shell; and determining the forming forces on the can end shell based on a difference between the first measured load and the second measured load.

[0048] Illustration 14. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the force measurement device is further configured to measure a position of the tool assembly.

[0049] Illustration 15. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, further comprising a position sensor configured to measure a position of the tool assembly.

[0050] Illustration 16. The can end conversion system of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station is a coining station.

[0051] Illustration 17. A method of forming features in a can end shell with a can end conversion system, the method comprising: receiving a can end shell at a tooling station of the can end conversion system, wherein the tooling station comprises a tool assembly with a forming surface; causing the tool assembly to at least partially form a can end feature in the can end shell; andmeasuring a load in the tool assembly of the tooling station using at least one force measurement device within the tool assembly while at least partially forming the can end feature.

[0052] Illustration 18. The method of any preceding or subsequent illustration or combination of illustrations, wherein the tooling station comprises at least one of a bubble-forming station, a button-forming station, a rivet-forming station, an embossing station, a down panel station, a scoring station, a tab-forming station, or a tab-staking station.

[0053] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations, further comprising measuring a position of the tool assembly while at least partially forming the can end feature in the can end shell.

[0054] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, wherein the measured load is a processing load, further comprising determining forming forces on the can end shell by receiving a calibration load from the force measurement device during a calibration process of the tool assembly before receiving the can end shell; and determining the forming forces based on a difference between the calibration load and the processing load.

[0055] Illustration 21. The method of any preceding or subsequent illustration or combination of illustrations, wherein measuring the load comprises measuring the load during each stage of a forming process performed by the tooling station.

[0056] Illustration 22. The method of any preceding or subsequent illustration or combination of illustrations, wherein measuring the load comprises measuring the load during each stage of a forming process performed by the tooling station.

[0057] Illustration 23. The method of any preceding or subsequent illustration or combination of illustrations, wherein measuring tooling station is a coining station.

[0058] As used herein, the terms “invention,” “the invention,” “this invention,” and “the present invention” are intended to refer broadly to all of the subject matter of this patent application and the claims below. Statements containing these terms should be understood not to limit the subject matter described herein or to limit the meaning or scope of the patent claims below.

[0059] Throughout this disclosure, a reference numeral with a letter refers to a specific instance of an element and the reference numeral without an accompanying letter refers to the elementgenerically or collectively. Thus, as an example (not shown in the drawings), device “12A” refers to an instance of a device class, which may be referred to collectively as devices “12” and any one of which may be referred to generically as a device “12”.

[0060] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0061] In this description, reference is made to alloys identified by AA numbers and other related designations, such as “series” or “5xxx.” For an understanding of the number designation system most commonly used in naming and identifying aluminum and its alloys, see “International Alloy Designations and Chemical Composition Limits for Wrought Aluminum and Wrought Aluminum Alloys” or “Registration Record of Aluminum Association Alloy Designations and Chemical Compositions Limits for Aluminum Alloys in the Form of Castings and Ingot,” both published by The Aluminum Association.

[0062] The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this 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 conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up,” “down,” “top,” “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

[0063] The terms “comprising,” “having,” “including,” and “containing” are to be construed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the invention.

[0064] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

CLAIMSThat which is claimed:

1. A can end conversion system for forming features in a can end shell, the can end conversion system comprising: a tooling station comprising a tool assembly, the tool assembly configured to perform a can end conversion operation; and a force measurement device within the tooling station, wherein the force measurement device is configured to measure loads in the tool assembly during the can end conversion operation.

2. The can end conversion system of claim 1, wherein the tooling station is a first tooling station of a plurality of tooling stations and the force measurement device is a first force measurement device of a plurality of force measurement devices, and wherein each tooling station of the plurality of tooling stations comprises a corresponding force measurement device within the tooling station.

3. The can end conversion system of claim 1, wherein the tooling station is a rivet-forming station.

4. The can end conversion system of claim 1, wherein the tooling station is a paneling station.

5. The can end conversion system of claim 1, wherein the tooling station is a scoring station.

6. The can end conversion system of claim 1, wherein the tooling station is an embossing station.

7. The can end conversion system of claim 1, wherein the tooling station is a tab-staking station.

8. The can end conversion system of claim 1, wherein the tooling station is a doming station.

9. The can end conversion system of claim 1, wherein the tooling station is a tab-forming station.

10. The can end conversion system of claim 1, wherein the tool assembly comprises an upper tool assembly and a lower tool assembly, and wherein the force measurement device is on the upper tool assembly.

11. The can end conversion system of claim 1, wherein the tool assembly comprises an upper tool assembly and a lower tool assembly, and wherein the force measurement device is on the lower tool assembly.

12. The can end conversion system of claim 1, wherein the force measurement device is proximate to a forming surface of the tool assembly.

13. The can end conversion system of claim 1, further comprising a controller communicatively coupled to the force measurement device, wherein the controller is configured to measure forming forces on the can end shell by: receiving a first measured load from the force measurement device during a calibration process without the can end shell; receiving a second measured load from the force measurement device during the can end conversion operation of the tool assembly with the can end shell; and determining the forming forces on the can end shell based on a difference between the first measured load and the second measured load.

14. The can end conversion system of claim 1, wherein the force measurement device is further configured to measure a position of the tool assembly.

15. The can end conversion system of claim 1, further comprising a position sensor configured to measure a position of the tool assembly.

16. The can end conversion system of claim 1, wherein the tooling station is a coining station.

17. A method of forming features in a can end shell with a can end conversion system, the method comprising:receiving a can end shell at a tooling station of the can end conversion system, wherein the tooling station comprises a tool assembly with a forming surface; causing the tool assembly to at least partially form a can end feature in the can end shell; and measuring a load in the tool assembly of the tooling station using at least one force measurement device within the tool assembly while at least partially forming the can end feature.

18. The method of claim 17, wherein the tooling station comprises at least one of a bubble-forming station, a button-forming station, a rivet-forming station, an embossing station, a down paneling station, a scoring station, a tab-forming station, or a tab-staking station.

19. The method of claim 17, further comprising measuring a position of the tool assembly while at least partially forming the can end feature in the can end shell.

20. The method of claim 17, wherein the measured load is a processing load, further comprising determining forming forces on the can end shell by: receiving a calibration load from the force measurement device during a calibration process of the tool assembly before receiving the can end shell; and determining the forming forces based on a difference between the calibration load and the processing load.

21. The method of claim 17, wherein measuring the load comprises measuring the load during each stage of a forming process performed by the tooling station.

22. The method of claim 17, wherein the tooling station is a coining station.

Images