Press system and shell supply assembly therefor
The novel supply assembly with a servo motor-driven feed roll and pinch roll design addresses the challenge of high-speed feeding in shell press systems, achieving a 50% reduction in index stock and improving manufacturing efficiency.
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-01-25
- Publication Date
- 2026-04-07
AI Technical Summary
Existing shell press systems face challenges in efficiently and quickly producing large quantities of shells due to the design limitations in feeding wide coil stock at high speeds, particularly with increased die set sizes.
A novel supply assembly with a servo motor-driven feed roll and pinch roll design, featuring a lateral offset shaft configuration, pulley assembly, and lightweight structure, positioned close to the die set, reduces index stock and stock loop length, enabling high-speed feeding of wide coil stock up to 700 strokes per minute.
The improved supply assembly allows for a 50% reduction in index stock, minimizes stock loop length, and facilitates high-speed feeding of wide coil stock, enhancing manufacturing efficiency and production capacity.
Smart Images
Figure 2026510502000001_ABST
Abstract
Description
Technical Field
[0001] <Cross - Reference to Related Applications> This application claims priority to U.S. Patent Application No. 18 / 122,799, titled "Press System and Shell Feeding Assembly Therefor", filed on March 17, 2023.
[0002] <Technical Field> The disclosed concepts generally relate to press systems, and more particularly to shell presses and related methods for forming container closures or ends, commonly referred to as shells. This disclosure also relates to a feeding assembly for a shell press.
Background Art
[0003] The formation of bodies, i.e., can ends or shells for aluminum or steel cans, is generally well known in the art.
[0004] Figure 1 shows an exemplary press system 2 comprising a shell press 4, which is designed to form a shell 6 (shown in a simplified form) from a sheet of material 50 (e.g., aluminum, but not limited to aluminum) as the material is supplied between die sets 10 (outlined in Figure 1, but not shown in detail). More specifically, the material 50 is supplied as a coil stock 52 (shown in a simplified form). A supply assembly 20 having multiple rolls 22, 24 forms a stock loop 26 to facilitate the supply of material 50 to and between die sets 10 of the shell press 4. The supply assembly 20 is located at a distance d from the shell press 4. This distance d, measured between the centerline 14 of the shell press 4 and the centerline 28 of the supply assembly 20, corresponds to the indexing stock of the material 50. Support elements 30 are included to support the index stock of material 50 between the supply assembly 20 and the shell press 4, and a transport device 40 is provided to transport the shell 6 from the shell press 4 after the shell 6 has been formed by the die set 10.
[0005] In the can manufacturing industry, there is always a desire to produce large quantities of shells as quickly and efficiently as possible. Methods that companies have attempted to achieve these objectives include: (1) increasing the number of pockets in the die set where shells are formed, and (2) increasing the speed at which the shell press operates (e.g., strokes per minute (spm)). Typically, one shell is formed in each tooling pocket of the die assembly in each stroke of the shell press ram. Therefore, for example, a 24-out die assembly with 24 tooling pockets can form 24 shells per stroke.
[0006] As the die set size increases, the corresponding size (e.g., width) of the coil stock also increases. Feeding such material at relatively high speeds presents several unique design challenges.
[0007] Therefore, there is room for improvement in the shell press and its supply assembly. [Overview of the Initiative]
[0008] These and other requirements are met by the disclosed embodiments of the concept, which pertain to improved supply assemblies and shell presses.
[0009] In one aspect of the disclosed concept, a feed assembly for supplying material to a press system is provided. The press system includes a shell press having a die set configured to form material into a plurality of shells. The feed assembly comprises a support element, a feed roll including an integrated shaft coupled to the support element and having a longitudinal axis, a drive assembly configured to drive the feed roll, including a motor and a drive shaft, the drive assembly having a longitudinal axis, and a pinch roll configured to cooperate with the feed roll to receive material and move it between the feed roll and the feed roll. The longitudinal axis of the integrated feed roll shaft is offset laterally with respect to the longitudinal axis of the motor drive shaft.
[0010] The motor may be a servo motor, and the drive assembly may further include a pulley assembly and a drive belt. The pulley assembly includes a drive member coupled to the motor drive shaft and a pulley coupled to the built-in shaft of the feed roll, and the drive belt may be configured to operably couple the drive member and the pulley and resist backlash.
[0011] The die set of the shell press may have a centerline, and the supply assembly may have a centerline, and the distance D between the centerline of the die set and the centerline of the supply assembly is the index stock, and the index stock is 70 inches or less.
[0012] The longitudinal axis of the integrated feed roll shaft may be positioned no more than 40 inches from the centerline of the die set. The shell press may have a base, and the support elements of the feed assembly may be configured to overlap at least a portion of the base.
[0013] The feed roll may comprise an outer cylinder, a concentric inner cylinder, and multiple webs extending between the outer and inner cylinders, connecting them and forming a lightweight, substantially hollow structure. The feed roll's mounting shaft may be a steel shaft extending through the inner cylinder.
[0014] A pinch roll may include a core, an outer cover that surrounds the core, a pair of bearings positioned at both ends within the core, and a shaft extending through the core between the pair of bearings. The core may be made of steel, and the outer cover may be made of polyurethane or other metallic material.
[0015] A press system including the supply assembly described above is also disclosed. The die set of the shell press may be arranged in a horizontal plane, and the shell press may have an input-side conveyor and an output-side conveyor, the input-side conveyor being arranged at an angle to the horizontal plane of the die set. [Brief explanation of the drawing]
[0016] The present invention can be fully understood from the following description relating to preferred embodiments, in conjunction with the accompanying drawings.
[0017] [Figure 1] This is an elevation view of a conventional shell press.
[0018] [Figure 2]An elevation view of a shell press and a supply assembly therefor, based on an embodiment of the disclosed concept.
[0019] [Figure 3] Another elevation view of the shell press of FIG. 2, showing a further aspect of the disclosed concept.
[0020] [Figure 4] An isometric view of the shell press of FIG. 3.
[0021] [Figure 5A] An isometric view of a part of the supply assembly.
[0022] [Figure 5B] Another isometric view of the supply assembly of FIG. 5A.
[0023] [Figure 6] A cross-sectional view taken along line 6-6 of FIG. 5B, broken away.
[0024] [Figure 7A] An isometric view of a supply roll for the supply assembly, based on another aspect of the disclosed concept.
[0025] [Figure 7B] An end view of the supply roll of FIG. 7A.
[0026] [Figure 8A] An isometric view of a pinch roll for the supply assembly, based on another aspect of the disclosed concept.
[0027] [Figure 8B] A cross-sectional view taken along line 8B-8B of FIG. 8A, broken away.
Mode for Carrying Out the Invention
[0028] For illustrative purposes, the embodiments of the disclosed concepts are described as applicable to wide-out-shell presses, but it will become apparent that they may also be applicable to a variety of alternative press systems having known or appropriate sizes and / or configurations of metal forming tooling and associated components.
[0029] The directional expressions used in the specification, such as clockwise, counterclockwise, upward, downward, up, down, and their derivatives, relate to the orientation of the illustrated elements and do not limit the claims unless expressly provided in the claims.
[0030] As used herein, the term “can” means any known or suitable container configured to hold contents (e.g., liquids, food, or any other suitable substance), and expressly, but not limited to, beverage cans such as aluminum beer and soda cans, as well as food cans.
[0031] As used herein, the term “can end” refers to a closure configured to be attached to a can in order to seal it.
[0032] As used herein, the terms “shell” and “can end shell” refer to a component formed by a shell press disclosed and subsequently converted, typically by appropriate tooling acting within a conversion press, to provide the desired can end.
[0033] Figures 2 and 3 show a supply assembly 120 for supplying material 150 to a press system 102, based on a non-limiting aspect of the disclosed concept. The press system 102 includes a shell press 104 having a die set 110 (shown overall in Figure 2, details not specifically shown), the die set 110 configured to form the material 150 into a plurality of shells (shown in a simplified form in Figure 2). It will be understood that the material 150 (e.g., sheet aluminum, but not limited to) and associated coil stock 152 are shown in a simplified form in the figures for convenience of reference and ease of illustration.
[0034] The disclosed supply assembly 120 includes several novel and unique features, described in detail below, that significantly improve the manufacturing performance of the press system 102. In a non-limiting example, according to a preferred embodiment of the disclosed concept, the supply assembly 120 enables high-speed (e.g., faster than preferably 450 strokes / min (spm), and more preferably faster than 700 spm) feeding of a wide (e.g., a coil stock 152 shown in a simplified form in Figures 2 and 3) aluminum coil stock (e.g., a coil stock 152 shown in a simplified form in Figures 2 and 3) using an index dwell feeding cycle.
[0035] As shown in Figures 2 to 4, the supply assembly 120 preferably includes a support element 121 (e.g., a mounting base, but not limited to one). Figures 5A, 5B, and 6 are enlarged views of parts of the supply assembly 120, in which the support element 121 is not shown. As best shown in Figure 5B, the drive assembly 300 drives the supply roll 400 of the supply assembly 120, and the pinch roll 500 cooperates with the supply roll 400 to receive the aforementioned material 150 (Figures 2 and 3) and move it between them.
[0036] Continuing to refer to the cross-sectional views in Figures 5B and 6, it will be understood that the exemplary drive assembly 300 preferably includes a motor 200, such as a servo motor including a drive shaft 202 (partially shown in a simplified form with dashed lines in Figure 6), and a controller 250 (Schematically shown in Figure 5A) capable of driving the inertia of the feed roll 400 and pinch roll 500 at a desired speed of about 450–700 spm. As will be described in more detail below with respect to Figures 7A, 7B, 8A and 8B, the disclosed concept also incorporates a very lightweight design for the feed roll 400 and pinch roll 500.
[0037] The servo motor 200 is mounted below the feed roll 400, as shown in Figures 5A, 5B, and 6, resulting in an offset of the shaft centerline (i.e., the longitudinal axis). Specifically, as best shown in Figure 5B, the longitudinal axis 205 of the motor drive shaft 204 is laterally offset with respect to the centerline 305 of the built-in feed roll shaft 308. To resist backlash, the exemplary drive assembly 300 utilizes pulley assemblies 302, 304 and a drive belt 308. More specifically, the pulley assembly includes a drive member 302 coupled to the motor drive shaft 204 and a pulley 304 coupled to the built-in feed roll shaft 308. The drive belt 306 operably couples the drive member 302 and the pulley 304.
[0038] Referring again to Figure 2, and comparing the new supply assembly 120 and press system 102 with the prior art supply assembly 20 and press system 2 of Figure 1, it is understood that the supply rolls 400 and pinch rolls 500 are positioned substantially closer to the shell press 104, and in particular to the die set 110, than in the prior art design. More specifically, the die set 110 of the shell press 104 has a centerline 114, and the supply assembly 120 has a centerline 128. The distance D between the centerline 114 of the die sets 110, 112 and the centerline 128 of the shell press 104 corresponds to the index stock. The novel and unique design of the disclosed concept allows for a reduction of more than 50 percent in the amount of index stock. Thus, the weight of the material 150 (Figures 2 and 3) of the aluminum coil 152 (Figures 2 and 3), which needs to be accelerated and decelerated with each stroke of the shell press 104, is reduced by 50 percent. In one non-limiting preferred embodiment of the disclosed concept, the index stock is 70 inches or less. In another non-limiting preferred embodiment of the disclosed concept, the longitudinal axis 305 of the integrated feed roll shaft 308 is preferably positioned 40 inches or less from the centerline 114 of the die set 110.
[0039] This design also allows for a substantial reduction in the stock loop 126. The stock between the supply loop 126 and the die sets 110 and 112 moves intermittently, while the material stock 152 (Figures 2 and 3) supplied to the supply loop 126 of the supply assembly 120 moves continuously. The disclosed concept favorably minimizes the linear length of the intermittently moving stock.
[0040] The proximity of the disclosed press system 102 and supply assembly 120, as well as the reduction in installation area and space, will be further understood with reference to Figures 2 and 3. That is, the press 104 includes a base portion 105 with legs 107, 109 in the illustrated example. According to one non-limiting exemplary embodiment, the support element 121 of the supply assembly 120 (e.g., a mount base portion, but not limited to) overlaps with at least a portion of the press base portion 105 (e.g., a leg portion 109, but not limited to) as shown.
[0041] Another unique aspect of the disclosed concept is best illustrated in Figure 4. Specifically, the proximity of each component to one another, coupled with the unique structure and configuration of the aforementioned supply assembly 120, limits the space available for the conveying device, particularly on the input side of the shell press 104. To address this issue, the input-side conveying device 140 is positioned at an angle, as shown (see also Figure 3). More specifically, the die set 110 is positioned in a horizontal plane, and the input-side conveying device 140 is positioned at an angle 141 to that horizontal plane. In some non-limiting exemplary embodiments, this angle 141 may be 20 degrees or more.
[0042] As previously mentioned, the feed assembly 120 also utilizes a novel and unique lightweight feed roll 400 and pinch roll 500 design. The feed roll is best shown in the cross-sectional view of Figure 6, as well as in the enlarged views of Figures 7A and 7B. An exemplary feed roll 400 includes an outer cylinder 402 and a concentric inner cylinder 404. The inner cylinder 404 is connected to the outer cylinder 402 by a plurality of webs 406 extending between them. In non-limiting examples shown and described herein, the feed roll 400 has eight webs 406 extending between the outer cylinder 402 and the inner cylinder 404, as shown in Figures 7A and 7B. This structure is substantially hollow, resulting in a lightweight structure, which, among other advantages, reduces the inertia and momentum required to move at relatively high speeds (e.g., 450–700 spm, but not limited to). As shown in the cross-sectional view of Figure 6, the assembly shaft 308 extends through the inner cylinder 404 of the supply roll 400 and is preferably made of high-strength steel.
[0043] The pinch roll 500 is best illustrated in Figure 8A, and in the cross-sectional views of Figures 6 and 8B. In the non-limiting examples illustrated, the pinch roll 500 has a relatively small diameter (e.g., less than 5 inches, but not limiting) to reduce inertia, and also has a composite structure. More specifically, as best illustrated in the enlarged cross-sectional view of Figure 8B, the pinch roll 500 preferably includes a core 505 and an outer cover 502 covering the core 505. In some embodiments, the core is preferably made of solid steel, and the outer cover 502 is preferably made of polyurethane. Polyurethane has, among other advantages, the advantage of not producing residual deformation (memory set). In the illustrated example, the pinch roll 500 assembly further includes a pair of bearings 506, 508 positioned at both ends within the core 505. The shaft 600 extends through the core 505 between the bearings 506, 508.
[0044] Therefore, among the advantages, the disclosed supply assembly 120 offers several unique features that enable the supply of wide (e.g., up to 50 inches or wider) coiled aluminum stock 152 to the press system 102 at high speed (e.g., 450-700 spm) in order to improve the manufacturing production of the shell 106.
[0045] While specific embodiments of the present invention have been described in detail, it will be understood by those skilled in the art that various modifications and substitutions can be made to those details in light of the overall teachings of this disclosure. Accordingly, the specific configurations disclosed are intended to be illustrative only and are not limitations on the scope of the present invention, which is given as the entire scope of the appended claims and any and all equivalents.
Claims
1. In a supply assembly for supplying material to a press system, The press system includes a shell press having a die set configured to form the material into a plurality of shells. The aforementioned supply assembly is Support elements and, A supply roll coupled to the support element, the supply roll including an integrated shaft having a longitudinal axis, A drive assembly configured to drive the supply roll, comprising a motor and a drive shaft having a longitudinal axis, A pinch roll configured to cooperate with the supply roll to receive the material and move the material between itself and the supply roll, It is equipped with, A supply assembly in which the longitudinal axis of the built-in supply roll shaft is offset laterally with respect to the longitudinal axis of the motor drive shaft.
2. The supply assembly according to claim 1, wherein the motor is a servo motor, and the drive assembly further includes a pulley assembly and a drive belt.
3. The supply assembly according to claim 2, wherein the pulley assembly includes a drive member coupled to the motor drive shaft and a pulley coupled to the mounting shaft of the supply roll, and the drive belt is configured to operably couple the drive member and the pulley and resist backlash.
4. The supply assembly according to claim 1, wherein the die set of the shell press has a center line, the supply assembly has a center line, the distance D between the center line of the die set and the center line of the supply assembly is the index stock, and the index stock is 70 inches or less.
5. The supply assembly according to claim 4, wherein the longitudinal axis of the built-in supply roll shaft is located 40 inches or less from the centerline of the die set.
6. The supply assembly according to claim 1, wherein the shell press has a base portion, and the support element of the supply assembly is configured to overlap at least a portion of the base portion.
7. The feed assembly according to claim 1, wherein the feed roll comprises an outer cylinder, a concentric inner cylinder, and a plurality of webs extending between the outer cylinder and the inner cylinder, connecting them to form a lightweight, substantially hollow structure.
8. The supply assembly according to claim 7, wherein the incorporated shaft of the supply roll is a steel shaft extending through the inner cylinder.
9. The supply assembly according to claim 1, wherein the pinch roll includes a core, an outer cover covering the core, a pair of bearings positioned at both ends within the core, and a shaft extending through the core between the pair of bearings.
10. The supply assembly according to claim 10, wherein the core is made of steel and the outer cover is made of a non-metallic material.
11. In a press system, A shell press including the base and die set, A supply assembly for supplying material between the die sets to the shell press in order to form multiple shells, Support elements and, A supply roll coupled to the support element, the supply roll including an integrated shaft having a longitudinal axis, A drive assembly configured to drive the supply roll, comprising a motor and a drive shaft having a longitudinal axis, A pinch roll that cooperates with the supply roll to receive the material and move the material between itself and the supply roll, It is equipped with, The longitudinal axis of the built-in supply roll shaft is offset laterally with respect to the longitudinal axis of the motor drive shaft. Supply assembly and A conveying device for transporting the aforementioned multiple shells, A press system equipped with the following features.
12. The press system according to claim 11, wherein the motor is a servo motor, and the drive assembly further includes a pulley assembly and a drive belt.
13. The press system according to claim 12, wherein the pulley assembly includes a drive member coupled to the motor drive shaft and a pulley coupled to the mounting shaft of the supply roll, and the drive belt is configured to operably couple the drive member and the pulley and resist backlash.
14. The press system according to claim 11, wherein the die set of the shell press has a center line, the supply assembly has a center line, the distance D between the center line of the die set and the center line of the supply assembly is the index stock, and the index stock is 70 inches or less.
15. The press system according to claim 14, wherein the longitudinal axis of the built-in supply roll shaft is positioned 40 inches or less from the centerline of the die set.
16. The press system according to claim 11, wherein the shell press has a base portion, and the support element of the supply assembly is configured to overlap at least a portion of the base portion.
17. The press system according to claim 11, wherein the feed roll comprises an outer cylinder, a concentric inner cylinder, and a plurality of webs extending between the outer cylinder and the inner cylinder, connecting them to form a lightweight, substantially hollow structure.
18. The press system according to claim 11, wherein the pinch roll includes a core, an outer cover covering the core, a pair of bearings positioned at both ends within the core, and a shaft extending through the core between the pair of bearings, the core being made of steel and the outer cover being made of a non-metallic material.
19. The press system according to claim 11, wherein the die set is arranged in a horizontal plane, the shell press has an input-side conveying device and an output-side conveying device, and the input-side conveying device is arranged at a certain angle with respect to the horizontal plane of the die set.
20. The press system according to claim 19, wherein the angle is at least 20 degrees.