Can body forming machine and the pulling and ironing method for can shaping.

Abstract

The can body forming machine comprises a sliding assembly that moves in a reciprocating linear motion and a tool set with multiple molds. A sensor is mounted behind the last of the many molds in the tool set. The invention also relates to a pulling and ironing method for can forming. During the pulling and ironing process, the sliding assembly presses the cup-shaped preform through multiple molds to deform the cup-shaped preform into a can body, and the sensor measures the total load during the pulling and ironing process.

Description

CAN BODY MAKER WITH TOOL-PACK MOUNTED SENSOR AND INSTRUMENTED PUNCH NOSE FOR MEASURING FRICTIONREFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 591,587, filed on October 19, 2023, and entitled CAN BODY MAKER WITH TOOLPACK MOUNTED LOADCELL AND INSTRUMENTED PUNCH NOSE FOR MEASURING FRICTION, the content of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] This application relates to metalworking techniques, and more particularly to can body making system and methods.BACKGROUND

[0003] Cylindrical or tubular structures (hereinafter referred to as “cans”) are generally formed by making a blank out of material (such as metal) and then drawing the blank to form a shallow cup. After the shallow cup is initially drawn, a can body maker may carry the cups on an end of a reciprocating ram through a series of dies to obtain a desired size and thickness of the can. The can body driven by the ram may contact a bottom forming tool to shape the bottom of the can (e.g., to have a dome). Some systems may include sensors on the body of the ram, but such instrumented rams must replace traditional, non-instrumented rams, and even when utilized, the sensors may suffer from vibrational noise and sensor fatigue due to the reciprocating motion of the ram, and the sensors are not easily accessed for installation, maintenance, and / or removal on the instrumented ram.SUMMARY

[0004] 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 notintended 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.

[0005] According to certain embodiments, a can body maker includes a ram assembly that is movable in a reciprocating linear motion along an axis and includes a ram and a punch. The can body maker also includes a tool pack with a plurality of dies that each include an aperture that a cup-shaped blank is driven through during a drawing and ironing process. The tool pack includes a sensor mounted behind a last die of the plurality of dies along the axis and relative to the ram assembly. The sensor includes an aperture through which the cup-shaped blank passes after the last die, and the sensor may measure a total load during the ironing process.

[0006] According to certain embodiments, a can body maker includes a ram assembly that is movable in a reciprocating linear motion along an axis and that includes a ram and a punch. The can body maker also includes a tool pack with a plurality of ironing dies and a sensor at a fixed location within the tool pack, and the sensor may measure a total load during a drawing and ironing process of the can body maker.

[0007] According to various embodiments, a drawing and ironing method for forming a can includes causing reciprocating linear motion of a ram assembly of a can body maker such that the reciprocating linear motion drives a cup-shaped blank through a plurality of dies of a tool pack. The method includes measuring a total force on the cup-shaped blank using a sensor supported behind a last die of the plurality of dies of the tool pack.

[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 body maker according to embodiments.

[0011] FIG. 2 is a perspective view a sensor of a tool pack of the can body maker of FIG. 1 according to embodiments.

[0012] FIG. 3 is an end view of the sensor of FIG. 2.

[0013] FIG. 4 is a sectional view of the sensor of FIG. 2.DETAILED DESCRIPTION

[0014] Described herein are can body makers and associated methods that includes a sensor for measuring total load during a drawing and ironing process. In various embodiments, the sensor measuring total load advantageously is at a fixed position within the can body maker. In certain embodiments, the sensor measuring total load is mounted within a tool pack of the can body maker, such as behind a third or last ironing die of the tool pack. Compared to traditional approaches of total load sensors being mounted inside of a ram, the systems and methods described herein reduce vibrational noise in sensor measurements and sensor fatigue due to the reciprocating motion of the ram. The systems and methods described herein may provide improved access to the sensor for installation, maintenance, and / or removal of the sensors. In various embodiments, the systems and methods described herein may allow for measurement of total load with a ram that need not be instrumented. In certain embodiments, the total load measured by the sensors may provide improved determination and calculation of friction during the drawing and ironing process. 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] FIG. 1 illustrates an example of a can body maker 100 according to embodiments. In general, the can body maker 100 includes various components for performing a drawing and ironing process in which a can body 104 is formed from a cup-shaped blank 102. The cup-shaped blank 102 may be formed from various materials as desired, and in some embodiments, the cupshaped blank 102 is a metal such as but not limited to an aluminum or an aluminum alloy such as a Ixxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, a 8xxx series aluminum alloy and / or any other aluminum or aluminum alloy as desired.

[0016] As illustrated in FIG. 1, the can body maker 100 generally includes a ram assembly 106, a tool pack 108, and optionally a domer 110, among other components. A housing or enclosure 138 optionally is included for at least partially housing one or more components of the can body maker 100.

[0017] The ram assembly 106 includes a ram 112 and a punch 114 supported by the ram 112. The ram 112 is generally elongated along an axis 128, and the punch 114 may be supported at or proximate to an end of the ram 112. The punch 114 generally includes a punch sleeve 116 and a punch nose 118. In some embodiments, the punch sleeve 116 and the punch nose 118 are separate components, although in other embodiments the punch sleeve 116 and the punch nose 118 may be a single or monolithic component. The can body maker 100 includes an actuator 120 that drives or otherwise causes the ram assembly 106 to have reciprocating linear motion (represented by arrow 122) in a predetermined direction. Various types of actuators may be utilized as the actuator 120 causing the reciprocating linear motion of the ram assembly 106.

[0018] The tool pack 108 includes one or more dies 124, and in certain embodiments the tool pack 108 includes a plurality of dies 124. Each die 124 includes an aperture 126 and is arranged along the axis 128 such that during drawing and ironing, the ram assembly 106 drives the cupshaped blank 102 through the dies 124. In the example illustrated, the tool pack 108 includes four dies 124A-D - an initial die 124A may be a redraw die and the subsequent dies 124B-D may be ironing dies. As discussed in detail below, the redraw die may deform the cup-shaped blank 102 from a shallower and wider body into a narrower and longer body, and the ironing dies may iron sidewalls of the cup-shaped blank 102 from an initial thickness to an end thickness and to elongate the cup-shaped blank 102 to form the can body 104. The number of dies 124 illustrated should not be considered limiting.

[0019] In certain embodiments, the can body maker 100 includes a cup holder 127 in alignment with the axis 128 for initially receiving and supporting the cup-shaped blank 102 along the axis 128 before it is driven through the tool pack 108. The domer 110 of the can body maker 100 may shape a bottom of the can body 104 after the tool pack 108.

[0020] During a drawing and ironing process, the ram assembly 106 (particularly the punch 114) engages the cup-shaped blank 102 along the axis 128 and forces the cup-shaped blank 102 through the tool pack 108. As the cup-shaped blank 102 is forced through the tool pack 108, the cup-shapedblank 102 is drawn and ironed such that it deformed from a shallower and wider body into a narrower and longer can body 104 and with a reduced wall thickness. The domer 110 may shape the bottom of the can body 104. The ram assembly 106 may be driven at any suitable speed to produce a desired number of can bodies 104 per minute. As some non-limiting examples, the ram assembly 106 may be driven at speeds of approximately 200-450 strokes per minute, such as about 400-450 strokes per minute, where one stroke refers to one cycle of engaging a cup-shaped blank 102, forming, and releasing one can body 104. In other words, at 200-450 strokes per minute, the assembly engages, forms, and releases can bodies at a rate of about 200-450 strokes per minute.

[0021] During the drawing and ironing process, the cup-shaped blank 102 is subjected to various forces. A total force or load is the force applied by the punch 114 (through the ram assembly 106) onto the cup-shaped blank 102 during ironing. The total force or load generally represents the sum of a friction force between the punch 114 and sidewalls of the cup-shaped blank 102 and a 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 may allow for a determination of the third (e g., obtaining measurements of the total force and the punch nose force may allow for determination of the friction force).

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

[0023] In certain embodiments, the second sensor 134 for measuring the punch nose force may be provided on the punch 114. In such embodiments, the second sensor 134 may be movable with the ram assembly 106 during the reciprocating linear motion of the drawing and ironing process.

[0024] Referring to FIG. 1, in various embodiments, the first sensor 132 for measuring the total load may be provided at a fixed location on or within the can body maker 100. In such embodiments, while the second sensor 134 is movable with the ram assembly 106, the first sensor 132 may generally maintain its position during the drawing and ironing process. Mounting the firstsensor 132 at the fixed location within the can body maker 100 relative to the ram assembly 106, and particularly behind the last ironing die 124 of the can body maker 100, may allow for a measurement of the total load during the drawing and ironing process without requiring that the ram 112 be instrumented. Mounting the first sensor 132 at the fixed location may further reduce vibrational noise in sensor measurements thereby allowing for improved determinations of friction forces or other information based on the measured data. In various embodiments, the fixed first sensor 132 may reduce fatigue on the sensor (and extend the working life of the sensor) and may increase ease of access for installation, maintenance, and / or repair.

[0025] In certain embodiments, the first sensor 132 is provided with the tool pack 108, and in some embodiments, the first sensor 132 may be provided behind a last ironing die of the one or more dies 124 along the axis 128. In various embodiments, the first sensor 132 may be provided in place of a wear plate traditionally provided behind the ironing die 124. In the embodiment illustrated in FIG. 1, the first sensor 132 is mounted behind the third ironing die 124 of the tool pack 108. In certain embodiments, and as discussed in detail below, the first sensor 132 may be aligned with the dies 124 along the axis 128, which may minimize and / or eliminate the impact of the first sensor 132 on the precision alignment of the tool pack 108.

[0026] Referring to FIGS. 2-4, in various embodiments, the first sensor 132 includes an aperture 140, and when the first sensor 132 is assembled in the tool pack 108, the aperture 140 may align with the apertures 126 of the dies 124 along the axis 128. In such embodiments, during the drawing and ironing process, the cup-shaped blank 102 may pass through the aperture 140 of the first sensor 132 after the last die 124.

[0027] In various embodiments, the first sensor 132 generally includes a loading face portion 142 and a support ring portion 144 that together define a first end 146 and a second end 148 of the first sensor 132. In various embodiments, the loading face portion 142 defines the aperture 140 o the first sensor 132. The support ring portion 144 may include one or more bores 150 or other suitable engagement features for facilitating mounting of the first sensor 132 in the tool pack 108. Wiring 152 optionally may extend from the first sensor 132, and in some non-limiting embodiments the wiring 152 may extend offset from an axis of the first sensor 132 as illustrated in FIGS. 2 and 3.

[0028] The first sensor 132, loading face portion 142, and support ring portion 144 may have various relative dimensions as desired. In certain embodiments, a width 154 of the loading faceportion 142 may be maximized to maximize contact area for the first sensor 132. In various optional embodiments, and as best illustrated in FIG. 4, the support ring portion 144 may be recessed relative to the loading face portion 142 on the first end 146 and the loading face portion 142 may be recessed relative to the support ring portion 144 on the second end 148. In other embodiments, a first sensor 132 with other shapes, dimensions, and / or features may be utilized for measuring the total load.

[0029] 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 example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0030] Illustration 1. A can body maker comprising: a ram assembly movable in a reciprocating linear motion along an axis, the ram assembly comprising a ram and a punch; and a tool pack comprising: a plurality of dies, each die of the plurality of dies comprising an aperture, wherein the punch is configured to press a cup-shaped blank through the apertures of the plurality of dies during a drawing and ironing process to form a can body; and a sensor mounted behind a last die of the plurality of dies along the axis and relative to the ram assembly, wherein the sensor comprises an aperture through which the cup-shaped blank passes after the last die, and wherein the sensor is configured to measure a total load during the ironing process.

[0031] Illustration 2. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the sensor is mounted within an enclosure of the tool pack.

[0032] Illustration 3. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the sensor is a first sensor, and wherein the ram assembly comprises a second sensor on the punch configured to measure punch nose forces during the ironing process.

[0033] Illustration 4. The can body maker of any preceding or subsequent illustration or combination of illustrations, further comprising a controller configured to determine friction during the ironing process based on the total load from the first sensor and the punch nose forces from the second sensor.

[0034] Illustration 5. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the sensor comprises a loading face portion and a support ring portion, wherein the loading face portion defines the aperture.

[0035] Illustration 6. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the support ring portion is be recessed relative to the loading face portion on a first end of the sensor and the loading face portion is recessed relative to the support ring portion on a second end of the sensor.

[0036] Illustration 7. A can body maker comprising: a ram assembly movable in a reciprocating linear motion along an axis, the ram assembly comprising a ram and a punch; and a tool pack comprising a plurality of ironing dies and a sensor at a fixed location within the tool pack, wherein the sensor is configured to measure a total load during a drawing and ironing process of the can body maker.

[0037] Illustration 8. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the plurality of dies comprises at least three ironing dies, and wherein the sensor is mounted within the tool pack behind a last ironing die of the at least three ironing dies.

[0038] Illustration 9. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the sensor comprises an outer diameter and an inner diameter, wherein the inner diameter defines an aperture for receiving a cup-shaped blank during the drawing and ironing process.

[0039] Illustration 10. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the sensor is centered on the axis.

[0040] Illustration 11. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the sensor is a first sensor, and wherein the ram assembly further comprises a second sensor for measuring punch nose forces during the ironing process.

[0041] Illustration 12. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the second sensor is on a punch nose of the ram assembly.

[0042] Illustration 13. The can body maker of any preceding or subsequent illustration or combination of illustrations, further comprising a controller configured to determine frictionduring the ironing process using the total load from the first sensor and the punch nose forces from the second sensor.

[0043] Illustration 14. The can body maker of any preceding or subsequent illustration or combination of illustrations, wherein the second sensor is movable with the ram assembly.

[0044] Illustration 15. A drawing and ironing method for forming a can, the method comprising: causing reciprocating linear motion of a ram assembly of a can body maker, the reciprocating linear motion driving a cup-shaped blank through a plurality of dies of a tool pack; and measuring a total force on the cup-shaped blank using a sensor supported behind a last die of the plurality of dies of the tool pack.

[0045] Illustration 16. The method of any preceding or subsequent illustration or combination of illustrations, wherein causing reciprocating linear motion comprises driving the cup-shaped blank through an aperture of the sensor supported behind the last die of the plurality of dies of the tool pack.

[0046] Illustration 17. The method of any preceding or subsequent illustration or combination of illustrations, wherein the sensor is fixed while the ram assembly drives the cup-shaped blank through the aperture of the sensor.

[0047] Illustration 18. The method of any preceding or subsequent illustration or combination of illustrations, further comprising measuring punch nose forces on the cup-shaped blank using a sensor on the ram assembly.

[0048] Illustration 19. The method of any preceding or subsequent illustration or combination of illustrations, wherein the sensor on the ram assembly is a punch nose sensor of a punch of the ram assembly.

[0049] Illustration 20. The method of any preceding or subsequent illustration or combination of illustrations, further comprising determining friction during ironing based on the measured punch nose forces and the total force.

[0050] 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.

[0051] 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.

[0052] As used herein, the meaning of “a,” “an,” and “the” includes singular and plural references unless the context clearly dictates otherwise.

[0053] 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.

[0054] 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.

[0055] 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 substantiallyfrom 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 body maker comprising: a ram assembly movable in a reciprocating linear motion along an axis, the ram assembly comprising a ram and a punch; and a tool pack comprising: a plurality of dies, each die of the plurality of dies comprising an aperture, wherein the punch is configured to press a cup-shaped through the apertures of the plurality of dies during a drawing and ironing process to form a can body; and a sensor mounted behind a last die of the plurality of dies along the axis and relative to the ram assembly, wherein the sensor comprises an aperture through which the cup-shaped blank passes after the last die, and wherein the sensor is configured to measure a total load during the ironing process.

2. The can body maker of claim 1, wherein the sensor is mounted within an enclosure of the tool pack.

3. The can body maker of claim 1, wherein the sensor is a first sensor, and wherein the ram assembly comprises a second sensor on the punch configured to measure punch nose forces during the ironing process.

4. The can body maker of claim 3, further comprising a controller configured to determine friction during the ironing process based on the total load from the first sensor and the punch nose forces from the second sensor.

5. The can body maker of claim 1, wherein the sensor comprises a loading face portion and a support ring portion, wherein the loading face portion defines the aperture.

6. The can body maker of claim 5, wherein the support ring portion is be recessed relative to the loading face portion on a first end of the sensor and the loading face portion is recessed relative to the support ring portion on a second end of the sensor.

7. A can body maker comprising: a ram assembly movable in a reciprocating linear motion along an axis, the ram assembly comprising a ram and a punch; and a tool pack comprising a plurality of ironing dies and a sensor at a fixed location within the tool pack, wherein the sensor is configured to measure a total load during a drawing and ironing process of the can body maker.

8. The can body maker of claim 7, wherein the plurality of dies comprises at least three ironing dies, and wherein the sensor is mounted within the tool pack behind a last ironing die of the at least three ironing dies.

9. The can body maker of claim 7, wherein the sensor comprises an outer diameter and an inner diameter, wherein the inner diameter defines an aperture for receiving a cup-shaped blank during the ironing process.

10. The can body maker of claim 7, wherein the sensor is centered on the axis.

11. The can body maker of claim 7, wherein the sensor is a first sensor, and wherein the ram assembly further comprises a second sensor for measuring punch nose forces during the ironing process.

12. The can body maker of claim 11, wherein the second sensor is on a punch nose of the ram assembly.

13. The can body maker of claim 11, further comprising a controller configured to determine friction during the ironing process using the total load from the first sensor and the punch nose forces from the second sensor.

14. The can body maker of claim 11, wherein the second sensor is movable with the ram assembly.

15. A drawing and ironing method for forming a can, the method comprising: causing reciprocating linear motion of a ram assembly of a can body maker, the reciprocating linear motion driving a cup-shaped blank through a plurality of dies of a tool pack; and measuring a total force on the cup-shaped blank using a sensor supported behind a last die of the plurality of dies of the tool pack.

16. The method of claim 15, wherein causing reciprocating linear motion comprises driving the cup-shaped blank through an aperture of the sensor supported behind the last die of the plurality of dies of the tool pack.

17. The method of claim 16, wherein the sensor is fixed while the ram assembly drives the cupshaped blank through the aperture of the sensor.

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

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

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

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