Can Bodymaker Load-Cell Monitoring for Alignment Drift
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Solution Overview
Problem
Can bodymakers produce varying quality can bodies due to changes in machine alignment, coolant temperature, lubrication, and metal cup quality, leading to misalignment, wear, and vibration issues, resulting in wastage and costly downtime.
Innovation Solution
A can bodymaker equipped with load cells and a radial offset monitor to measure axial forces and detect misalignment, allowing for real-time adjustment of operating parameters and mitigation of tool wear and damage, using a processor to adjust parameters such as ram reciprocation rate, coolant supply, and lubricant application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the can bodymaker operates at high speed for extended periods, then productivity increases, but manufacturing precision deteriorates due to alignment variations, wear, and vibration
Solution Approach 1:
The patent implements continuous monitoring of axial forces on tools during the DWI process using load cells. This feedback mechanism detects variations in forces that indicate alignment issues, wear, or vibration problems, allowing the system to maintain manufacturing precision even during high-speed extended operation by identifying and addressing degradation in real-time
Solution Approach 2:
The system performs preliminary detection of alignment variations and tool wear by monitoring axial forces before they lead to serious quality problems. By detecting early signs of misalignment or wear through force variations, the system can take preventive action before manufacturing precision significantly deteriorates
2Manufacturing precision
If traditional alignment and re-alignment processes are used, then manufacturing precision can be restored, but loss of time increases due to the complex and time-consuming nature of the process
Solution Approach 1:
The continuous monitoring system provides real-time feedback on alignment status through axial force measurements, eliminating the need for periodic manual alignment checks. The system detects alignment variations as they occur and can trigger automated compensation or alert operators only when intervention is truly necessary, dramatically reducing downtime
Solution Approach 2:
The monitoring system enables the machine to self-diagnose alignment issues and tool wear conditions through continuous force measurement. This self-monitoring capability allows the system to maintain optimal performance without requiring frequent manual intervention for alignment verification and adjustment
3Manufacturing precision
If load cells are installed in the adapter plate to monitor axial forces, then manufacturing precision can be maintained through real-time detection, but device complexity increases
Solution Approach 1:
The load cells installed in the adapter plate serve multiple functions: they monitor axial forces on tools, detect alignment variations, identify tool wear conditions, and provide data for process optimization. This multi-functionality justifies the added complexity by delivering comprehensive monitoring capabilities from a single integrated system
Solution Approach 2:
The adapter plate acts as an intermediary structure that naturally incorporates the load cells into the existing machine architecture. By installing sensors in the adapter plate rather than modifying critical tool components, the system adds monitoring capability with minimal disruption to the core DWI process and existing tooling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system ensures consistent can body quality by continuously monitoring and adjusting for misalignment and wear, reducing downtime and production costs by maintaining optimal machine operation.
Implementation Method 1
one or more load cells located in or on the adapter plate and configured to generate an output signal or signals indicative of an axial force exerted on the tools by the cup passing therethrough
Data Source
AI summary
A can bodymaker for producing can bodies from cups. The can bodymaker comprises a ram configured to reciprocate along an axis, a punch mounted on the ram; a tool pack comprising a cradle and a plurality of tools located in the cradle for drawing and ironing a cup mounted on the punch during a forward stroke of the ram. The can bodymaker further comprises a bolster plate fixed to the can bodymaker, an adapter plate fixed to the bolster plate and a stripper assembly fixed to the adapter plate for removing a can body from the punch during a return stroke of the ram and clamping mechanism for biasing the tools against a front face of the adapter late. The can bodymaker further comprises one or more load cells located in or on the adapter plate and configured to generate an output signal or signals indicative of an axial force exerted on the tools by the cup passing therethrough.