Automated Bodymaker Toolpack Changeout for Safer, Faster Can Production
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Solution Overview
Problem
In can production factories, frequent manual replacement of large and heavy toolpack modules leads to operator fatigue, risk of injury, and potential for poor can quality due to improper tooling installation, resulting in inefficiencies and equipment damage.
Innovation Solution
A machine-controlled maintenance system comprising a housing with a changeout arrangement and a robotic arm, along with a mobilization arrangement that can move the housing and changeout arrangement above or on the floor, allowing for automated removal and replacement of toolpacks and other components without human intervention, reducing manual labor and improving tooling accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual replacement of toolpack modules is performed frequently, then tooling can be changed to clear jams or switch products, but operator fatigue and risk of injury increase due to handling large heavy modules
Solution Approach 1:
The system enables automated self-service tooling replacement where the maintenance device autonomously removes and installs toolpack modules without human physical intervention. The robotic arm with gripper automatically performs the replacement task that previously required manual handling by operators, eliminating the harmful physical strain and injury risk while maintaining the ability to change tooling for different products or jam clearance.
Solution Approach 2:
The patent replaces the manual mechanical system with an automated robotic system. The robotic arm equipped with a controlled gripper mechanism substitutes human operators for the mechanical task of removing and installing heavy toolpack modules. This mechanical substitution eliminates the need for operators to manually handle the tooling, thereby removing the associated injury risks while preserving tooling adaptability.
2Adaptability or versatility
If manual tooling replacement is performed frequently, then tooling changes can be made, but production downtime increases due to the manual process
Solution Approach 1:
The automated maintenance device performs tooling replacement autonomously without requiring operator intervention for each change. The system can quickly remove failed tooling and install replacement modules automatically, significantly reducing the time lost during tooling changes compared to manual processes. This self-service capability maintains full adaptability for different products and jam clearance operations.
Solution Approach 2:
The system appears to maintain ready-stock replacement toolpack modules, allowing for quick swap operations when jams occur or product changes are needed. By having replacement tooling prepared in advance and positioned for immediate installation, the system minimizes downtime during tooling changes while maintaining the ability to adapt to different production requirements.
3Ease of operation
If operators manually install tooling components, then tooling can be replaced, but improper installation occurs leading to poor can quality and equipment damage
Solution Approach 1:
The automated robotic system performs tooling installation with consistent, precise movements controlled by a programmable controller. The robotic arm positions and installs toolpack modules and individual components with high accuracy, eliminating the human error that leads to improper torquing, backwards installation, or incorrect carrier placement. This maintains ease of operation through automation while dramatically improving installation precision.
Solution Approach 2:
The system incorporates sensors and controllers that provide feedback to ensure proper tooling installation. The robotic arm's movements are controlled and monitored to achieve correct positioning and installation of tooling components. This feedback mechanism prevents improper installation by verifying that each tooling element is correctly placed and secured, thereby maintaining both operational ease and manufacturing precision.
Data Source
AI summary
A system for manufacturing a plurality of can bodies includes a number of forming machines for forming one or more portions of the can bodies. Each forming machine includes a number of removable components. The system further includes a maintenance device including a housing, a changeout arrangement coupled to the housing, and a controller positioned on or in the housing. The changeout arrangement is configured to selectively remove and replace a removeable component of one or more of the number of removeable components of one or more of the number of forming machines under the direction and control of the controller.