Can Base Forming Die With Resilient Alignment Compensation
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Solution Overview
Problem
Existing can bodymakers face challenges in accurately aligning the dome station with the punch, leading to defects such as 'smile marks', 'local thinning', and 'split domes' due to misalignment, which is time-consuming and costly to correct, especially in high-volume production environments.
Innovation Solution
An apparatus and method that includes a deflectable die and hold down ring with a resilient support, along with eddy current sensors for measuring deflection, and an adjustment mechanism with linear actuators and locking mechanisms to facilitate precise alignment and realignment of the dome station relative to the punch, reducing sensitivity to misalignments and allowing for easier operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the dome station is aligned statically when the machine is not running, then alignment is initially achieved, but misalignment occurs when the bodymaker is running due to dynamic effects
Solution Approach 1:
The die is made deflectable perpendicular to the punch axis using a resilient support, allowing the die to dynamically adjust its position in response to impact forces and misalignments during operation, transforming the rigid static alignment system into a dynamic adaptive system
2Reliability
If the dome station is aligned to ensure perfect can quality, then defect occurrence is reduced, but the alignment process becomes time-consuming and requires halting production
Solution Approach 1:
The resilient support enables the die to self-adjust and self-align during operation by deflecting in response to impact forces, automatically compensating for misalignments without requiring external intervention or production halt for realignment
3Adaptability or versatility
If the die is made deflectable to accommodate misalignment, then sensitivity to misalignment is reduced, but the complexity of the apparatus increases
Solution Approach 1:
The physical state of the die is changed from rigid to resilient by introducing a resilient support, fundamentally altering the mechanical parameter of stiffness to enable deflection and misalignment compensation
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 solution reduces the occurrence of defects by allowing the die and hold down ring to move radially in response to impact, providing a restoring force to align with the punch, and using sensors for precise measurement and feedback to operators, thereby improving the efficiency and quality of can base formation.
Implementation Method 1
a resilient support for holding the die in a resting position substantially along said axis whilst allowing the die to be deflectable perpendicular to said axis and providing a restoring force to return the die to the resting position
Implementation Method 2
The apparatus may comprise one or more sensors for measuring deflection of the die and/or the hold down ring perpendicular to said axis. The sensors may be eddy current sensors.
Data Source
AI summary
An apparatus for forming a base profile on a metal container carried on a punch moving along an axis. The apparatus comprises a die for forming the base profile on the container and a resilient support for holding the die in a resting position substantially along said axis whilst allowing the die to be deflectable perpendicular to said axis and providing a restoring force to return the die to the resting position.