Integrated Can Bodymaker for Direct Disc-to-Cup Forming
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Solution Overview
Problem
Conventional cupping presses for producing thin-walled metal cans are expensive and require significant space, leading to high capital expenditures and scrap material handling costs.
Innovation Solution
A can bodymaker system that feeds pre-cut metal discs directly into the machine, using rollers, a blankholder, and a draw pad to form cups and can bodies, eliminating the need for a separate cupping press and associated scrap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a conventional cupping press is used to form cups from metal coils, then cup formation capability is achieved, but capital expenditure and machine footprint increase significantly
Solution Approach 1:
The patent combines the cupping press and bodymaker functions into a single integrated machine. The cupping press forms cups from metal discs, and the bodymaker immediately forms these cups into can bodies in the same machine footprint, eliminating the need for separate equipment and reducing overall space requirements.
Solution Approach 2:
The integrated machine performs multiple functions: it feeds metal discs, forms cups from discs, forms can bodies from cups, and manages scrap material. This multi-functionality replaces what would traditionally require separate specialized machines, reducing capital expenditure and floor space.
2Ease of manufacture
If a conventional cupping press forms discs from metal coils, then cup formation is achieved, but scrap material (web) is generated requiring handling and shipping
Solution Approach 1:
Metal discs are pre-cut from coils before being fed into the integrated machine, rather than being formed on-site by the cupping press. This preliminary action eliminates the generation of web scrap material that would otherwise require handling, storage, and shipping back to suppliers.
3Productivity
If a separate cupping press is used before the bodymaker, then cup production capability is achieved, but operational costs and complexity increase
Solution Approach 1:
The patent merges the cupping press and bodymaker into a single automated system where discs are fed, cups are formed, and can bodies are produced in one continuous process. This integration maintains high productivity while reducing operational complexity by eliminating the need to operate and coordinate two separate machines.
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
Reduces capital expenditures and scrap handling by directly forming can bodies from pre-cut discs, minimizing the footprint and operational costs of the manufacturing process.
Implementation Method 1
the disc feed may comprise a vacuum feed 30 to separate the discs
Implementation Method 2
a flighted belt 32 to push the discs along
Data Source
AI summary
A can bodymaker, which includes a disc feed (1) for feeding a disc (5) directly to the bodymaker itself. A locator (9) positions the disc (5) centrally to a blankholder (12) and a draw pad (10) clamps the disc (5) against a draw die (11). The blankholder (12) then forms the disc into a cup (20) and clamps the cup against a redraw die (14) ready to be picked up by a punch and carried through dies for forming a can body.