Can Bodymaker Sensor Layout for Dynamic Punch Alignment
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Solution Overview
Problem
Existing can bodymakers suffer from misalignment of the punch/ram with the tool pack due to droop and other factors, leading to mis-formed cans and premature wear, requiring time-consuming manual adjustments and machine downtime for measurement and alignment.
Innovation Solution
A sensing system with multiple sensors positioned around a sensing axis on the can bodymaker, providing real-time feedback for dynamic alignment and adjustment of components during normal operation, allowing for active positioning and alignment without stopping the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If static alignment of tool pack, domer and stripper to punch/ram is performed, then alignment compensation for droop is attempted, but misalignment occurs during operation due to dynamic factors
Solution Approach 1:
The patent transitions from static alignment to dynamic alignment by using sensors to continuously monitor the punch position during operation. The system actively adjusts the tool pack, domer, and stripper positions based on real-time feedback from sensors, allowing the alignment to adapt to dynamic conditions rather than relying on fixed pre-set positions.
Solution Approach 2:
The patent implements a feedback mechanism where sensors continuously measure the punch position and provide data to a control system. This feedback loop enables real-time detection of misalignment and triggers automatic adjustments to maintain proper alignment during operation, resolving the issue of static alignment failing under dynamic conditions.
2Manufacturing precision
If manual measurement and adjustment of punch alignment is performed, then alignment accuracy can be improved, but machine downtime increases
Solution Approach 1:
The patent enables continuous alignment monitoring and adjustment during machine operation. Sensors continuously track punch position, and the control system continuously makes adjustments as needed, eliminating the need to stop production for periodic manual alignment checks and maintaining uninterrupted can body formation.
Solution Approach 2:
The system performs self-alignment through automated sensor-based detection and control system adjustments. The machine monitors its own punch position and automatically corrects misalignment without requiring external manual intervention, thereby maintaining production continuity while ensuring alignment accuracy.
3Manufacturing precision
If punch/ram is misaligned with tool pack, then manufacturing errors occur, but replacement of worn parts is time-consuming
Solution Approach 1:
The patent performs preliminary alignment detection and correction before misalignment causes manufacturing defects or component wear. Sensors continuously monitor punch position and trigger adjustments before errors occur, preventing the need for time-consuming part replacements by maintaining proper alignment throughout operation.
Data Source
AI summary
A sensing arrangement for use in a can bodymaker includes a plurality of sensors positioned around, and spaced a radial distance from, a sensing axis. Each sensor of the plurality of sensors is structured to determine a number of characteristics of a can body positioned on a punch of the can bodymaker as the punch passes along the sensing axis during normal operation of the bodymaker producing can bodies.