Can Bottom Former Alignment Using Torsion-Rod Actuation
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Solution Overview
Problem
Existing bottom-forming machinery in can manufacturing relies heavily on operator skill and experience, leading to inaccuracies and variances due to wear and tear, which affect the quality and repeatability of can production.
Innovation Solution
A torque-operated actuator assembly with a floating clamp ring and dome die design, utilizing elastomer springs and wear rings for alignment adjustment, combined with strain sensors and actuators for real-time alignment monitoring and adjustment, ensures precise alignment and consistent can production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional bottom-forming machinery setup relies on operator skill and experience, then the equipment can be operated with simple mechanisms, but manufacturing precision and repeatability deteriorate due to inaccuracies and wear
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated sensor-based system. Strain sensors and actuators form a closed-loop control system that automatically measures and adjusts alignment, eliminating reliance on operator skill while maintaining simple mechanical components.
Solution Approach 2:
The bottom former assembly performs self-alignment through the automated sensor-actuator system. The system continuously monitors its own alignment status and makes automatic adjustments without external intervention, ensuring consistent precision while keeping the control mechanism relatively simple.
2Reliability
If manual alignment adjustment methods are used, then the device structure remains simple, but reliability deteriorates due to wear and tear affecting alignment consistency
Solution Approach 1:
The patent implements a feedback control system where strain sensors continuously monitor alignment status and provide real-time data to the control system. The actuators adjust alignment based on this feedback, ensuring consistent reliability despite the added complexity of the sensor-actuator-loop system.
Solution Approach 2:
Manual alignment adjustment mechanisms are replaced with an automated electromechanical system. The strain sensors and actuators create an automated control loop that maintains reliable alignment without the wear and inconsistency associated with purely mechanical adjustment methods.
3Manufacturing precision
If automated alignment monitoring and adjustment systems are implemented, then manufacturing precision and reliability improve, but device complexity increases
Solution Approach 1:
The patent uses strain sensors to continuously monitor alignment and feeds this information to actuators that make real-time adjustments. This closed-loop feedback system ensures high manufacturing precision and repeatability, with the complexity of the sensor-actuator system justified by the significant improvement in can production consistency.
Solution Approach 2:
The actuator assembly serves multiple functions: it provides mechanical force for bottom formation, enables alignment monitoring through strain sensors, and performs automatic alignment adjustment. This multi-functionality reduces the need for separate systems, thereby limiting the increase in overall device complexity while achieving high precision.
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 significantly reduces misalignment issues, enhances the quality and repeatability of can production, and allows for automatic or manual adjustments to maintain optimal alignment, leading to higher production rates and consistent can specifications.
Implementation Method 1
utilizing elastomer springs and wear rings for alignment adjustment
Implementation Method 2
strain sensors and actuators for real-time alignment monitoring and adjustment
Implementation Method 3
torque-operated actuator assembly with a floating clamp ring and dome die design
Data Source
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AI summary
An actuator assembly for dynamically or manually positioning a dome die and clamp ring of a can bottom former assembly. The actuator assembly is also usable for other purposes where accurate and repeatable adjustments in position are needed. The actuator assembly may include an anchor member and at least one torsion rod having a torque end and an actuation end, with 2 bends at or near the actuation end, such that a torque applied to the torque end creates a substantially linear actuation force at or near the actuation end of the torsion rod.