Cupper Air Passage Restrictor for Low-Air Cup Ejection
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Solution Overview
Problem
Existing cuppers waste significant amounts of air, which is not captured or reused, leading to increased power consumption due to the need for larger air compressors or more compressors to operate can manufacturing lines.
Innovation Solution
A flow restrictor is integrated into the air passage of the cupper, reducing the diameter of the air flow path to minimize the amount of air needed to eject cups, thereby reducing wasted air.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuous air passage with large diameter is used in the cupper, then the air can effectively eject the cup from the die center, but a large amount of air is wasted and power consumption increases
Solution Approach 1:
The patent changes the parameter of air passage diameter from large to small. The flow restrictor reduces the air passage diameter at the die center tip, limiting the air flow rate while maintaining sufficient ejection capability. This parameter change directly reduces the volume of wasted air and associated power consumption.
Solution Approach 2:
The flow restrictor creates a local restriction at the die center tip where the air exits. This localized change in passage geometry affects only the ejection point, allowing the rest of the air passage to remain open while controlling the actual air consumption at the critical ejection location.
2Quantity of substance
If air compressors are increased in size or number to provide sufficient air for the manufacturing line, then adequate air supply is ensured, but power usage increases
Solution Approach 1:
By changing the air passage diameter parameter through the flow restrictor, the system reduces the total air consumption to levels that can be supplied by smaller, more energy-efficient compressors, thereby reducing power usage while maintaining adequate air supply for the manufacturing line.
3Loss of energy
If a flow restrictor with small diameter passage is installed, then air usage is reduced by up to 42%, but the air passage diameter is reduced
Solution Approach 1:
The flow restrictor applies the local quality principle by creating a small diameter passage only at the critical ejection point (die center tip), while the rest of the air passage system can maintain larger dimensions. This localized restriction achieves air savings without compromising the overall air delivery capability of the system.
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 flow restrictor effectively reduces air usage by up to 42%, minimizing power consumption and optimizing air usage without requiring substantial modifications to the cupper components.
Implementation Method 1
A flow restrictor is integrated into the air passage of the cupper, reducing the diameter of the air flow path to minimize the amount of air needed to eject cups
Data Source
AI summary
A flow restrictor for a cupper having a riser and a die center structured to form a metal blank into a cup, wherein a continuous air passage having a first diameter is formed axially through the riser and the die center and is in fluid communication with a base of the die center, the flow restrictor includes a small diameter passage having a second diameter that is smaller than the first diameter, wherein the flow restrictor is structured to be disposed in and in fluid communication with the air passage of the cupper.