Metal Container Carrier Ring Forming for Air Conveyor Compatibility
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Solution Overview
Problem
Metal containers lack a carrier ring, making them incompatible with existing manufacturing lines that use air conveyor channels for transporting plastic containers with carrier rings.
Innovation Solution
A method and apparatus for forming a metal container with a carrier ring using a turret-head assembly that includes a top plate, a housing with cams, a base plate, and a rolling assembly with roller arms and cam followers, allowing the carrier ring to be formed radially on the metal container.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal containers are formed using conventional metal forming processes, then manufacturing efficiency and strength are improved, but the ability to include a carrier ring is lost
Solution Approach 1:
The carrier ring formation process is segmented into multiple stages: initial protrusion formation by inner roller, groove formation by outer roller, and final carrier ring shaping through coordinated roller movement. This segmentation allows the complex forming process to be broken down into manageable steps that can be performed sequentially during the metal container forming operation.
Solution Approach 2:
The invention transitions from conventional single-plane forming to multi-dimensional forming by introducing radial roller movement in addition to axial pressing. The rollers move radially inward and outward to shape the carrier ring, adding a radial dimension to the forming process that enables complex three-dimensional carrier ring geometry to be created during metal container formation.
2Adaptability or versatility
If a carrier ring is added to metal containers to enable compatibility with air conveyor channels, then adaptability is improved, but device complexity increases
Solution Approach 1:
The turret-head assembly serves multiple functions: it forms the carrier ring, shapes the container opening, and controls the forming process through cam mechanisms. The inner and outer rollers work together to create both the protrusion and groove features necessary for the carrier ring, while the cam followers coordinate the radial movement of rollers with the axial pressing motion, consolidating multiple operations into a single universal forming station.
Solution Approach 2:
The cam mechanisms automatically control the radial movement of rollers based on the axial pressing motion. As the pressing member moves axially, the cam followers ride along the cam surfaces, which automatically translate this motion into the required radial roller movement for carrier ring formation. This self-regulating mechanism eliminates the need for separate control systems for each forming stage.
3Ease of manufacture
If conventional forming tools are used for metal containers, then manufacturing simplicity is maintained, but the ability to form carrier rings is lost
Solution Approach 1:
The invention merges the carrier ring forming operation with the existing metal container forming process. The turret-head assembly with its rollers and cam mechanisms is integrated into the conventional pressing operation, allowing the carrier ring to be formed simultaneously with the container body shaping. This combination eliminates the need for separate carrier ring attachment or formation steps.
Solution Approach 2:
The cam mechanisms act as intermediaries that translate the simple axial pressing motion into the complex radial roller movements required for carrier ring formation. The cam surfaces serve as the mediating element that converts the straightforward up-and-down pressing motion into the coordinated radial-inward-and-outward roller movements needed to shape the carrier ring protrusion and groove features.
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
Enables metal containers to be transported and processed on existing manufacturing lines, facilitating filling and capping processes by integrating a carrier ring that mimics the functionality of plastic container carrier rings.
Implementation Method 1
Each of the plurality of roller arms further includes a cam follower configured to engage a respective one of the plurality of cams such that the rollers are configured to move radially with respect to a turret-head assembly axis extending generally through the center of the turret-head assembly between the top plate and the base plate. The radial movement corresponds with axial movement of the forming tool.
Data Source
AI summary
A method of forming a carrier ring on a metal article having an open end and a sidewall extending therefrom. The method includes contacting an inner surface of the sidewall with an inner roller to form a protrusion and contacting an outer surface of the sidewall with an outer roller to form a first groove positioned below the protrusion. The protrusion forms a gap therein. The method further includes contacting a portion of the outer sidewall with at least one second outer roller to form a second groove below the protrusion. The method further includes contacting a portion of the outer sidewall with at least one third outer roller to flatten the protrusion, such that the gap is substantially reduced or eliminated. The flattened protrusion forms the carrier ring.