Modular Can Bodymaker Toolpack for Rapid Diameter Changeovers
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Solution Overview
Problem
Reconfiguring known can bodymakers to produce cans of different diameters is a time-consuming process, requiring significant downtime and reducing manufacturing flexibility, especially in high-volume can production.
Innovation Solution
A modular can bodymaker design with alignable components, including a toolpack module and domer module, utilizing quick-release fixings and alignment mechanisms for precise, rapid module attachment and alignment, allowing for quick changeovers between production runs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If known bodymakers are reconfigured to produce cans of different diameters, then manufacturing flexibility is improved, but changeover time increases significantly
Solution Approach 1:
The bodymaker is divided into separate modular components (toolpack module, domer module, infeed-discharge module) that can be independently removed and replaced. Each module contains specific functional elements that can be pre-configured for different can diameters, enabling rapid changeover without reconfiguring the entire machine.
Solution Approach 2:
Modules can be pre-configured and prepared for different can diameters before being installed on the bodymaker. The alignment mechanisms are pre-positioned on the machine bed, and modules include pre-assembled tooling components, allowing for quick installation and immediate operation with minimal setup time.
2Adaptability or versatility
If tooling is replaced and realigned in known bodymakers, then production of different can diameters is achieved, but production downtime increases
Solution Approach 1:
The tooling system is segmented into removable modules that can be exchanged as complete units rather than individual components. This maintains production continuity because entire toolpacks designed for specific can diameters can be quickly swapped without disassembling and realigning individual tooling elements during changeover.
Solution Approach 2:
Complete toolpack modules are pre-configured for specific can diameters with all necessary tooling components (draw dies, ironing dies, cup holders) pre-assembled and pre-aligned on the module frame. This preliminary preparation eliminates the need for time-consuming realignment operations during production changeovers.
3Manufacturing precision
If precise alignment of components is required, then manufacturing precision is improved, but alignment time and complexity increase
Solution Approach 1:
Alignment mechanisms act as intermediary elements between the machine bed and the removable modules. These mechanisms (including alignment pins, datum surfaces, and adjustable mounting features) provide precise reference points that automatically establish correct component alignment when modules are installed, eliminating the need for complex manual alignment procedures.
Solution Approach 2:
The modules are designed with self-aligning features such as precision-machined datum surfaces and keyed mounting interfaces that automatically position components correctly when installed on the machine bed. This self-alignment capability reduces the need for operator skill and time in achieving precise alignment while maintaining high manufacturing precision.
Data Source
AI summary
A can bodymaker comprising a plurality of components that require relative alignment to one another. The can bodymaker comprises a toolpack module which includes a toolpack frame and components including one or more dies supported by the toolpack frame. The die(s) are alignable with respect to the toolpack frame when the toolpack module is not attached to the bodymaker. The can bodymaker further comprises a fixing that allows removable fixing of the toolpack module to the can bodymaker.