Modular Can Bodymaker Toolpack for Fast Diameter Changeovers
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Solution Overview
Problem
Reconfiguring existing can bodymakers to produce cans of different diameters is a time-consuming process, requiring significant downtime and reducing manufacturing flexibility, making it costly and inefficient for high-volume can production.
Innovation Solution
A modular can bodymaker design with alignable and removably fixed toolpack and domer modules, utilizing wear bars and bearing adjustment mechanisms for precise alignment, and quick-release fixings like zero-point clamps for rapid module changes, allowing for minimal realignment during diameter changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If known bodymakers are reconfigured to produce cans of different diameter, then manufacturing flexibility is improved, but changeover time increases significantly
Solution Approach 1:
The bodymaker is divided into separate modular components (toolpack module with dies, domer module with bottom forming tool, redraw sleeve module) that can be independently removed and replaced. This segmentation allows quick changeover by simply swapping modules rather than reconfiguring the entire machine, resolving the contradiction between flexibility and changeover time.
Solution Approach 2:
Multiple toolpack modules and domer modules are prepared in advance for different can diameters. When a changeover is needed, the pre-prepared module is already ready for immediate installation, eliminating the time-consuming process of assembling and aligning components during changeover.
2Adaptability or versatility
If tooling is replaced and realigned during changeover, then production of different can diameters is enabled, but production downtime increases
Solution Approach 1:
By segmenting the tooling into removable modules, the bodymaker can quickly switch between different can diameter productions without extensive realignment. Each module is pre-aligned during manufacturing, so installation is rapid and maintains production continuity.
Solution Approach 2:
The modular design creates universal interfaces that work across different module types. The standardized mounting and alignment system allows any toolpack module to work with any domer module, enabling quick reconfiguration for different can diameters while maintaining production efficiency.
3Manufacturing precision
If precise alignment of components is achieved, then manufacturing precision is improved, but alignment time during setup increases
Solution Approach 1:
Precise alignment features (datum surfaces, locating pins, precision mounting holes) are built into the modules during manufacturing. This preliminary alignment work is done once during module production, eliminating the need for time-consuming alignment adjustments during each changeover while maintaining high precision.
Solution Approach 2:
The patent replaces complex mechanical alignment procedures with precision-engineered geometric features (datum surfaces, fixed locating elements). This substitution eliminates manual measurement and adjustment, achieving high alignment accuracy through precision manufacturing rather than time-consuming mechanical alignment processes.
Data Source
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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.