Opposing Operation Wheels for High-Speed Vessel Forming
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current metal forming technologies are inadequate for high-speed, flexible, and cost-effective production of contoured metal vessels with dynamic customization capabilities, as they face limitations in production line efficiency, customization flexibility, and cost-effectiveness, particularly in achieving line speeds of 600 vessels per minute and accommodating diverse vessel shapes and decorations.
Innovation Solution
A vessel forming station with multiple operation wheels configured in opposing pairs, interconnected with linear drives and a conveyor system, allowing for dynamic indexing and operation on vessels, enabling simultaneous performance of various forming and decoration operations, such as die forming, hydro forming, and printing, to achieve high-speed production and customization of vessels.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If hydro forming is used to shape metal vessels, then reliable forming is achieved, but forming time becomes lengthy and production speed decreases
Solution Approach 1:
The forming process is divided into multiple sequential forming stations (first forming station, second forming station, third forming station) that work in parallel on different vessels. Each station performs a portion of the forming operation, allowing multiple vessels to be processed simultaneously through the production line, thereby increasing overall production speed while maintaining reliable forming at each station.
Solution Approach 2:
The metal perform is pre-positioned and pre-aligned in the forming stations before the actual forming operation begins. The linear drives and conveyors are pre-configured to bring the forming tools and performs into precise engagement positions, eliminating setup time during production and enabling immediate high-speed forming operations.
2Shape
If pressure ram forming with molds is used, then vessel shaping is achieved, but customization flexibility is limited due to tight design relationship between ram and mold
Solution Approach 1:
The forming process is segmented into multiple independent forming stations, each with its own linear drive and tooling. This allows different forming operations (die forming, hydro forming, pressure ram forming) to be applied at different stations on the same vessel or on different vessels, enabling customization without requiring complete reconfiguration of a single forming system.
Solution Approach 2:
The production line is designed with dynamic reconfigurability, where the sequence and type of forming operations can be adjusted by repositioning tools and performs using the linear drives and conveyor system. This allows the same production line to produce different vessel shapes and sizes by changing the positioning and sequencing of forming operations rather than requiring dedicated fixed tooling for each product variant.
3Shape
If multiple dies are used for die forming, then vessel shaping is achieved, but the number of dies required limits customization flexibility
Solution Approach 1:
The forming stations are designed with universal tooling capabilities where the same linear drive mechanism and conveyor system can accommodate different die types (die forming, hydro forming, pressure ram forming). The operation wheels and forming tools can be repositioned and reconfigured to perform multiple forming functions, reducing the total number of dedicated dies needed while maintaining the ability to produce various vessel shapes.
Solution Approach 2:
The production line adds the dimension of time and sequencing to the forming process. Instead of requiring multiple physical dies to be present simultaneously, the system uses a single production line that sequences different forming operations at different stations and times. The linear drives and conveyors enable the same physical infrastructure to support multiple die configurations through temporal and spatial arrangement of forming operations.
4Productivity
If traditional production lines are used, then metal packaging is manufactured, but dynamic on-the-fly changeovers and customization capabilities are not possessed
Solution Approach 1:
The production line incorporates dynamic control systems where linear drives, conveyors, and forming tools can be repositioned and reconfigured during production operations. This allows on-the-fly changeovers between different vessel types, sizes, and forming methods without shutting down the line, maintaining high throughput while enabling real-time customization in response to consumer or event data.
Solution Approach 2:
The system enables parameter changes in the forming process by adjusting the positioning, speed, and sequencing of linear drives and conveyors. Different forming parameters (pressure, speed, temperature, positioning) can be modified dynamically by reconfiguring the operation wheels and tool positions, allowing the production line to adapt to different product specifications while maintaining continuous high-speed operation.
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
This solution enhances production line efficiency, reduces costs, and increases customization capabilities, enabling the production of a wide range of vessel types and sizes with on-the-fly changeovers, meeting consumer demands for varied packaging options while maintaining high throughput and quality.
Implementation Method 1
a plurality of linear drives are interconnected with the plurality of operation wheels, the plurality of linear drives push opposing facing pairs of the plurality of operations to a closed position causing opposing facing pairs of the operation wheels to engage the vessel and perform operations on the vessel
Implementation Method 2
the linear drives pull the plurality of operation wheels to an open position allowing the vessel to be indexed to other operation positions
Implementation Method 3
a conveyor system positioned between opposing facing pairs of the plurality of operation wheels engages the vessel and indexes the vessel through the plurality of operations
Data Source
AI summary
A system and method of forming a vessel may include providing multiple operation wheels configured in opposing facing pairs. Each operation wheel may include multiple work zones, each work zone of an operation wheel being configured in an opposing facing pair with a work zone of another operation wheel to engage the vessel and perform a forming operation on the vessel. Opposing facing pairs of the operation wheels may be linearly pushed to a closed position to engage the vessel, and pulled to an open position. The work zone(s) may perform least one forming operation on the vessel. The vessel may be indexed through the operations at a rotational timing coordinated to index the vessel when opposing facing pairs of the operation wheels are in the open position, the indexing may be clockwise or counterclockwise based on whether a decoration operation is to be performed on the vessel.