Pulsed Air Can Handling for Fast Punch Release and Fewer Jams
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Solution Overview
Problem
Existing can handling systems using air pressure devices face issues such as adhesion between punches and cans, frequent jams, inefficient air usage, and mechanical extraction device reliance, leading to reduced production speed and increased costs.
Innovation Solution
The implementation of high-speed electromagnetic valves capable of providing very brief pulses of pressurized air, combined with a pneumatic check valve, to create an air hammer effect for efficient can removal from tooling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If standard spool valves are used to provide continuous high pressure air to punches, then cans can be removed from punches, but the valves wear rapidly and require frequent rebuilding
Solution Approach 1:
The patent applies periodic action by using pulsed air delivery instead of continuous air supply. The system delivers brief pulses of high-pressure air (approximately 5 milliseconds or less) to the punches at regular intervals corresponding to the can formation cycle. This periodic pulsing achieves effective can removal while dramatically reducing valve wear and extending service life to over 1 billion cycles, as the valve remains closed most of the time rather than continuously handling high-pressure flow.
Solution Approach 2:
The patent replaces the traditional mechanical spool valve system with an electromagnetic valve system. This substitution allows for much faster opening and closing speeds (5 milliseconds or less compared to 20-30 milliseconds for spool valves), enabling the valve to respond quickly to pulsed air delivery requirements and achieve both high reliability and production speed.
2Productivity
If standard spool valves operate slowly (20-30 milliseconds), then the system is simpler, but production speed is limited
Solution Approach 1:
The patent replaces the mechanical spool valve with an electromagnetic valve system that operates 4-6 times faster (5 milliseconds or less vs. 20-30 milliseconds). This substitution enables the valve to keep up with high-speed can production requirements while the control system manages the increased operational complexity through automated pulsed air delivery sequencing.
3Reliability
If continuous high pressure air is supplied to punches, then cans are reliably removed, but air consumption increases costs
Solution Approach 1:
The patent implements periodic action by delivering air in brief pulses (5 milliseconds or less) rather than continuously. The pulsed air delivery is timed to coincide with when cans need to be removed from punches, maintaining reliable can removal while reducing air consumption by keeping the air supply valve closed during periods when it is not needed, thereby lowering operational costs.
4Productivity
If continuous high pressure air flows over dropping cups, then cans are pushed off punches, but cups flutter causing false jams
Solution Approach 1:
The patent applies periodic action by pulsing the air delivery to punches rather than providing continuous flow. The brief pulses (5 milliseconds or less) are timed to provide just enough force to push cans off punches during the discharge phase, while the air supply is cut off during cup dropping to eliminate the continuous airflow that causes cup flutter and false jams, thus improving both productivity and reducing harmful effects.
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 significantly reduces jam occurrences, conserves air, extends valve lifespan, and increases production speed, allowing for over 1 billion cycles before valve rebuild, while minimizing mechanical stripper usage.
Implementation Method 1
high-speed electromagnetic valves capable of providing very brief pulses of pressurized air, combined with a pneumatic check valve, to create an air hammer effect for efficient can removal from tooling
Implementation Method 2
high-speed electromagnetic valves capable of providing very brief pulses of pressurized air
Data Source
AI summary
A process, with enabling mechanical system, for providing very brief pulses of pressurized air to can making tooling, in particular, punches found in cuppers and bodymakers. Electromagnetic valves having very high speeds of operation are used. The electromagnetic valves can operate in a fraction of the time of the standard valves used in the prior art. This in turn means that air can be conserved since continuous high pressure air is no longer required, and production can be accelerated. High speed valves, combined with a pneumatic check valve, can be used to deliver a sequence of pulses of air pressure, resulting in air hammer. The air hammer is found to be very effective for can removal from tooling.