Ram Alignment Detection in Can Bodymaker
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Solution Overview
Problem
In the manufacturing of two-piece cans, the alignment of the ram with the doming station is prone to misalignment due to friction, wear, and vibration, leading to issues like split domes and burst cans, which are difficult to detect visually.
Innovation Solution
A detector system with sensors positioned at 90° to each other for measuring ram displacement and converting data into real-time alignment measurements, capable of dynamically tracking potential faults and adjusting the dome station position for precise alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the ram is supported in bearings to enable high speed reciprocating motion, then productivity is improved, but alignment stability deteriorates due to friction, wear, and vibration
Solution Approach 1:
The system performs preliminary measurement of ram alignment using sensors positioned around the ram's path. The measured data is used to calculate predetermined compensation values that are applied before the doming operation, proactively correcting alignment issues before they cause defects
Solution Approach 2:
The system continuously monitors ram alignment using displacement sensors and feeds this information back to the control system. The control system processes the sensor data and adjusts the dome station position or ram positioning in real-time to maintain proper alignment despite friction, wear, and vibration during high-speed operation
2Device complexity
If manual visual inspection is used to detect base defects, then device complexity is minimized, but measurement precision deteriorates due to difficulty in detecting smile defects and human fatigue
Solution Approach 1:
The patent replaces manual visual inspection with an automated sensor-based measurement system. Displacement sensors mounted on the bodymaker frame measure ram position and alignment objectively, eliminating human fatigue and the inability to detect subtle smile defects that characterize manual inspection limitations
3Measurement precision
If sensors are positioned around the fully extended position of the ram to provide comprehensive angular displacement measurements, then measurement precision is improved, but device complexity increases due to cable routing limitations
Solution Approach 1:
The system transitions from single-point measurement to multi-dimensional measurement by positioning sensors at multiple angular positions (0°, 90°, 180°, 270°) around the ram's path. This spatial arrangement enables comprehensive measurement of ram alignment in both X and Y axes simultaneously, providing complete angular displacement data for accurate alignment assessment
Data Source
AI summary
A real time detector system for monitoring ram alignment in a can bodymaker measures ram (10) position immediately before and during impact with the dome forming station (1). Displacement measurements of the ram enable the user to adjust dome (1) position or otherwise correct ram (10) alignment and avoid multiple can failures.