Rectangular Can Deep Drawing with Split Press Stages
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Solution Overview
Problem
Existing can manufacturing methods using dedicated press machines are costly and time-consuming, as they require precise specification setting and are inflexible for producing other products, leading to extended delivery times and increased costs.
Innovation Solution
A can manufacturing method and system utilizing a pre-step press machine for blank processing and coining, followed by a post-step press machine for drawing and ironing processing, with a conveyor to transfer blanks between machines, allowing for efficient production of various can sizes and types using general-purpose press machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a dedicated press machine is designed and manufactured based on specific can models, then manufacturing precision and productivity are improved, but device complexity and manufacturing cost increase, and adaptability deteriorates
Solution Approach 1:
The deep drawing process is segmented into two independent stages: blank processing (punching and coining) and drawing/ironing processing. Each stage is performed by a separate press machine, allowing each machine to be optimized for its specific function while maintaining overall system flexibility. The blank processing machine can be dedicated to preparing blanks, while the drawing machine handles various can shapes and sizes.
Solution Approach 2:
The system incorporates dynamic adaptability through the conveyor mechanism that can adjust to different blank sizes and the drawing machine that can accommodate various can models. This dynamic configuration allows the production line to switch between different product types without requiring complete reconfiguration, resolving the contradiction between specialization and flexibility.
2Manufacturing precision
If a dedicated press machine is designed and manufactured for specific can models, then manufacturing precision is improved, but delivery time increases due to considerable design and manufacturing time
Solution Approach 1:
Blank processing is performed as a preliminary action in a dedicated blank processing machine before the drawing operation. This separates the preparation phase from the forming phase, allowing blanks to be pre-prepared and stored, while the drawing machine can be quickly reconfigured for different can models without needing to redesign the entire system.
Solution Approach 2:
By segmenting the production process into blank processing and drawing operations, each segment can be independently optimized and maintained. This reduces the overall system complexity and allows for faster implementation when new can models are introduced, as only the drawing machine needs adjustment rather than the entire press machine.
3Productivity
If a dedicated press machine is used for specific can models, then productivity is improved, but manufacturing cost increases due to inability to repurpose for other products
Solution Approach 1:
The production system is divided into separate blank processing and drawing operations, each with its own dedicated machine. This segmentation allows the drawing machine to be repurposed for different can models while the blank processing machine remains dedicated, thereby maintaining productivity for blank preparation while reducing overall manufacturing costs through flexible drawing operations.
Solution Approach 2:
The drawing press machine is designed with universal capabilities to handle multiple can models and configurations. By making the drawing machine multi-functional while keeping the blank processing machine specialized, the system achieves both high productivity through dedicated operations and cost-effectiveness through repurposability of the drawing machine for different product lines.
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 approach enables the construction of an optimal manufacturing system for specific products, reducing production costs and delivery times, while allowing for easy adaptation to changes in product type or size.
Implementation Method 1
first pressing for blank processing on a metal plate and coining processing to reduce a plate thickness of the blank
Implementation Method 2
second pressing for drawing processing and/or drawing and ironing processing to form a rectangular can
Implementation Method 3
conveyor configured to convey a blank from the pre-step press machine to the post-step press machine
Data Source
AI summary
A can manufacturing method by deep drawing processing using a press machine, wherein a pre-step press machine, a post-step press machine, and a conveyor configured to convey a blank from the pre-step press machine to the post-step press machine are provided, the can manufacturing method including: first pressing for blank processing on a metal plate and coining processing to reduce a plate thickness of the blank by using the pre-step press machine; conveying the blank from the pre-step press machine to the post-step press machine; and second pressing for drawing processing and/or drawing and ironing processing to form a rectangular can by using the post-step press machine.