Six-Out Conversion Press Layout for Shell Alignment and Belt Stability
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing conversion presses face limitations in producing more than four can ends per cycle due to constraints in legacy ram presses, such as limited power, space, and efficiency, leading to issues like deformation of transfer belts and misalignment of shells.
Innovation Solution
A six-out conversion press is designed with three two-lane die sets and a transfer belt assembly that includes two columns of recesses to maintain a deformation-resistant width, allowing for effective positioning of kiss blocks and reducing mass in components like the lift gate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the conversion press increases production capacity to six can ends per cycle, then productivity improves, but transfer belt deformation increases due to exceeded power and space constraints
Solution Approach 1:
The press is divided into multiple independent press stations (first press station, second press station, third press station) that operate in parallel. Each station handles specific forming operations for different can ends, distributing the total production load of six can ends across multiple stations rather than overloading a single station, thereby preventing transfer belt deformation while maintaining high productivity
Solution Approach 2:
The press utilizes a multi-level spatial arrangement with upper and lower toolings positioned at different vertical levels. The first press station is positioned at a first level while the second and third press stations are positioned at a second level, creating a three-dimensional workspace that increases production capacity without proportionally increasing the horizontal footprint, thus avoiding excessive stress on the transfer belt
2Productivity
If the conversion press increases production capacity to six can ends per cycle, then productivity improves, but misalignment of shells occurs due to space constraints
Solution Approach 1:
The press is divided into multiple independent press stations (first press station, second press station, third press station) that operate in parallel. Each station handles specific forming operations for different can ends, distributing the total production load of six can ends across multiple stations rather than overloading a single station, thereby preventing transfer belt deformation while maintaining high productivity
Solution Approach 2:
The press utilizes a multi-level spatial arrangement with upper and lower toolings positioned at different vertical levels. The first press station is positioned at a first level while the second and third press stations are positioned at a second level, creating a three-dimensional workspace that increases production capacity without proportionally increasing the horizontal footprint, thus avoiding excessive stress on the transfer belt
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A transfer belt assembly (70) includes a plurality of transfer belts (80). The transfer belt assembly (70) is structured to move any of an increased number of shells (3), a very increased number of shells (3), or an extremely increased number of shells (3) through said conversion press (10).)