Staged Piston Domer Assembly for Lower-Impact Can Forming
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Solution Overview
Problem
Existing container-forming processes produce excessive noise and stress due to the impact of the punch engaging a fixed domer during the formation of an inwardly extending dome in cup-shaped bodies, and while a floating domer reduces this impact, it still applies significant force in a single instant.
Innovation Solution
A domer station with a stacked piston assembly, where multiple pistons are aligned and biased by a pressurized fluid supply, allowing incremental pressure application to the domer, which moves between positions to distribute the force of the punch over time, reducing stress on the machine.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If a fixed domer is used during cup-shaped body deformation, then the domer can apply force to deform the cup, but excessive noise and vibration are produced due to impact
Solution Approach 1:
The domer is transformed from a fixed structure to a movable structure that can reciprocate along the punch axis. The domer moves forward to apply deformation force to the cup-shaped body, then retracts to create clearance, reducing impact and vibration during the deformation process
Solution Approach 2:
A cushioning element is introduced between the domer and the cup-shaped body to absorb impact energy. This cushioning mechanism reduces the harmful shock and vibration generated when the domer engages with the cup during deformation, protecting the press from excessive stress
2Object-affected harmful factors
If a floating domer mounted on spring and/or piston is used, then impact force is reduced, but the force is still applied in essentially a single instant
Solution Approach 1:
The force application process is segmented into multiple stages through the use of a multi-position domer system. The domer progresses through forward, retracted, and intermediate positions, applying deformation force in discrete steps rather than a single instantaneous action, thereby extending the duration of force application
Solution Approach 2:
The domer operates through periodic reciprocating motion, alternating between forward movement to apply force and rearward retraction to create clearance. This periodic action distributes the deformation process over multiple cycles, extending the total duration of force application while reducing peak impact forces
3Object-affected harmful factors
If the domer moves away from the punch after bottom deformation, then impact force is reduced, but the deformation process is extended
Solution Approach 1:
The domer maintains continuous engagement with the cup-shaped body throughout the deformation process by operating in a controlled reciprocating manner. Rather than moving away immediately after deformation begins, the domer performs multiple forward-and-retract cycles, ensuring continuous application of deformation force without creating excessive clearance or extending the overall process time
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 reduces the stress and noise on the machine by distributing the force of the punch engagement over time, allowing for complete deformation of the cup-shaped body without excessive impact, thereby improving the efficiency and reliability of the container-forming process.
Implementation Method 1
The pistons are disposed behind the domer in pressure chambers and have a constant pressure applied thereto by a pressurized fluid supply
Data Source
AI summary
A domer station having a domer assembly, a housing assembly, and a stacked piston assembly is provided. The domer assembly is movably disposed within a domer body passage located in the housing assembly and structured to move between a forward, first position and a retracted, second position. The stacked piston assembly includes a plurality of pistons, preferably three pistons, disposed in series and a pressure supply. The pistons are disposed behind the domer in pressure chambers. The pistons have a constant pressure applied thereto and are biased towards the domer. The pistons are, however, each restrained by a stop and do not contact, or operatively engage, the domer when the domer is in the domer first position.