Tilting Die Assembly for Can Body Alignment
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Solution Overview
Problem
The alignment and re-alignment of can bodymakers in the production of thin-walled metal two-piece can bodies is complex, time-consuming, and prone to misalignment issues, leading to variations in can quality, wear of precision components, and increased production costs due to the high-speed, high-volume nature of the industry.
Innovation Solution
A die assembly with a support mechanism that allows the die to tilt relative to the housing, utilizing a fluid-filled chamber to provide resistance and improve alignment, reducing misalignment by redistributing fluid and applying a reaction force to counteract unbalanced forces during the drawing and wall ironing processes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the die is fixed rigidly in the housing, then the structural stability is improved, but the alignment precision deteriorates due to unbalanced forces during drawing and wall ironing
Solution Approach 1:
The die is made dynamically adjustable through a tilting mechanism that allows it to rotate about an axis during operation. This enables the die to self-align with the ram by tilting in response to unbalanced forces, thereby maintaining alignment precision while preserving structural stability through the controlled rotational degree of freedom.
Solution Approach 2:
The orientation parameter of the die is changed dynamically during operation. By allowing the die to tilt and adjust its angular orientation in response to loading conditions, the system maintains optimal alignment between the die and ram, resolving the contradiction between fixed structural stability and adjustable alignment precision.
2Device complexity
If static alignment adjustment is used, then the device complexity is reduced, but the productivity deteriorates due to frequent downtime for re-alignment
Solution Approach 1:
The die assembly performs self-alignment through its tilting mechanism, automatically adjusting to compensate for misalignment caused by wear or manufacturing tolerances. This eliminates the need for external intervention and frequent manual re-alignment operations, thereby maintaining high productivity without significantly increasing device complexity.
Solution Approach 2:
The alignment adjustment is made dynamic rather than static. The die can tilt and self-correct during operation, eliminating the need for production stoppages to manually re-align components. This dynamic self-adjustment capability maintains productivity while keeping the overall system relatively simple.
3Manufacturing precision
If precise alignment is maintained statically, then the manufacturing precision is improved, but the device complexity increases due to the need for frequent manual re-alignment by skilled operators
Solution Approach 1:
The die assembly self-aligns through its tilting mechanism, automatically compensating for misalignment issues without requiring skilled operators to perform manual adjustments. This maintains manufacturing precision while eliminating the complex human intervention process, thereby reducing operational complexity.
Solution Approach 2:
The system transitions from static alignment requiring manual intervention to dynamic self-alignment. The die can tilt and adjust its orientation automatically during operation, maintaining precision without the need for skilled operators to perform complex re-alignment procedures.
4Manufacturing precision
If the die is allowed to tilt freely, then the alignment precision is improved, but the structural stability deteriorates due to potential excessive movement
Solution Approach 1:
The die is given a controlled rotational degree of freedom rather than complete freedom. It can tilt about a specific axis to achieve alignment, but the movement is constrained to prevent excessive displacement. This dynamic constraint allows precision improvement while maintaining structural stability.
Solution Approach 2:
The orientation parameter of the die is made variable within controlled limits. The die can change its angular position to achieve optimal alignment, but the range of motion is constrained to maintain structural stability. This controlled parameter change resolves the contradiction between freedom for alignment and stability for structural integrity.
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 dynamically adjusts the die alignment during operation, reducing the need for static adjustments and extending the working life of precision components, thereby improving can body quality and reducing production downtime and costs.
Implementation Method 1
Movement of the one or more surfaces may cause the fluid to be redistributed in the chamber in response to the tilting of the die or die holder. The fluid may provide resistance to movement of the die whilst still allowing the die to be tilted by the ram
Data Source
AI summary
A die assembly comprising: a housing; a die for drawing and/or wall ironing a metal cup mounted on an end of a ram to form a container body; and a support mechanism for the die or a die holder in which the die is mounted. The support mechanism is configured to allow the die to tilt relative to the housing to reduce misalignment of a longitudinal axis of the die with respect to the ram during drawing and/or wall ironing of a metal cup. The die assembly further comprises a chamber provided in the housing and adapted for sealing fluid therein. The chamber is sealed by one or more surfaces coupled to or provided on the die or die holder such that tilting of the die during drawing and/or wall ironing of a metal cup moves the one or more or more surfaces against fluid sealed in the chamber.