Can Bodymaker Toolpack Alignment Using Dynamic In-Process Adjustment
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Solution Overview
Problem
Conventional can bodymakers suffer from misalignment issues due to ram/punch droop and thermal effects, leading to can defects and premature wear, requiring time-consuming manual adjustments and stoppages for measurement and alignment correction.
Innovation Solution
A toolpack arrangement with adjustment mechanisms and a sensing system that dynamically adjusts the positioning of components like the ram and toolpack during operation, using sensors and controllers to maintain alignment and correct for misalignments in real-time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If static alignment is used for toolpack and ram, then device complexity is reduced, but manufacturing precision deteriorates due to droop and thermal effects
Solution Approach 1:
The patent implements dynamic alignment adjustment mechanisms that allow the toolpack and/or ram to be repositioned in real-time during operation. This converts the static alignment system into a dynamic one that can compensate for droop and thermal effects, thereby maintaining manufacturing precision without excessive complexity
Solution Approach 2:
The patent incorporates sensing systems (such as lasers, cameras, or sensors) that continuously monitor the alignment between the ram/punch and toolpack, and feed this information back to control systems. This feedback loop enables automatic correction of misalignment, maintaining precision while managing system complexity through intelligent control
2Manufacturing precision
If manual measurement and adjustment is performed, then manufacturing precision can be improved, but productivity deteriorates due to production stoppages
Solution Approach 1:
The patent enables continuous production by implementing real-time dynamic adjustment capabilities. The alignment correction occurs during operation without requiring production stoppages, maintaining both precision and productivity. The system continuously monitors and adjusts alignment while the can bodymaker operates
Solution Approach 2:
The patent implements self-aligning capabilities where the system automatically detects and corrects its own misalignment without external intervention. The sensing and adjustment systems work autonomously to maintain precision, eliminating the need for manual measurement and adjustment that would cause production interruptions
3Ease of operation
If static alignment is used, then ease of operation is improved, but reliability deteriorates due to misalignment causing defects and wear
Solution Approach 1:
The patent implements self-aligning and self-correcting capabilities where the system automatically monitors and adjusts its own alignment during operation. This maintains reliability by preventing misalignment-related defects and wear, while requiring minimal operator intervention, thus preserving ease of operation
Solution Approach 2:
The patent incorporates continuous monitoring systems that detect alignment deviations and automatically trigger correction mechanisms. This feedback loop ensures consistent can body quality by preventing defects caused by misalignment, while the automated nature of the system maintains ease of operation
Data Source
AI summary
A toolpack arrangement for a can bodymaker having a frame. The toolpack includes a toolpack having a number of forming dies and an adjustment arrangement. The adjustment includes a number of adjustment mechanisms coupled between the toolpack and the frame, each adjustment mechanism being dynamically adjustable so as to selectively adjust the positioning of the toolpack with regard to the frame and/or a ram body of the can bodymaker as the ram body passes within the toolpack during normal can body making operations of the can bodymaker.