Toolpack Biasing Medium for Adjustable Dampening
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Solution Overview
Problem
Existing metal forming toolpacks lack adjustability and external attenuation control, leading to significant degradation in product quality and production efficiency due to fixed directional force rates and limited ability to optimize ironing process variance, especially at high production speeds.
Innovation Solution
The introduction of an integral and contiguous biasing medium structure within the toolpack that is externally excited and communicated, allowing for adjustable dampening and force attenuation, enabling improved control over can weight and wall thickness variation, and optimizing production processes without machine downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If fixed mechanical springs or Urethane type spring replacements are used in fixed radial locations, then the toolpack structure is simple and reliable, but the directional force rate has no adjustability and causes significant degradation of product quality
Solution Approach 1:
The patent replaces fixed mechanical springs with a dynamic, adjustable dampening system that can modify force attenuation characteristics in real-time. The system allows operators to adjust dampening levels and force attenuation rates during operation, transforming the static toolpack into a dynamic system that adapts to varying production requirements and maintains manufacturing precision.
Solution Approach 2:
The invention enables changeable physical parameters of the dampening system without requiring machine shutdown. Operators can adjust dampening coefficients, force attenuation rates, and spring rates dynamically, allowing the system to optimize container wall thickness control for different production conditions while maintaining continuous operation.
2Adaptability or versatility
If different spring rates are changed through mechanical exchanges of spring elements, then the dampening characteristics can be adjusted, but significant machine down time and operator intervention are required
Solution Approach 1:
The system incorporates self-adjusting mechanisms that allow dampening characteristics to be modified without external operator intervention. The adjustable dampening system enables operators to change force attenuation rates and spring rates through automated or semi-automated controls, eliminating the need for manual spring element exchanges and maintaining continuous production.
Solution Approach 2:
The patent implements a dynamically adjustable dampening system where spring rates and dampening characteristics can be changed during operation. This dynamic capability allows the toolpack to adapt to different production requirements without stopping the press, thereby maintaining high productivity while providing versatile dampening control.
3Productivity
If high production speeds are maintained without external attenuation control, then productivity is high, but variance in ironing process cannot be optimized leading to material misuse
Solution Approach 1:
The patent incorporates feedback mechanisms that monitor the ironing process in real-time and adjust dampening and force attenuation accordingly. This feedback control allows the system to optimize material formation at high speeds, detecting variations in wall thickness or forming quality and automatically adjusting dampening parameters to prevent material waste while maintaining productivity.
Solution Approach 2:
The system enables dynamic parameter adjustments during high-speed production, allowing operators to optimize force attenuation rates and dampening characteristics based on real-time process conditions. This capability ensures that material is formed efficiently at high speeds without excessive variance, preventing both material waste and quality defects.
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 enhances production speed, product quality, reduces tooling wear, and achieves higher efficiency, enabling 90% or greater production efficiency while minimizing material waste and labor requirements, thereby improving overall manufacturing performance and reducing unit costs.
Implementation Method 1
an integral and contiguous biasing medium structure within the toolpack that is externally excited and communicated, allowing for adjustable dampening and force attenuation
Data Source
AI summary
A precision high cyclic rate metal forming toolpack is disclosed for ironing processes used to produce can or other bodies and preforms of ultra-high precision. An example of the toolpack provides improved centering, dampening and force attenuation response. In an example, the toolpack may be implemented with integrated feedback communication and sensoring. An example of the toolpack also provides unified coolant distribution, including enhanced locational intelligence of infinitely variable tooling positions. An example of the toolpack also provides improved axial and longitudinal articulation for improved tool tracking and floatation. The toolpack may enable improved product quality, throughput, manufacturing efficiency, reduced costs, and reduced labor.