CONVERSION PRESS FOR CAN ENDS

Abstract

A quick-change cartridge assembly for a conversion press includes a downstacker assembly having at least one can shell delivery apparatus for delivering can shells during use of a conversion press incorporating the quick-change cartridge assembly; one or more forming stations; a tab stake station; and a transfer belt. The transfer belt defines at least one active forming lane for conveying the can shells from the at least one can shell delivery apparatus to the one or more forming stations and the tab stake station during use of the conversion press incorporating the quick-change cartridge assembly.

Description

FIELD OF THE INVENTION

The present invention relates to a conversion press including a cartridge assembly for forming can ends, and to a method for exchanging cartridge assemblies in a conversion press.

BACKGROUND OF THE INVENTION

Metallic containers (e.g., cans) for holding products such as, for example, food and beverages, are typically provided with an easy open can end on which a pull tab is attached (e.g., without limitation, riveted) to a tear strip or severable panel. The severable panel is defined by a scoreline in the exterior surface (e.g., public side) of the can end. The pull tab is structured to be lifted and/or pulled to sever the scoreline and deflect and/or remove the severable panel, thereby creating an opening for dispensing the contents of the can.

SUMMARY OF THE INVENTION

In accordance with embodiments, a conversion press is provided for forming can ends with tabs. The press comprises a frame; a ram movably coupled to the frame; and at least one cartridge assembly releasably coupled to a bolster of the frame and the ram. Each cartridge assembly comprises one or more forming stations; a tab stake station; and a transfer belt that receives can shells. The transfer belt defines at least one active forming lane for conveying the can shells to the one or more forming stations and the tab stake station. The can shells are formed into can ends with tabs as they are conveyed along the at least one active forming lane.

The at least one cartridge assembly may include an upper mounting plate releasably coupled to the ram and/or a lower mounting plate releasably coupled to the bolster of the frame. A downstacker assembly and the transfer belt may be coupled to the lower mounting plate.

The at least one cartridge assembly may include any one or more of the following: a light tester assembly that checks the formed can ends with tabs for defects; a drive drum that is releasably coupled to a drive shaft of the conversion press for driving the transfer belt; or a scrap chopper apparatus for chopping the remainder of the tab feed stock into scrap material. The conversion press may further comprise a scrap chute apparatus for discharging the scrap material from the scrap chopper apparatus

The conversion press may further comprise a tab forming and feeder apparatus configured to progressively form tabs in a tab feed stock and deliver the tab feed stock with the formed tabs to the tab stake station where the tabs are separated from a remainder of the tab feed stock and coupled to the can shells.

The at least one cartridge assembly may comprise two cartridge assemblies. The first cartridge assembly may include the same number of active forming lanes as the second cartridge assembly or a different number of active forming lanes than the second cartridge assembly. The first cartridge assembly may form first can ends with first tabs and the second cartridge assembly may form second can ends with second tabs, where the first can ends have the same size and shape or at least one of a different size or shape than the second can ends.

The one or more forming stations may comprise one or more of a primary bubble station, a secondary bubble station, a score and button station, a panel and button restrike station, or a tab wipe down station.

The at least one cartridge assembly may comprise an upper mounting plate releasably coupled to the ram using mechanical fasteners or using a first magnetic fastener assembly and a lower mounting plate releasably coupled to the bolster of the frame using mechanical fasteners or using a second magnetic fastener assembly.

The number of can shell delivery apparatuses in each cartridge assembly may correspond to the number of active forming lanes in the corresponding cartridge assembly.

The at least one cartridge assembly may comprise a lower mounting plate, and two or more of the downstacker assembly, the one or more forming stations, the tab stake station, or the transfer belt are coupled to the lower mounting plate.

The at least one cartridge assembly may comprise a lower mounting plate, and the downstacker assembly, the one or more forming stations, the tab stake station, and the transfer belt are coupled to the lower mounting plate. The at least one cartridge assembly may further comprise: a light tester assembly that checks the formed can ends with tabs for defects; and a drive drum that is releasably coupled to a drive shaft of the conversion press for driving the transfer belt, wherein the light tester assembly and the drive drum may be coupled to the lower mounting plate.

In accordance with embodiments, a method is provided for exchanging a cartridge assembly in a conversion press which comprises a frame and a ram movably coupled to the frame. The method comprises removing a first cartridge assembly from the conversion press and installing a second cartridge assembly into the conversion press in place of the first cartridge assembly. The first cartridge assembly comprises: a first upper mounting plate; a first lower mounting plate; one or more first forming stations; a first tab stake station; and a first transfer belt. The first transfer belt receives can shells and defines at least one first active forming lane for conveying the can shells to the one or more first forming stations and the first tab stake station. The can shells are formed into can ends with tabs as they are conveyed along the at least one first active forming lane. The second cartridge assembly comprises a second upper mounting plate; a second lower mounting plate; one or more second forming stations; a second tab stake station; and a second transfer belt. The second transfer belt receives can shells and defines at least one second active forming lane for conveying the can shells to the one or more second forming stations and the second tab stake station. The can shells are formed into can ends with tabs as they are conveyed along the at least one second active forming lane. Removing the first cartridge assembly from the conversion press comprises: removing the first upper mounting plate from the ram; and removing the first lower mounting plate from a bolster of the frame. Installing the second cartridge assembly into the conversion press comprises: releasably coupling the second upper mounting plate to the ram; and releasably coupling the second lower mounting plate to the bolster of the frame.

A first downstacker assembly and the first transfer belt may be coupled to the first lower mounting plate and a second downstacker assembly and the second transfer belt may be coupled to the second lower mounting plate.

The first cartridge assembly may further comprise a first light tester assembly coupled to the first lower mounting plate and the second cartridge assembly may further comprise a second light tester assembly coupled to the second lower mounting plate, wherein the first and second light tester assemblies check can ends with tabs formed by the respective first and second cartridge assemblies for defects.

The first cartridge assembly may further comprise a first scrap chopper apparatus and the second cartridge assembly may further comprise a second scrap chopper apparatus, the first and second scrap chopper apparatuses for chopping a remainder of tab feed stock into scrap material.

The first cartridge assembly may include the same number of active forming lanes as the second cartridge assembly or a different number of active forming lanes than the second cartridge assembly.

The first cartridge assembly may form first can ends with first tabs and the second cartridge assembly may form second can ends with second tabs, where the first can ends have the same size and shape as the second can ends or at least one of a different size or shape than the second can ends.

The method may further comprise removing a first tab forming and feeder apparatus from the conversion press, the first tab forming and feeder apparatus configured to progressively form first tabs in a first tab feed stock and deliver the first tab feed stock with the formed first tabs to the first tab stake station where the first tabs are separated from a remainder of the first tab feed stock and coupled to the can shells that are being conveyed on the first transfer belt of the first cartridge assembly. The method may also comprise installing a second tab forming and feeder apparatus into the conversion press, the second tab forming and feeder apparatus configured to progressively form second tabs in a second tab feed stock and deliver the second tab feed stock with the formed second tabs to the second tab stake station where the second tabs are separated from a remainder of the second tab feed stock and coupled to the can shells that are being conveyed on the second transfer belt of the second cartridge assembly. The second tab forming and feeder apparatus may comprise at least one of: a different output volume of formed tabs than the first tab forming and feeder apparatus; or tooling to form tabs having at least one of a different size or shape than the first tab forming and feeder apparatus.

The one or more first and second forming stations may respectively comprise one or more of a primary bubble station, a secondary bubble station, a score and button station, a panel and button restrike station, or a tab wipe down station.

The first and second upper mounting plates may be respectively releasably coupled to the ram using mechanical fasteners or magnetic fastener assemblies and the first and second lower mounting plates are respectively releasably coupled to the bolster of the frame using mechanical fasteners or magnetic fastener assemblies.

The number of can shell delivery apparatuses in each cartridge assembly may correspond to the number of active forming lanes in the corresponding cartridge assembly.

Installing the second cartridge assembly into the conversion press may further comprise: prior to releasably coupling the second upper mounting plate to the ram and releasably coupling the second lower mounting plate to the bolster, using a locational guide pin assembly that is fixed to the frame to position the second cartridge assembly in a desired location. When the second upper mounting plate is releasably coupled to the ram with the second cartridge assembly in the desired location and the second lower mounting plate is releasably coupled to the bolster with the second cartridge assembly in the desired location, the second upper and lower mounting plates are properly positioned to allow the one or more second forming stations and the second tab stake station to form can shells delivered by the at least one second can shell delivery apparatus into can ends with tabs.

The first cartridge assembly may further comprise a scrap chopper apparatus coupled to the first lower mounting plate and the second cartridge assembly may further comprise a second scrap chopper apparatus coupled to the second lower mounting plate, wherein the first and second scrap chopper apparatuses are provided for chopping a remainder of a tab feed stock into scrap material.

The method may further comprise: prior to removing the first lower mounting plate from the bolster of the frame, removing a scrap chute apparatus from the frame, the scrap chute apparatus provided for discharging the scrap material from the first scrap chopper apparatus; and after releasably coupling the second lower mounting plate to the bolster of the frame, releasably coupling the scrap chute apparatus to the frame, the scrap chute apparatus provided for discharging the scrap material from the second scrap chopper apparatus.

The method may further comprise removing a first drive drum of the first cartridge assembly from a drive shaft that is fixed to the frame, the drive shaft configured to drive the first drive drum to rotate the first transfer belt. The method may further comprise releasably coupling a second drive drum of the second cartridge assembly to the drive shaft, the drive shaft configured to drive the second drive drum to rotate the second transfer belt. The first drive drum may be coupled to the first lower mounting plate and the second drive drum may be coupled to the second lower mounting plate.

The method may further comprise, prior to removing the first upper mounting plate from the ram, extending the ram to a bottom dead center position so that the first upper mounting plate rests on the first lower mounting plate.

According to embodiments, a quick-change cartridge assembly is provided for a conversion press. The quick-change cartridge assembly comprises one or more forming stations; a tab stake station; and a transfer belt. The transfer belt defines at least one active forming lane for conveying can shells to the one or more forming stations and the tab stake station during use of the conversion press incorporating the quick-change cartridge assembly.

The quick-change cartridge assembly may further comprise an upper mounting plate configured to be releasably coupled to a ram of the conversion press and/or a lower mounting plate configured to be releasably coupled to a bolster of a frame of the conversion press. The downstacker assembly and the transfer belt may be coupled to the lower mounting plate.

The quick-change cartridge assembly may further comprise one or more of: a light tester assembly that checks can ends with tabs formed by the quick-change cartridge assembly for defects; a drive drum that is configured to be releasably coupled to a drive shaft of the conversion press for driving the transfer belt; or a scrap chopper apparatus that is configured to chop a remainder of a tab feed stock into scrap material.

The one or more forming stations may comprise one or more of a primary bubble station, a secondary bubble station, a score and button station, a panel and button restrike station, or a tab wipe down station.

The quick-change cartridge assembly may further comprise a lower mounting plate, and two or more of a downstacker assembly, the one or more forming stations, the tab stake station, or the transfer belt are coupled to the lower mounting plate.

The quick-change cartridge assembly may further comprise a lower mounting plate, and a downstacker assembly, the one or more forming stations, the tab stake station, and the transfer belt are coupled to the lower mounting plate.

The quick-change cartridge assembly may further comprise: a light tester assembly that checks can ends with tabs formed by the quick-change cartridge assembly for defects; and a drive drum that is configured to be releasably coupled to a drive shaft of the conversion press for driving the transfer belt. The light tester assembly and the drive drum may be coupled to the lower mounting plate.

According to embodiments, a conversion press is provided for forming can ends with tabs comprising: a frame: a ram movably coupled to the frame: a cartridge assembly releasably coupled to a bolster of the frame and the ram; and a locational guide device coupled to the frame and the ram, wherein the cartridge assembly is located within the frame via alignment with the locational guide device.

The cartridge assembly may comprise: one or more forming stations: a tab stake station; and a transfer belt that conveys can shells to the one or more forming stations and the tab stake station.

The cartridge assembly may further comprise a downstacker assembly comprising at least one can shell delivery apparatus for delivering can shells.

The locational guide device may comprise an alignment block coupled to the frame and a locator block coupled to the alignment block. The locator block may comprise a through-hole for receiving an alignment pin which is also received in a corresponding opening provided in the cartridge assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are perspective views of a conversion press according to embodiments;

FIG. 2 is a sectional side view of a conversion press according to embodiments;

FIG. 3 is a sectional top view of a conversion press according to embodiments;

FIGS. 4A and 4B are perspective views of a cartridge assembly for a conversion press according to embodiments;

FIG. 5 is a perspective view of the cartridge assembly of FIGS. 4A and 4B with a top mounting plate thereof removed;

FIGS. 6-12 are sectional top views of conversion press configurations according to embodiments;

FIGS. 13A and 13B are perspective views of a drive shaft and a drive drum (FIG. 13A) or drive drums (FIG. 13B) according to embodiments;

FIG. 14 illustrates a cartridge assembly releasably coupled to a conversion press using mechanical fasteners according to embodiments;

FIG. 15 illustrates a cartridge assembly releasably coupled to a conversion press using magnetic fastener assemblies according to embodiments;

FIG. 16 illustrates two cartridge assemblies releasably coupled to a conversion press using magnetic fastener assemblies according to embodiments;

FIGS. 17-22 illustrate a press having a first cartridge assembly removed therefrom and a second cartridge assembly being releasably coupled thereto according to embodiments; and

FIGS. 23-29 illustrate steps for exchanging a cartridge assembly in a conversion press according to embodiments.

DETAILED DESCRIPTION OF THE INVENTION

For purposes of illustration, embodiments disclosed herein will be described as applied to can ends for food or beverage cans, although it is noted that they could also be employed to containers for other products.

It will be appreciated that the specific elements illustrated in the figures herein and described in the following specification are simply exemplary embodiments, which are provided as non-limiting examples solely for the purpose of illustration. Therefore, any specific dimensions, orientations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.

Directional phrases used herein, such as, for example, clockwise, counterclockwise, left, right, top, bottom, upwards, downwards, and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.

As used herein, the terms “can” and “container” are used substantially interchangeably to refer to any known or suitable container, which is structured to contain a substance, e.g., liquid, food, or any other suitable substance. As used herein, the term “can end” refers to the lid or closure that is structured to be coupled to a can, in order to seal the can. As used herein, a “multi-out” conversion press is a conversion press wherein there is more than one lane of shells being coupled to tabs during a cycle.

As used herein, the statement that two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, “directly coupled” means that two elements are directly in contact with each other. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other. As used herein, “movably coupled” means that two components are coupled so as to move relative to each other. As used herein, “releasably coupled” means that two components are coupled together in such a way that they can be uncoupled from each other without structure damage to either component.

As used herein, the word “unitary” means a component is created as a single piece or unit. That is, a component that includes pieces that are created separately and then coupled together as a unit is not a “unitary” component or body.

As used herein, “configured to [verb]” means that the identified element or assembly has a structure that is shaped, sized, disposed, and/or coupled to perform the identified verb.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.”

With reference now to the drawings, FIGS. 1A, 1B, and 2 illustrate a conversion press 10 (hereinafter “press 10”) that is configured to interchangeably and releasably receive one or more quick change cartridge assemblies according to embodiments. According to the exemplary embodiment shown, the press 10 may releasably receive either a single quick-change cartridge 12 as shown in FIG. 1A, or first and second quick change cartridges 12A, 12B as shown in FIG. 1B. The number of quick-change cartridges releasably received in the press 10 may vary depending on the desired output, e.g., volume and type, of can ends with tabs formed by the press 10, as will be discussed in detail herein.

The press 10 includes a static frame 20 that defines a main structural component of the press 10. The frame 20 includes a plurality of feet 22 for supporting the press 10 on a supporting surface, such as a floor, tabletop, etc. The frame 20 further defines a work support or bolster 86 (see FIGS. 14 and 15) that does not move relative to the remainder of the frame 20 or the supporting surface on which the frame 20 is located.

The press 10 further comprises a ram 40 that is movably coupled to the frame 20 between a first position, also referred to as a non-engaged position or a top dead center position, and a second position, also referred to as an engaged position or a bottom dead center position. The press 10 still further comprises a conventional ram drive assembly 42 mounted to the frame 20, which drives movement of the ram 40 between the first and second position. The ram drive assembly 42 is schematically shown in FIGS. 1A, 1B, and 2 and the components thereof are conventional and will not be described in detail herein.

With reference to FIGS. 3-5, the press 10 additionally comprises a tab die, also referred to herein as a tab forming and feeder apparatus 60, hereinafter “tab apparatus 60”, which is releasably coupled to the frame 20, e.g., via a plurality of mechanical fasteners such as bolts. The tab apparatus 60 receives a tab feed stock 62 from a conventional tab feed stock source 64, such as a continuous coil of aluminum or steel material, which is schematically shown in FIG. 3. As shown in FIG. 3, the tab apparatus 60 is configured to progressively form tabs 66 in the tab feed stock 62 and to deliver the tab feed stock 62 with the formed tabs 66 to a tab stake station of the cartridge(s), as will be discussed below. The components of the tab apparatus 60 are conventional and will not be described in detail herein.

The specific configuration of the tab apparatus 60 that is used in the press 10 depends on the type of can ends with tabs that are being formed by the quick-change cartridge(s) currently installed in the press 10. Additional details in connection with the selection of the tab apparatus 60 for the press 10 will be discussed in more detail herein.

An exemplary quick-change cartridge assembly 80 for use in the press 10 according to embodiments will now be described. With reference to FIGS. 4A, 4B, and 5, the illustrated quick-change cartridge assembly 80 (hereinafter “cartridge assembly 80”) is releasably coupled to the press 10 in the configuration shown in FIG. 1A, i.e., a single-cartridge configuration of the press 10. The cartridge assembly 80 includes a lower mounting plate 82 and an upper mounting plate 84. The lower mounting plate 82 is releasably coupled to the bolster 86 of the frame 20, for example via mechanical fasteners, e.g., bolts 88A (see FIGS. 14 and 18A), or via a magnetic fastener assembly 90 (see FIGS. 15 and 16). The upper mounting plate 84 is releasably coupled to the ram 40, for example via mechanical fasteners, e.g., bolts 88B (see FIGS. 14 and 18A), or via the magnetic fastener assembly 90. In embodiments including the magnetic fastener assembly 90, the lower and upper mounting plates 82, 84 would be formed from a magnetic material or the plates 82, 84 would be coupled to magnetic plates or other mounting members formed from a magnetic material, and a controller 92 may be provided to control activation of a power supply to energize first and second pairs of lower and upper magnetic plates 94A. 94B of the magnetic fastener assembly 90, which magnetic plates 94A. 94B are respectively fixedly coupled to the bolster 86 and the ram 40. The controller 92 could be used to power on and off the magnetic plates 94A. 94B to selectively hold the lower and upper mounting plates 82, 84 in place or release them.

The cartridge assembly 80 further comprises a transfer belt 100 that is coupled to the lower mounting plate 82 and defines one or more active forming lanes, which active forming lanes extend parallel to a longitudinal axis LA of the cartridge assembly 80. In the exemplary embodiment shown in FIGS. 4A, 4B, and 5, the transfer belt 100 defines first and second active forming lanes 102A, 102B, although the transfer belt 100 could also define more active forming lanes, such as three active forming lanes. Each active forming lane 102A. 102B receives can shells 104A. 104B (see FIG. 3) from a respective can shell delivery apparatus 106A, 106B of a downstacker assembly 108, which downstacker assembly 108 is part of the cartridge assembly 80 and is coupled to the lower mounting plate 82. The downstacker assembly 108 comprises a servo motor 110 that controls delivery of the can shells 104A. 104B from the can shell delivery apparatuses 106A. 106B to the transfer belt 100 in a conventional manner. According to embodiments, the number of can shell delivery apparatuses in the cartridge assembly 80 may correspond to the number of active forming lanes in the cartridge assembly 80.

The transfer belt 100 conveys the can shells 104A. 104B received from the can shell delivery apparatuses 106A. 106B from a first end portion 101A of the transfer belt 100 to a second end portion 101B of the transfer belt 100 downstream from the first end portion 101A, during which conveyance the can shells 104A, 104B are formed into can ends with tabs 110A, 110B, see FIG. 3. The transfer belt 100 may also define one or more inactive lanes I_L, i.e., lanes that do not receive can shells and in which can ends with tabs are not formed. FIGS. 6, 8, 9, and 12 illustrate transfer belts 100 that include an inactive lane I_L.

The transfer belt 100, which in the illustrated embodiment comprises an endless belt, includes the first end portion 101A, which extends around a tail drum 120 that is coupled to the lower mounting plate 82, and the second end portion 101B, which extends around a drive drum 122 that is also coupled to the lower mounting plate 82. In the exemplary embodiment shown, the drive drum 122 is releasably coupled to a drive shaft 124 of the press 10 (see FIG. 3 and also FIGS. 13A and 13B) for driving the transfer belt 100. Any suitable coupling structure may be used to releasably couple the drive drum 122 to the drive shaft 124. A crankshaft of the press 10 drives a roller 300 mounted to the frame 20 that drives an endless timing belt 310, which drives a gearbox 320 mounted to the frame 20. The gearbox 320 is coupled to and drives the drive shaft 124, see FIGS. 13A and 13B.

As most clearly shown in FIG. 5, the cartridge assembly 80 includes lower and upper tooling members, respectively coupled to the lower and upper mounting plates 82, 84 (the upper mounting plate 84 has been removed from FIG. 5 for clarity). Each pair of lower and upper tooling members may define a forming station or a tab stake station. Hence, the tooling members form a plurality of forming stations and a tab stake station for forming can ends with tabs. The exemplary forming stations shown in FIG. 5 include a primary bubble station 140, a secondary bubble station 142, a score and button station 144, a panel and button restrike station 146, and a tab wipe down station 148. The tab stake station 150 is located between the panel and button restrike station 146 and the tab wipe down station 148. The number of sets of forming/tab stake stations may correspond to the number of active forming lanes in the cartridge assembly 80, e.g., in FIG. 5, the cartridge assembly 80 includes two active forming lanes and two sets of forming and tab stake stations.

The role of each of these stations in forming a can shell into a can end with a tab will be briefly described. The primary bubble station 140 and secondary bubble station 142 are provided for forming a bubble in the can shell. The score and button station 144 is provided for converting the bubble into a rivet button and also score, i.e., partially cut, or otherwise cause metal in the can shell to thin, which cut or thinned metal in the can shell outlines and defines a shape of a removable tab. The panel and button restrike station 146 is provided for further defining the rivet button shape. The tab stake station 150 is provided for separating the tab 66 from a remainder of the tab feed stock 62 and coupling the tab 66 to the can shell by staking or flattening the rivet button on the can shell into a rivet and thereby coupling the tab 66 to the can shell. The tab wipe down station 148 is provided for wiping the tab to remove any sharp surfaces on the tab, e.g., occurring during the tab separation process in the tab stake station 150.

The cartridge assembly 80 additionally comprises a scrap chopper apparatus 160, which is coupled to the lower mounting plate 82 and located adjacent and downstream to the tab stake station 150 in a direction perpendicular to the longitudinal axis LA of the cartridge assembly 80. The scrap chopper apparatus 160 is provided for chopping the remainder of the tab feed stock. i.e., a portion of the tab feed stock 62 that was not formed into a tab 66 by the tab apparatus 60 and then applied to the can shell by the tab stake station 150, into scrap material. A scrap chute apparatus 162 is coupled to the frame 20 and is positioned adjacent to the scrap chopper apparatus 160 for discharging the scrap material from the scrap chopper apparatus 160, e.g., into a recycling container.

Downstream from the forming stations, the cartridge assembly 80 further comprises a light tester assembly 180, which is also coupled to the lower mounting plate 82. The light tester assembly 180 includes one or more light tester units that check the formed can ends with tabs for defects, i.e., if light passes through a can end the can end may be deemed defective. The number of light tester units may correspond to the number of active forming lanes in the cartridge assembly 80, e.g., in FIG. 5, the cartridge assembly 80 includes two active forming lanes and two light tester units 182A. 182B.

All of the parts of the cartridge assembly 80, including the transfer belt 100, the downstacker assembly 108, the drive drum 122, the scrap chopper apparatus 160, the light tester assembly 180, and the tooling members that form the forming stations of the press 10 discussed above (the primary bubble station 140, secondary bubble station 142, score and button station 144, panel and button restrike station 146, tab wipe down station 148, and tab stake station 150) may be directly coupled to either the lower or/and upper mounting plates 82, 84. For example, the transfer belt 100, the downstacker assembly 108, the drive drum 122, the scrap chopper apparatus 160, the light tester assembly 180, and the lower tooling members of the forming and tab stake stations may be all coupled to the lower mounting plate 82, and the upper tooling members of the forming and tab stake stations may be coupled to the upper mounting plate 84. It is also contemplated that a cartridge assembly may comprise the tooling members that form the forming and tab stake stations of the press 10, the drive drum 122 and one or more of the following: the downstacker assembly 108, the scrap chopper apparatus 160, and/or the light tester assembly 180. That is, one or more of the downstacker assembly 108, the scrap chopper apparatus 160, and/or the light tester assembly 180 may be coupled to the frame and not to the lower mounting plate 82 of the cartridge assembly 80.

Since the cartridge assembly 80 is interchangeably and releasably received in the press 10, all of the cartridge assembly parts mounted to the upper and lower mounting plates 84, 82 can be conveniently removed from the press 10 at once, i.e., without requiring them to be individually removed, when the cartridge assembly 80 is removed and then one or more other cartridge assemblies can be inserted into and coupled to the press 10, without requiring that each of the parts of the one or more new cartridge assemblies be individually mounted to the press 10, thereby allowing easy access to the initially installed cartridge assembly and the one or more replacement cartridge assemblies and their respective parts and further allowing for a more time and labor efficient process for modifying the press 10 to change the output volume or output type of can ends with tabs being formed by the press 10.

The press 10 is capable of interchangeably and releasably receiving a number of different types of cartridge assemblies for forming a number of different types and volumes of can ends with tabs. A number of exemplary cartridge assembly configurations that can be interchangeably and releasably received in the press 10 are shown in FIGS. 6-12, it being noted that other cartridge assembly configurations are contemplated but not specifically shown herein for brevity.

FIG. 6 depicts a 1-out configuration, i.e., one can end with tab 110A is output per cycle by the press 10 according to this embodiment. The press 10 includes a single cartridge assembly 80 and the transfer belt 100 of the single cartridge assembly 80 defines a single active forming lane 102A and an inactive lane I_L. Since the cartridge assembly 80 according to this embodiment includes a single active forming lane 102A, the cartridge assembly 80 according to this embodiment includes a single can shell delivery apparatus 106A, a single set of forming/tab stake stations, and a single light tester unit 182A.

FIG. 7 depicts a 2-out configuration, i.e., two can ends with tabs 110A. 110B are output per cycle by the press 10 according to this embodiment. The press 10 includes a single cartridge assembly 80 and the transfer belt 100 of the single cartridge assembly 80 defines two active forming lanes 102A. 102B. Different types of can ends with tabs 110A. 110B are formed in the active forming lanes 102A. 102B according to this embodiment. Specifically, first can ends with tabs 110A are formed in the first active forming lane 102A, and second can ends with tabs 110B are formed in the second active forming lane 102B. The first can ends according to this embodiment have a different size and shape than the second can ends, although it is understood that first can ends formed in a cartridge could have the same size and/or shape as second can ends formed in a same cartridge.

Since the cartridge assembly 80 according to this embodiment includes two active forming lanes 102A. 102B, the cartridge assembly 80 according to this embodiment includes two can shell delivery apparatuses 106A. 106B, two sets of forming/tab stake stations, and two light tester units 182A. 182B. The tab apparatus 60, scrap chopper apparatus 160, and scrap chute apparatus 162 service both active forming lanes 102A. 102B according to this embodiment.

FIG. 8 depicts a 2-out configuration, i.e., two can ends with tabs 110A. 110B are output per cycle by the press 10 according to this embodiment. The press 10 includes two cartridge assemblies 80A. 80B, and the transfer belts 100A. 100B of both cartridge assemblies 80A. 80B each define a single active forming lane 102A. 102B. The same types of can ends with tabs 110A. 110B are formed by the first and second cartridge assemblies 80A. 80B according to this embodiment, although it is noted that different types of can ends with tabs may be formed by the first and second cartridge assemblies 80A. 80B, as shown in the embodiment of FIG. 12.

Since each cartridge assembly 80A. 80B according to this embodiment includes a single active forming lane 102A. 102B, each cartridge assembly 80A. 80B according to this embodiment includes a single can shell delivery apparatus 106A. 106B, a single set of forming/tab stake stations, and a single light tester unit 182A. 182B. The tab apparatus 60, scrap chopper apparatus 160, and scrap chute apparatus 162 service the active forming lanes 102A. 102B of both cartridge assemblies 80A. 80B according to this embodiment. It is noted that the tab apparatus 60 and the scrap chute apparatus 162 may be mounted directly to the frame 20, while the scrap chopper apparatus 160 may be mounted to the second cartridge assembly 80B. A scrap chopper apparatus may not be provided on the first cartridge assembly 80A.

FIG. 9 depicts a 3-out configuration, i.e., three can ends with tabs 110A. 110B. 110C are output per cycle by the press 10 according to this embodiment. The press 10 includes two cartridge assemblies 80A. 80B. The transfer belt 100A of the first cartridge assembly 80A defines two active forming lanes 102A. 102B, and the transfer belt 100B of the second cartridge assembly 80B defines a single active forming lane 102C and an inactive lane I_L. The same types of can ends with tabs 110A. 110B. 110C are formed by the first and second cartridge assemblies 80A. 80B according to this embodiment, although it is noted that different types of can ends with tabs may be formed by the first and second cartridge assemblies 80A. 80B.

Since the first cartridge assembly 80A according to this embodiment includes two active forming lanes 102A. 102B, the first cartridge assembly 80A according to this embodiment includes two can shell delivery apparatuses 106A. 106B, two sets of forming/tab stake stations, and two light tester units 182A. 182B. And since the second cartridge assembly 80B according to this embodiment includes a single active forming lane 102C, the second cartridge assembly 80B according to this embodiment includes a single can shell delivery apparatus 106C, a single set of forming/tab stake stations, and a single light tester unit 182C. The tab apparatus 60, scrap chopper apparatus 160, and scrap chute apparatus 162 service the active forming lanes 102A. 102B. 102C of the first and second cartridge assemblies 80A. 80B according to this embodiment. The tab apparatus 60) and the scrap chute apparatus 162 may be mounted directly to the frame 20, while the scrap chopper apparatus 160 may be mounted to the second cartridge assembly 80B. A scrap chopper apparatus may not be provided on the first cartridge assembly 80A.

FIG. 10 depicts a 4-out configuration, i.e., four can ends with tabs 110A. 110B. 110C. 110D are output per cycle by the press 10 according to this embodiment. The press 10 includes two cartridge assemblies 80A. 80B. The transfer belt 100A of the first cartridge assembly 80A defines two active forming lanes 102A, 102B, and the transfer belt 100B of the second cartridge assembly 80B defines two active forming lanes 102C, 102D. The same types of can ends with tabs 110A, 110B, 110C, 110D are formed by the first and second cartridge assemblies 80A, 80B according to this embodiment, although it is noted that different types of can ends with tabs may be formed by the first and second cartridge assemblies 80A, 80B.

Since the first and the second cartridge assembly 80A, 80B according to this embodiment include two active forming lanes 102A, 102B, 102C, 102D, the first and the second cartridge assembly 80A, 80B according to this embodiment each include two can shell delivery apparatuses 106A, 106B, 106C, 106D, two sets of forming/tab stake stations, and two light tester units 182A, 182B, 182C, 182D. The tab apparatus 60, scrap chopper apparatus 160, and scrap chute apparatus 162 service the active forming lanes 102A, 102B, 102C, 102D of the first and second cartridge assemblies 80A, 80B according to this embodiment. The tab apparatus 60 and the scrap chute apparatus 162 may be mounted directly to the frame 20, while the scrap chopper apparatus 160 may be mounted to the second cartridge assembly 80B. A scrap chopper apparatus may not be provided on the first cartridge assembly 80A.

FIG. 11 depicts a 6-out configuration, i.e., six can ends with tabs 110A, 110B, 110C, 110D, 110E, 110F, are output per cycle by the press 10 according to this embodiment. The press 10 includes two cartridge assemblies 80A, 80B. The transfer belt 100A of the first cartridge assembly 80A defines three active forming lanes 102A, 102B, 102C, and the transfer belt 100B of the second cartridge assembly 80B defines three active forming lanes 102D, 102E, 102F. The same types of can ends with tabs 110A, 110B, 110C, 110D, 110E, 110F, are formed by the first and second cartridge assemblies 80A, 80B according to this embodiment, although it is noted that different types of can ends with tabs may be formed by the first and second cartridge assemblies 80A. 80B.

Since the first and second cartridge assembly 80A. 80B according to this embodiment include three active forming lanes 102A, 102B, 102C, 102D, 102E, 102F, the first and second cartridge assembly 80A, 80B according to this embodiment each include three can shell delivery apparatuses 106A, 106B, 106C, 106D, 106E, 106F, three sets of forming/tab stake stations, and three light tester units 182A, 182B, 182C, 182D, 182E, 182F. The tab apparatus 60, scrap chopper apparatus 160, and scrap chute apparatus 162 service the active forming lanes 102A, 102B, 102C, 102D, 102E, 102F of the first and second cartridge assemblies 80A, 80B according to this embodiment. The tab apparatus 60 and the scrap chute apparatus 162 may be mounted directly to the frame 20, while the scrap chopper apparatus 160 may be mounted to the second cartridge assembly 80B. A scrap chopper apparatus may not be provided on the first cartridge assembly 80A.

FIG. 12 depicts an embodiment similar to that of FIG. 8, with the exception that different types of can ends with tabs are formed by the first and second cartridge assemblies 80A, 80B. Specifically, first can ends with tabs 110A are formed in the single active forming lane 102A of the first cartridge assembly 80A, and second can ends with tabs 110B are formed in the single active forming lane 102B of the second cartridge assembly 80B, where the first can ends according to this embodiment have a different size and shape than the second can ends.

In a single cartridge assembly configuration of the press 10, such as illustrated in FIGS. 6 and 7, the single cartridge assembly may be located in a central position within a cartridge assembly receiving opening 10A of the frame 20, i.e., on a central position of the bolster 86, and in a double cartridge assembly configuration of the press 10, such as illustrated in FIGS. 8-12, the cartridge assemblies may be located offset from the central position and respectively toward left and right sides of the cartridge assembly receiving opening 10A of the frame 20. These positionings of the cartridge assemblies are intended to centralize and balance forces and reduce or avoid tipping moment issues of the press 10.

A locational guide pin assembly 230 (also referred to herein as a locational guide device), see FIGS. 18 and 21, is coupled directly to the bolster 86 of the press frame 20 and the ram 40 via fasteners such as bolts and may not form part of the cartridge assembly 80. The guide pin assembly 230 comprises lower and upper shoes/blocks 232, 234 (also referred to herein as alignment blocks), where the lower block 232 is fixed to the bolster 86 via bolts 232A (see FIG. 4B) and the upper block 234 is fixed to the ram 40 via bolts (not shown): first and second pins 236, 238 fixedly mounted to the upper shoe 234, which pins 236, 238 extend from the upper shoe 234 towards and into the lower shoe 232; and bushings/cylindrical bearings 236A, 238A, fixedly mounted to the lower shoe 232, which receive the first and second pins 236, 238 such that the pins 236, 238 move relative to the bushings 236A, 238A as the upper shoe 234 moves relative to the lower shoe 232, see also FIG. 18A.

Lower and upper stop blocks 400 and 402 may be fixedly mounted to the lower and upper mounting plates 82 and 84. One or more pairs of lower and upper stop blocks 400 and 402 may be provided, e.g., four or more pairs of lower and upper stop blocks 400 and 402 may be used. For example, the pairs of stop blocks 400 and 402 may be spaced apart from one another, such as on opposite sides of the forming and tab stake stations of the press 10. Each upper stop block 402 engages with a corresponding lower stop block 400 just after the upper tooling members have contacted corresponding lower tooling members of the forming and tab stake stations of the press 10.

First and second upper locator blocks 242, 244 may be mounted to the upper shoe 234 and first and second lower locator blocks 246, 248 may be mounted to the lower shoe 232, see FIGS. 18A, 19, and 21. Each of the first and second upper and lower locator blocks 242, 244, 246, 248 comprises a corresponding through hole 242A. 244A. 246A. 248A that can receive a corresponding locator pin (to be discussed below) during installation of a cartridge assembly 80 in a press 10 as will be described below. When the first and second stop blocks 400 and 402 are in engagement with one another, see FIG. 18A, a first minimum spacing is defined between outer surfaces of the first upper block 242 and the first lower block 246, which are generally aligned with one another in a direction generally parallel to a longitudinal length of the pins 236, 238, and a second minimum spacing S₂ is defined between outer surfaces of the second upper block 244 and the second lower block 248, which are generally aligned with one another in a direction generally parallel to the longitudinal length of the pins 236, 238. The first and second minimum spacings are generally equal to one another and also slightly less than a spacing between an upper surface of the lower mounting plate 82 and a lower surface of the upper mounting plate 84 when the first and second stop blocks 400 and 402 are in engagement.

With reference to FIGS. 17-22, an exemplary process of removing a cartridge assembly 80 from a press 10 and then installing a replacement cartridge assembly 80 in the press 10 will now be described. The cartridge assembly 80 may be disconnected and removed from the press 10 as follows. First, the ram 40 may be lowered so that the first and second stop blocks 400 and 402 are in engagement with one another, see FIG. 18A. It is also contemplated that spacer blocks 404 may be provided between the first and second stop blocks 400 and 402, see FIG. 18B. Hence, the ram 40) is lowered until the first and second stop blocks 400 and 402 engage or clamp the spacer blocks 404. Thereafter, the bolts coupling the upper mounting plate 84 to the ram 40) are removed. Then the ram 40 may be raised. The bolts coupling the lower mounting plate 82 to the bolster 86 may be removed before or after the ram 40 is raised. The drive drum 122 may be uncoupled from the drive shaft 124, and then the cartridge assembly 80 may be removed from the bolster 86, i.e., the lower and upper mounting plates 82 and 84 and all components coupled to the same are removed from the press 10 concurrently, see FIGS. 18 and 19.

If the tab apparatus 60 needs to be replaced, e.g., if the type of tabs to be applied to the can shells are to be changed once the replacement cartridge assembly 80 is installed, the tab apparatus 60 is then removed from the press 10 by decoupling the tab apparatus 60 from the frame 20, see FIG. 20. A replacement tab apparatus 60 is then installed in the press 10 by coupling the tab apparatus 60 to the frame 20, see FIG. 21. It is noted that the tab apparatus 60) used with the initially installed cartridge assembly 80 may also be used with the replacement cartridge assembly 80, e.g., if the type of tabs to be applied to the can shells are not to be changed once the replacement cartridge assembly 80 is installed, and in this case, this step may be skipped. It is also noted that additional situations may require the tab apparatus 60 to be replaced, such as when switching between certain output volume configurations, e.g., when going from a 2-out configuration to a 3-out configuration.

The cartridge assembly 80 may be mounted to the press 10 as follows. Each of the first and second upper and lower locator blocks 242, 244, 246, 248 may be removed from their corresponding upper and lower alignment blocks 234, 232 prior to inserting the cartridge assembly 80 in the press 10. The ram 40 may be raised to its uppermost or top dead center position, see FIG. 21. Then, the cartridge assembly 80 is inserted or moved into the press 10 such that the lower mounting plate 82 is located on the bolster 86. When the cartridge assembly 80 is moved into the press 10, the first and second stop blocks 400 and 402 may be in engagement with one another, or if spacer blocks 404 are used, the spacer blocks 404 may be clamped between the first and second stop blocks 400 and 402. Once the cartridge assembly 80 is moved into the press 10, the first and second upper and lower locator blocks 242, 244, 246, 248 may be mounted to their corresponding upper and lower alignment block 234, 232 via fasteners, such as bolts and/or dowels.

The cartridge assembly 80 is then positioned such that the upper and lower mounting plates 84 and 82 are located adjacent to inner side edges 234B. 232B (see FIG. 21) of the upper and lower shoes (alignment blocks) 234, 232 of the locational guide pin assembly 230. Thereafter, first and second locator pins 252, 254 are inserted into the holes 246A. 248A in the first and second lower locator blocks 246, 248, which locator pins 252, 254 also extend into locator holes 82A. 82B in the lower mounting plate 82 (see FIGS. 3 and 18A) when the lower mounting plate 82 is aligned relative to the bolster 86 and the locational guide pin assembly 230 in a direction parallel to longitudinal axes of the upper and lower shoes 234, 232, i.e., in a direction parallel to a work flow direction of a can shell as it moves through the cartridge assembly 80, and also in a direction perpendicular to the longitudinal axes of the upper and lower shoes 234, 232. After alignment of the lower mounting plate 82, the lower mounting plate 82 may be secured to the bolster 86 via the bolts 88A (see FIG. 18A). Next, third and fourth locator pins 256, 258 are then inserted into the holes 242A. 244A in the first and second upper locator blocks 242, 244 and also extend into locator holes 84A. 84B in the upper mounting plate 84 when the upper mounting plate 84 is aligned relative to the locational guide pin assembly 230 in a direction parallel to the longitudinal axes of the upper and lower shoes 234, 232 and also in a direction perpendicular to the longitudinal axes of the upper and lower shoes 234, 232. It is noted that the first and second locator pins 252, 254 could also service the alignment of the upper mounting plate by removing the first and second locator pins 252, 254 from the first and second lower locator blocks 246, 248 and then inserting the first and second locator pins 252, 254 into the holes 242A. 244A in the first and second upper locator blocks 242, 244 and also into the locator holes 84A. 84B in the upper mounting plate 84. After alignment of the upper mounting plate 84, the ram 40 is lowered so that it engages the upper mounting plate 84, such that the upper mounting plate 84 can be mounted to the ram 40 via the bolts 88B, see FIGS. 18A and 22. It is also contemplated that the lower and upper mounting plates 82, 84 could be aligned in the press 10 without using lower and upper locator blocks, such as, for example, by using pins that extend into horizontal bores formed in side edges of the lower and upper shoes 232, 234 and into corresponding bores formed in side edges of the lower and upper mounting plates 82, 84.

If first and second cartridge assemblies 80A. 80B are mounted to the press 10, first and second locational guide pin assemblies 230A. 230B are coupled directly to the bolster 86 of the press frame 20 and the ram 40 via fasteners such as bolts and may not form part of the cartridge assemblies 80A. 80B, see FIG. 19. Alignment of each of the first and second cartridge assemblies 80A. 80B using the first and second locational guide pin assemblies 230A. 230B occurs in the same manner as the alignment discussed above for the cartridge assembly 80 using the locational guide pin assembly 230. The locational guide pin assembly 230A could be the same as the locational guide pin assembly 230 illustrated in FIGS. 18A and 18B, but the locational guide pin assembly 230 has been moved laterally toward the outer edge of the press 10 using fasteners such as bolts to define the locational guide pin assembly 230A.

If the upper and lower mounting plates 84, 82 comprise magnetic plates, after alignment of the upper and lower mounting plates 84, 82 has been completed, the ram 40 may be lowered onto the upper mounting plate 84. Thereafter, the controller 92 may activate the power supply to energize the pairs of first and second magnetic plates 94A. 94B to magnetically secure the lower and upper mounting plates 82, 84 in place on the bolster 86 and ram 40.

An exemplary method 500 for exchanging a cartridge assembly in a conversion press which comprises a frame and a ram movably coupled to the frame will now be described with reference to FIG. 23. The method 500 will be described with reference to the exemplary conversion press 10 described above, wherein the conversion press 10 includes an exemplary first cartridge assembly 80 that is provided in the press 10 in a single cartridge assembly configuration. The first cartridge assembly 80 may be mounted in the press 10, for example, via bolts or a magnetic fastener assembly as described herein. The steps described for the method 500 do not need to be performed in any specific order unless stated otherwise.

The first cartridge assembly 80 includes the following components: a first upper mounting plate 84; a first lower mounting plate 82: a first downstacker assembly 108 comprising at least one first can shell delivery apparatus 106A for delivering can shells 104A; one or more first forming stations as described herein; a first tab stake station 150; and a first transfer belt 100A that receives the can shells 104A from the at least one first can shell delivery apparatus 106A. The first transfer belt 100A defines at least one first active forming lane 102A for conveying the can shells 104A to the one or more first forming stations and the first tab stake station 150, where the can shells 104A are formed into can ends with tabs 110A as they are conveyed along the at least one first active forming lane 102A.

At step 502, the first cartridge assembly 80 is removed from the press 10 by removing the first upper mounting plate 84 of the first cartridge assembly 80 from a ram 40 of the press 10, and by removing a first lower mounting plate 82 from a frame 20 of the press 10. According to embodiments, the first lower mounting plate 82 may be removed from a bolster 86 of the frame 20.

At step 504, a second cartridge assembly 80 is installed into the press 10 in place of the removed first cartridge assembly 80. The second cartridge assembly 80 includes the following components: a second upper mounting plate 84: a second lower mounting plate 82; a second downstacker assembly 108 comprising at least one second can shell delivery apparatus 106A for delivering can shells 104A; one or more second forming stations as described herein; a second tab stake station 150; and a second transfer belt 100A that receives the can shells 104A from the at least one second can shell delivery apparatus 106A. The second transfer belt 100A defines at least one second active forming lane 102A for conveying the can shells 104A to the one or more second forming stations and the second tab stake station 150, where the can shells 104A are formed into can ends with tabs 110A as they are conveyed along the at least one second active forming lane 102A.

The second cartridge assembly 80 is installed into the press 10 by releasably coupling the second lower mounting plate 82 to frame 20 of the press 10, e.g., to the bolster 86, and by releasably coupling the second upper mounting plate 84 of the second cartridge assembly 80 to the ram 40. The second cartridge assembly 80 may be releasably coupled in the press 10, for example, via bolts or a magnetic fastener assembly as described herein.

According to embodiments, prior to removing the first upper mounting plate 84 from the ram 40, the ram 40 may be extended at step 506 in FIG. 24 to a position such that one or more spacer blocks 404 are positioned between corresponding pairs of lower and upper stop blocks 400, 402, wherein the one or more lower stop blocks 400 are coupled to the lower mounting plate 82 and the one or more upper stop blocks 402 are coupled to the upper mounting plate 84. This step 506 allows the first lower and upper mounting plates 82, 84 to be removed from the press 10 at step 502 concurrently as a single unit.

A scrap chute apparatus 162 may need to be removed from the frame 20 at step 508 in FIG. 25. This step 508 would be performed prior to removing the first lower mounting plate 82 from the frame 20 at step 502, and would be required if the scrap chute apparatus 162 would otherwise prevent removal of the first lower mounting plate 82 from the frame 20. If the scrap chute apparatus 162 is removed from the frame 20 at step 508 in FIG. 25, it may be releasably coupled back onto the frame 20 at step 510 in FIG. 26 after the second lower mounting plate 82 is releasably coupled to the frame 20.

As shown in FIG. 27, a locational guide pin assembly 230 that is fixed to the frame 20 may optionally be used at step 512 to position the second cartridge assembly 80 in a desired location prior to releasably coupling the second upper mounting plate 84 to the ram 40 and releasably coupling the second lower mounting plate 82 to the bolster 86.

Removing the first cartridge assembly 80 from the press 10 may additionally comprise removing a first drive drum 122 of the first cartridge assembly 80 from the press drive shaft 124 at step 514, as shown in FIG. 28. Installing the second cartridge assembly 80 into the press 10 may in turn comprise releasably coupling a second drive drum 122 of the second cartridge assembly 80 to the press drive shaft 124 at step 516.

As noted above, certain situations may require the tab apparatus 60 to be replaced, such as, for example, when the second cartridge assembly 80 is configured to form can ends with different tabs than the first cartridge assembly 80. In such a situation, at step 518 in FIG. 29 a first tab apparatus 60 is removed from the frame 20, and at step 520, a second tab apparatus 60 is installed into the press 10 by releasably coupling the second tab apparatus 60 to the frame 20. The second apparatus 60 may comprise at least one of: a different output volume of formed tabs than the first tab apparatus 60; or tooling to form tabs having at least one of a different size or shape than the first apparatus 60.

Any document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made within the scope of the present embodiments. It is therefore intended to cover in the appended claims all such changes and modifications.

Claims

1. A conversion press for forming can ends with tabs comprising: a frame;a ram movably coupled to the frame; andat least one cartridge assembly releasably coupled to a bolster of the frame and the ram, each cartridge assembly comprising: one or more forming stations;a tab stake station; anda transfer belt that receives can shells, the transfer belt defining at least one active forming lane for conveying the can shells to the one or more forming stations and the tab stake station, where the can shells are formed into can ends with tabs as they are conveyed along the at least one active forming lane.

2. The conversion press of claim 1, wherein: each cartridge assembly further comprises a downstacker assembly comprising at least one can shell delivery apparatus for delivering can shells; andthe transfer belt receives the can shells from the at least one can shell delivery apparatus.

3. The conversion press of claim 1, wherein the at least one cartridge assembly includes an upper mounting plate releasably coupled to the ram and a lower mounting plate releasably coupled to the bolster of the frame.

4. The conversion press of claim 3, wherein the transfer belt is coupled to the lower mounting plate.

5. The conversion press of claim 1, further comprising a tab forming and feeder apparatus configured to progressively form tabs in a tab feed stock and deliver the tab feed stock with the formed tabs to the tab stake station where the tabs are separated from a remainder of the tab feed stock and coupled to the can shells.

6. The conversion press of claim 5, wherein the at least one cartridge assembly further comprises a scrap chopper apparatus for chopping the remainder of the tab feed stock into scrap material and the conversion press further comprises a scrap chute apparatus for discharging the scrap material from the scrap chopper apparatus.

7. The conversion press of claim 1, wherein the at least one cartridge assembly comprises two cartridge assemblies.

8. The conversion press of claim 1, wherein the one or more forming stations comprise one or more of a primary bubble station, a secondary bubble station, a score and button station, a panel and button restrike station, or a tab wipe down station.

9. The conversion press of claim 1, wherein the at least one cartridge assembly comprises: an upper mounting plate releasably coupled to the ram using mechanical fasteners or a first magnetic fastener assembly; anda lower mounting plate releasably coupled to the bolster of the frame using mechanical fasteners or a second magnetic fastener assembly.

10. The conversion press of claim 1, wherein the at least one cartridge assembly comprises a lower mounting plate, and the one or more forming stations, the tab stake station, and the transfer belt are coupled to the lower mounting plate.

11. The conversion press of claim 1, wherein the at least one cartridge assembly further comprises at least one of: a light tester assembly that checks the formed can ends with tabs for defects; ora drive drum that is releasably coupled to a drive shaft of the conversion press for driving the transfer belt;wherein the at least one of the light tester assembly, or the drive drum are coupled to a lower mounting plate of the at least one cartridge assembly.

12. A method for exchanging a cartridge assembly in a conversion press that comprises a frame and a ram movably coupled to the frame, the method comprising: removing a first cartridge assembly from the conversion press, the first cartridge assembly comprising: a first upper mounting plate;a first lower mounting plate;one or more first forming stations;a first tab stake station; anda first transfer belt that receives can shells, the first transfer belt defining at least one first active forming lane for conveying the can shells to the one or more first forming stations and the first tab stake station, where the can shells are formed into can ends with tabs as they are conveyed along the at least one first active forming lane;wherein removing the first cartridge assembly from the conversion press comprises: removing the first upper mounting plate from the ram; andremoving the first lower mounting plate from a bolster of the frame; andinstalling a second cartridge assembly into the conversion press in place of the first cartridge assembly, the second cartridge assembly comprising: a second upper mounting plate;a second lower mounting plate;one or more second forming stations;a second tab stake station; anda second transfer belt that receives can shells, the second transfer belt defining at least one second active forming lane for conveying the can shells to the one or more second forming stations and the second tab stake station, where the can shells are formed into can ends with tabs as they are conveyed along the at least one second active forming lane; andwherein installing the second cartridge assembly into the conversion press comprises: releasably coupling the second upper mounting plate to the ram; andreleasably coupling the second lower mounting plate to the bolster of the frame.

13. The method of claim 12, wherein: the first cartridge assembly further comprises a first downstacker assembly comprising at least one first can shell delivery apparatus for delivering can shells, wherein the first transfer belt receives the can shells from the at least one first can shell delivery apparatus; andthe second cartridge assembly further comprises a second downstacker assembly comprising at least one second can shell delivery apparatus for delivering can shells, wherein the second transfer belt receives the can shells from the at least one second can shell delivery apparatus.

14. The method of claim 12, further comprising: removing a first tab forming and feeder apparatus from the conversion press, the first tab forming and feeder apparatus configured to progressively form first tabs in a first tab feed stock and deliver the first tab feed stock with the formed first tabs to the first tab stake station where the first tabs are separated from a remainder of the first tab feed stock and coupled to the can shells that are being conveyed on the first transfer belt of the first cartridge assembly; andinstalling a second tab forming and feeder apparatus into the conversion press, the second tab forming and feeder apparatus configured to progressively form second tabs in a second tab feed stock and deliver the second tab feed stock with the formed second tabs to the second tab stake station where the second tabs are separated from a remainder of the second tab feed stock and coupled to the can shells that are being conveyed on the second transfer belt of the second cartridge assembly;wherein the second tab forming and feeder apparatus comprises at least one of: a different output volume of formed tabs than the first tab forming and feeder apparatus; or tooling to form tabs having at least one of a different size or shape than the first tab forming and feeder apparatus.

15. The method of claim 12, wherein the first and second upper mounting plates are respectively releasably coupled to the ram using mechanical fasteners or magnetic fastener assemblies, and the first and second lower mounting plates are respectively releasably coupled to the bolster of the frame using mechanical fasteners or magnetic fastener assemblies.

16. The method of claim 12, wherein installing the second cartridge assembly into the conversion press further comprises: prior to releasably coupling the second upper mounting plate to the ram and releasably coupling the second lower mounting plate to the bolster, using a locational guide pin assembly that is fixed to the frame to position the second cartridge assembly in a desired location;wherein, when the second upper mounting plate is releasably coupled to the ram with the second cartridge assembly in the desired location and the second lower mounting plate is releasably coupled to the bolster with the second cartridge assembly in the desired location, the second upper and lower mounting plates are properly positioned to allow the one or more second forming stations and the second tab stake station to form can shells delivered by the at least one second can shell delivery apparatus into can ends with tabs.

17. The method of claim 12, further comprising: removing a first drive drum of the first cartridge assembly from a drive shaft that is fixed to the frame, the drive shaft configured to drive the first drive drum to rotate the first transfer belt; andreleasably coupling a second drive drum of the second cartridge assembly to the drive shaft, the drive shaft configured to drive the second drive drum to rotate the second transfer belt;wherein the first drive drum is coupled to the first lower mounting plate and the second drive drum is coupled to the second lower mounting plate.

18. The method of claim 12, further comprising, prior to removing the first upper mounting plate from the ram, extending the ram to a position such that one or more spacer blocks are positioned between corresponding pairs of lower and upper stop blocks, wherein the one or more lower stop blocks are coupled to the first lower mounting plate and the one or more upper stop blocks are coupled to the first upper mounting plate.

19. A quick-change cartridge assembly for a conversion press comprising: one or more forming stations;a tab stake station; anda transfer belt defining at least one active forming lane for conveying can shells to the one or more forming stations and the tab stake station during use of the conversion press incorporating the quick-change cartridge assembly.

20. The quick-change cartridge assembly of claim 19, further comprising: a downstacker assembly comprising at least one can shell delivery apparatus for delivering can shells during use of a conversion press incorporating the quick-change cartridge assembly; andthe transfer belt receives the can shells from the at least one can shell delivery apparatus.

21. A conversion press for forming can ends with tabs comprising: a frame;a ram movably coupled to the frame;a cartridge assembly releasably coupled to a bolster of the frame and the ram; anda locational guide device coupled to the frame and the ram, wherein the cartridge assembly is located within the frame via alignment with the locational guide device.

22. The conversion press of claim 21, wherein the cartridge assembly comprises: one or more forming stations;a tab stake station; anda transfer belt that conveys can shells to the one or more forming stations and the tab stake station.

23. The conversion press of claim 22, wherein the cartridge assembly further comprises a downstacker assembly comprising at least one can shell delivery apparatus for delivering can shells.

24. The conversion press of claim 21, wherein the locational guide device comprises an alignment block coupled to the frame and a locator block coupled to the alignment block.

25. The conversion press of claim 24, wherein the locator block comprises a through-hole for receiving an alignment pin which is also received in a corresponding opening provided in the cartridge assembly.

26. A method for centralizing and balancing forces in a conversion press that comprises a frame and a ram movably coupled to the frame, the conversion press being configured to releasably receive a single cartridge assembly or first and second cartridge assemblies, the method comprising: when the conversion press is to releasably receive a single cartridge assembly, positioning the single cartridge assembly in a central position within a cartridge assembly receiving opening of the frame; andwhen the conversion press is to releasably receive first and second cartridge assemblies; positioning the first cartridge assembly offset from the central position toward a left side of the cartridge assembly receiving opening; andpositioning the second cartridge assembly offset from the central position toward a right side of the cartridge assembly receiving opening.

27. The method of claim 26, wherein each cartridge assembly comprises an upper mounting plate that is releasably couplable to the ram, and a lower mounting plate that is releasably couplable to a bolster of the frame.

28. The method of claim 27, wherein each cartridge assembly further comprises: one or more forming stations;a tab stake station; anda transfer belt that receives can shells, the transfer belt defining at least one active forming lane for conveying the can shells to the one or more forming stations and the tab stake station, where the can shells are formed into can ends with tabs as they are conveyed along the at least one active forming lane;wherein the one or more forming stations, the tab stake station, and the transfer belt are directly coupled to at least one of the upper or lower mounting plates.

29. The method of claim 26, further comprising converting the conversion press from a single cartridge assembly configuration to a dual cartridge assembly configuration or from a dual cartridge assembly configuration to a single cartridge assembly configuration comprising: if the conversion press is in a single cartridge assembly configuration, removing the single cartridge assembly from the conversion press and releasably coupling first and second cartridge assemblies to the conversion press, wherein the first cartridge assembly is releasably coupled to the conversion press offset from the central position toward the left side of the cartridge assembly receiving opening, and the second cartridge assembly is releasably coupled to the conversion press offset from the central position toward the right side of the cartridge assembly receiving opening; orif the conversion press is in a dual cartridge assembly configuration, removing the first and second cartridge assemblies from the conversion press and releasably coupling a single cartridge assembly to the conversion press, wherein the single cartridge assembly is releasably coupled to the conversion press in the central position within the cartridge assembly receiving opening.