Patent Application
20220364639
The disclosed and claimed concepts relate to drive assemblies and, more particularly, to drive assemblies for necker machines.
Can bodies are, typically, formed in a bodymaker. That is, a bodymaker forms blanks such as, but not limited to, disks or cups into an elongated can body. A can body includes a base and a depending sidewall. The sidewall is open at the end opposite the base. The bodymaker, typically, includes a ram/punch that moves the blanks through a number of dies to form the can body. The can body is ejected from the ram/punch for further processing such as, but not limited to, trimming, washing, printing, flanging, and inspecting, before being placed on pallets which are then shipped to a filler. At the filler, the cans are taken off of the pallets, filled, have ends placed on them, and then are typically repackaged in various quantities (e.g., six packs, twelve pack or other multi-can cases, etc.) for sale to the consumer.
Some can bodies after being formed in a bodymaker are further formed in a die necking machine, commonly referred to as simply a necker machine. Necker machines are structured to reduce the cross-sectional area of a portion of a can body sidewall, i.e., at the open end of the sidewall. That is, prior to coupling a can end to the can body (and prior to filling), the diameter/radius of the can body sidewall open end is reduced relative to the diameter/radius of other portions of the can body sidewall. The necker machine includes a number of processing and/or forming modules disposed in series. That is, the processing and/or forming modules are disposed adjacent to each other and a transfer assembly moves a can body between adjacent processing and/or forming modules. As the can body moves through the processing and/or forming modules the can body is processed or formed. A greater number of processing and/or forming modules in a necker machine is not desirable. That is, it is desirable to have the least number of processing and/or forming modules possible while still completing the desired forming.
Some die necking machine configurations require a large number of necking modules. The rotational position of each module must be kept in sync with adjacent modules, which is typically accomplished through the use of a gear train that effectively connects/drives all of the other modules. Such gear train is typically driven only at one end. The gear tooth load at the aforementioned driven end of the gear train is very high, whereas load on the opposite end of the gear train is low. This results in uneven gear wear along the gear train and requires the majority of gears in the train to be oversized which incurs additional and unnecessary expense.
Embodiments of the disclosed concepts provide solutions that spread the induced loads and wear more evenly throughout the gear train, thus improving upon known arrangements. As one aspect of the disclosed concepts, a distributed drive assembly for a necker machine having a frame assembly and a plurality of modules is provided. Each module having a number of drive shafts, with the number of drive shafts of each module interconnected via a gear train with the number of drive shafts of the other modules of the plurality of processing modules. The distributed drive assembly comprises: a plurality of drive sub-modules, each drive sub-module comprising: an input shaft; a first output shaft operatively coupled to the input shaft; and a second output shaft operatively coupled to the input shaft; wherein for a first drive sub-module of the plurality of drive sub-modules: the input shaft is structured to be operatively coupled to, and driven by, a main drive assembly motor, and the first output shaft is structured to be operatively coupled to, and drive, an associated first drive shaft of the number of drive shafts of a first module of the plurality of modules, and wherein for a second drive sub-module of the plurality of drive sub-modules: the input shaft is operatively coupled to, and driven by, the second output shaft of the first drive sub-module, and the first output shaft is structured to be operatively coupled to, and drive, an associated first drive shaft of the number of drive shafts of a second module of the plurality of modules that is separated from the first module by at least one other module.
The distributed drive assembly may further comprise an extension shaft, wherein the input shaft of the second drive sub-module is operatively coupled to the second output shaft of the first drive sub-module by the extension shaft. The extension shaft may be sized and configured to space the first output shaft of the second drive sub-module a distance from the first output shaft of the first drive sub-module, and wherein the distance is greater than an overall width of one module of the plurality of processing modules.
The plurality of drive modules may comprise at least three drive sub-modules, and for a third drive sub-module of the plurality of drive sub-modules: the input shaft may be operatively coupled to, and driven by, the second output shaft of the second drive sub-module, and the first output shaft may be structured to be operatively coupled to, and drive, one drive shaft of the number of drive shafts of a third module of the number of modules.
For each drive sub-module, the first output shaft may be operatively coupled to the input shaft via a right-angle gearbox.
For each drive sub-module, the second output shaft may be axially aligned with the input shaft.
The distributed drive assembly may further comprise the main drive assembly motor coupled to the input shaft of the first drive sub-module of the plurality of drive sub-modules.
The distributed drive assembly may further comprise at least two extension shafts, wherein the input shaft of the second drive sub-module is operatively coupled to the second output shaft of the first drive sub-module by the at least two extension shafts connected together in series.
The distributed drive assembly may further comprise a winding arrangement operatively coupled to the second output shaft of the second drive sub-module.
As another aspect of the disclosed concepts a necker machine comprises: a frame assembly; a plurality of modules coupled to the frame assembly, each module having a number of drive shafts, and a drive assembly comprising: a gear train comprising a plurality of gears, each gear coupled to a respective drive shaft of the number of drive shafts of the plurality of modules and interconnecting the number of drive shafts of each module with the number of drive shafts of the other modules of the plurality of modules; and a distributed drive assembly comprising a plurality of drive sub-modules, each drive sub-module comprising: an input shaft; a first output shaft operatively coupled to the input shaft; and a second output shaft operatively coupled to the input shaft; wherein for a first drive sub-module of the plurality of drive sub-modules: the input shaft is structured to be operatively coupled to, and driven by, a main drive assembly motor, and the first output shaft is operatively coupled to, for driving, an associated first drive shaft of the number of drive shafts of a first module of the plurality of modules, and wherein for a second drive sub-module of the plurality of drive sub-modules: the input shaft is operatively coupled to, and driven by, the second output shaft of the first drive sub-module, and the first output shaft is operatively coupled to, for driving, an associated first drive shaft of the number of drive shafts of a second module of the plurality of modules that is separated from the first module by at least one other module.
The necker machine may further comprise the main drive assembly motor coupled to the input shaft of the first drive sub-module of the plurality of drive sub-modules.
The first output shaft of the first drive sub-module may be coupled to the associated first drive shaft of the number of drive shafts of the first module via a speed reducing gearbox and a drive hub, and the first output shaft of the second drive sub-module may be coupled to the associated first drive shaft of the number of drive shafts of the second module via another speed reducing gearbox and another drive hub.
The necker machine may further comprise an extension shaft, wherein the input shaft of the second drive sub-module is operatively coupled to the second output shaft of the first drive sub-module by the extension shaft. The extension shaft may be sized and configured to space the first output shaft of the second drive sub-module a distance from the first output shaft of the first drive sub-module, and wherein the distance is greater than an overall width of one module of the plurality of processing modules.
The plurality of drive modules may comprise at least three drive sub-modules, and wherein for a third drive sub-module of the plurality of drive sub-modules: the input shaft is operatively coupled to, and driven by, the second output shaft of the second drive sub-module, and the first output shaft is operatively coupled to, and drives, one drive shaft of the number of drive shafts of a third module of the number of modules.
For each drive sub-module, the first output shaft may be operatively coupled to the input shaft via a right-angle gearbox.
For each drive sub-module, the second output shaft may be axially aligned with the input shaft.
The necker machine may further comprise at least two extension shafts, wherein the input shaft of the second drive sub-module is operatively coupled to the second output shaft of the first drive sub-module by the at least two extension shafts connected together in series.
The necker machine may further comprise a winding arrangement operatively coupled to the second output shaft of the second drive sub-module.
These and other objects, features, and characteristics of the disclosed concepts, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying drawings, all of which form a part of this specification, wherein like reference numerals designate corresponding parts in the various figures. It is to be expressly understood, however, that the drawings are for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosed concepts.
A full understanding of the disclosed concepts can be gained from the following description of some example embodiments when read in conjunction with the accompanying drawings in which:
It is to be appreciated that portions of the figures not pertinent to the portions being discussed may be shown in simplified form or omitted therefrom.
It will be appreciated that the specific elements illustrated in the figures herein and described in the following specification are simply exemplary embodiments of the disclosed concept, which are provided as non-limiting examples solely for the purpose of illustration. Therefore, specific dimensions, orientations, assembly, quantity of components used, embodiment configurations 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 singular form of “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
As used herein, “structured to [verb]” means that the identified element or assembly has a structure that is shaped, sized, disposed, coupled and/or configured to perform the identified verb. For example, a member that is “structured to move” is movably coupled to another element and includes elements that cause the member to move or the member is otherwise configured to move in response to other elements or assemblies. As such, as used herein, “structured to [verb]” recites structure and not function. Further, as used herein, “structured to [verb]” means that the identified element or assembly is intended to, and is designed to, perform the identified verb. Thus, an element that is merely capable of performing the identified verb but which is not intended to, and is not designed to, perform the identified verb is not “structured to [verb].”
As used herein, “associated” means that the elements are part of the same assembly and/or operate together, or, act upon/with each other in some manner. For example, an automobile has four tires and four hub caps. While all the elements are coupled as part of the automobile, it is understood that each hubcap is “associated” with a specific tire.
As used herein, a “coupling assembly” includes two or more couplings or coupling components. The components of a coupling or coupling assembly are generally not part of the same element or other component. As such, the components of a “coupling assembly” may not be described at the same time in the following description.
As used herein, a “coupling” or “coupling component(s)” is one or more component(s) of a coupling assembly. That is, a coupling assembly includes at least two components that are structured to be coupled together. It is understood that the components of a coupling assembly are compatible with each other. For example, in a coupling assembly, if one coupling component is a snap socket, the other coupling component is a snap plug, or, if one coupling component is a bolt, then the other coupling component is a nut or threaded bore. Further, a passage in an element is part of the “coupling” or “coupling component(s).” For example, in an assembly of two wooden boards coupled together by a nut and a bolt extending through passages in both boards, the nut, the bolt and the two passages are each a “coupling” or “coupling component.”
As used herein, a “fastener” is a separate component structured to couple two or more elements. Thus, for example, a bolt is a “fastener” but a tongue-and-groove coupling is not a “fastener.” That is, the tongue-and-groove elements are part of the elements being coupled and are not a separate component.
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 coupled in direct 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, “adjustably fixed” means that two components are coupled so as to move as one while maintaining a constant general orientation or position relative to each other while being able to move in a limited range or about a single axis. For example, a doorknob is “adjustably fixed” to a door in that the doorknob is rotatable, but generally the doorknob remains in a single position relative to the door. Further, a cartridge (nib and ink reservoir) in a retractable pen is “adjustably fixed” relative to the housing in that the cartridge moves between a retracted and extended position, but generally maintains its orientation relative to the housing. Accordingly, when two elements are coupled, all portions of those elements are coupled. A description, however, of a specific portion of a first element being coupled to a second element, e.g., an axle first end being coupled to a first wheel, means that the specific portion of the first element is disposed closer to the second element than the other portions thereof. Further, an object resting on another object held in place only by gravity is not “coupled” to the lower object unless the upper object is otherwise maintained substantially in place. That is, for example, a book on a table is not coupled thereto, but a book glued to a table is coupled thereto.
As used herein, the phrase “removably coupled” or “temporarily coupled” means that one component is coupled with another component in an essentially temporary manner. That is, the two components are coupled in such a way that the joining or separation of the components is easy and would not damage the components. For example, two components secured to each other with a limited number of readily accessible fasteners, i.e., fasteners that are not difficult to access, are “removably coupled” whereas two components that are welded together or joined by difficult to access fasteners are not “removably coupled.” A “difficult to access fastener” is one that requires the removal of one or more other components prior to accessing the fastener wherein the “other component” is not an access device such as, but not limited to, a door.
As used herein, “operatively coupled” means that a number of elements or assemblies, each of which is movable between a first position and a second position, or a first configuration and a second configuration, are coupled so that as the first element moves from one position/configuration to the other, the second element moves between positions/configurations as well. It is noted that a first element may be “operatively coupled” to another without the opposite being true.
As used herein, the statement that two or more parts or components “engage” one another means that the elements exert a force or bias against one another either directly or through one or more intermediate elements or components. Further, as used herein with regard to moving parts, a moving part may “engage” another element during the motion from one position to another and/or may “engage” another element once in the described position. Thus, it is understood that the statements, “when element A moves to element A first position, element A engages element B,” and “when element A is in element A first position, element A engages element B” are equivalent statements and mean that element A either engages element B while moving to element A first position and/or element A either engages element B while in element A first position.
As used herein, “operatively engage” means “engage and move.” That is, “operatively engage” when used in relation to a first component that is structured to move a movable or rotatable second component means that the first component applies a force sufficient to cause the second component to move. For example, a screwdriver may be placed into contact with a screw. When no force is applied to the screwdriver, the screwdriver is merely “temporarily coupled” to the screw. If an axial force is applied to the screwdriver, the screwdriver is pressed against the screw and “engages” the screw. However, when a rotational force is applied to the screwdriver, the screwdriver “operatively engages” the screw and causes the screw to rotate. Further, with electronic components, “operatively engage” means that one component controls another component by a control signal or current.
As used herein, “correspond” indicates that two structural components are sized and shaped to be similar to each other and may be coupled with a minimum amount of friction. Thus, an opening which “corresponds” to a member is sized slightly larger than the member so that the member may pass through the opening with a minimum amount of friction. This definition is modified if the two components are to fit “snugly” together. In that situation, the difference between the size of the components is even smaller whereby the amount of friction increases. If the element defining the opening and/or the component inserted into the opening are made from a deformable or compressible material, the opening may even be slightly smaller than the component being inserted into the opening. With regard to surfaces, shapes, and lines, two, or more, “corresponding” surfaces, shapes, or lines have generally the same size, shape, and contours.
As used herein, the word “unitary” means a component that 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, the term “number” shall mean one or an integer greater than one (i.e., a plurality). That is, for example, the phrase “a number of elements” means one element or a plurality of elements. It is specifically noted that the term “a ‘number’ of [X]” includes a single [X].
As used herein, in the phrase “[x] moves between its first position and second position,” or, “[y] is structured to move [x] between its first position and second position,” “[x]” is the name of an element or assembly. Further, when [x] is an element or assembly that moves between a number of positions, the pronoun “its” means “[x],” i.e., the named element or assembly that precedes the pronoun “its.”
As used herein, a “radial side/surface” for a circular or cylindrical body is a side/surface that extends about, or encircles, the center thereof or a height line passing through the center thereof. As used herein, an “axial side/surface” for a circular or cylindrical body is a side that extends in a plane extending generally perpendicular to a height line passing through the center of the cylinder. That is, generally, for a cylindrical soup can, the “radial side/surface” is the generally circular sidewall and the “axial side(s)/surface(s)” are the top and bottom of the soup can. Further, as used herein, “radially extending” means extending in a radial direction or along a radial line. That is, for example, a “radially extending” line extends from the center of the circle or cylinder toward the radial side/surface. Further, as used herein, “axially extending” means extending in the axial direction or along an axial line. That is, for example, an “axially extending” line extends from the bottom of a cylinder toward the top of the cylinder and substantially parallel to a central longitudinal axis of the cylinder.
As employed 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., without limitation, liquid; food; any other suitable substance), and expressly includes, but is not limited to, beverage cans, such as beer and beverage cans, as well as food cans.
As used herein, “about” in a phrase such as “disposed about [an element, point or axis]” or “extend about [an element, point or axis]” or “[X] degrees about an [an element, point or axis],” means encircle, extend around, or measured around. When used in reference to a measurement or in a similar manner, “about” means “approximately,” i.e., in an approximate range relevant to the measurement as would be understood by one of ordinary skill in the art.
As used herein, a “drive assembly” means elements that are operatively coupled to the rotating shafts extending back to front in a processing module. A “drive assembly” does not include the rotating shafts extending back to front in a processing module.
As used herein, a “lubrication system” means a system that applies a lubricant to the external surfaces of a linkage, e.g., shafts and gears, of a drive assembly.
As used herein, an “elongated” element inherently includes a longitudinal axis and/or longitudinal line extending in the direction of the elongation.
As used herein, “generally” means “in a general manner” relevant to the term being modified as would be understood by one of ordinary skill in the art.
As used herein, “substantially” means “for the most part” relevant to the term being modified as would be understood by one of ordinary skill in the art.
As used herein, “at” means on and/or near relevant to the term being modified as would be understood by one of ordinary skill in the art.
An example necker machine 10 for which a drive assembly in accordance with the concepts disclosed herein may be employed is illustrated in
As previously discussed in the Background Information above, the necker machine 10 is structured to reduce the diameter of a portion of a can body 1, such as illustrated in
Referring to
As is known, the processing modules 14 are disposed adjacent to each other and in series with the infeed module 12 and discharge module 15 disposed at opposite ends of the series of processing modules. That is, the can bodies 1 being processed by the necker machine 10 each move from an upstream location through a series of processing modules 14 in the same sequence. Movement of the can bodies 1 through the necker machine 10 is carried out by a transfer assembly 18 driven by a drive assembly 20 (
During processing, the can bodies 1 follow a path, hereinafter, the “work path 9” (
As noted above, each processing module 14 has a similar width W (i.e., the distance between the upstream and downstream edges thereof), and the can body 1 is processed and/or formed (or partially formed) as the can body 1 moves generally across the width W. Generally, the processing/forming of the can body occurs in/at a rotatable turret 22 in each processing module 14. That is, the term “turret 22” identifies a generic turret. Each processing module 14 includes a rotatable starwheel 24 associated with the turret 22. Depending on the application, the starwheel 24 may be a “non-vacuum starwheel” (i.e., a starwheel that does not include, or is not associated with, a vacuum assembly, that is structured to apply a vacuum to the starwheel pockets) or alternatively a “vacuum starwheel” (i.e., a starwheel that does include, or is associated with, a vacuum assembly, that is structured to apply a vacuum to the starwheel pockets) without varying from the scope of the disclosed concept. Further, each processing module 14 typically includes one turret 22 and one starwheel 24.
The transfer assembly 18 is structured to move the can bodies 1 between adjacent processing modules 14 as well as from the infeed module 12 and to the discharge module 15. The transfer assembly 18 includes a plurality of rotatable starwheels 26, with each starwheel 26 being a part of a respective processing module 14, infeed module 12, or discharge module 15. Similar to starwheels 24, depending on the application starwheels 26 may be of a “vacuum” or “non-vacuum” type without varying from the scope of the disclosed concept.
It is noted that the plurality of processing modules 14 may be structured to neck different types of can bodies 1 and/or to neck can bodies in different configurations. Thus, the plurality of processing modules 14 are structured to be added and removed from the necker machine 10 depending upon the need for the particular application. To accomplish this, the necker machine 10 includes a frame assembly 30 to which the plurality of processing modules 14 are removably coupled. Alternatively, the frame assembly 30 includes elements incorporated into each of the plurality of processing modules 14 so that the plurality of processing modules 14 are structured to be temporarily coupled to each other. The frame assembly 30 has an upstream end 32 and a downstream end 34. Further, the frame assembly 30 includes elongated members, panel members (neither numbered), or a combination of both. As is known, panel members coupled to each other, or coupled to elongated members, form a housing. Accordingly, as used herein, a housing is also identified as a “frame assembly 30.”
When necker machine 10 is operated, the infeed assembly 13 feeds individual can bodies 1 into the transfer assembly 18 which moves each can body 1 sequentially through each of the processing modules 14 from the most upstream processing module 14 to the most downstream processing module 14. More particularly, each can body 1 moves from a starwheel 26, to a starwheel 24, to a turret 22 where a forming operation occurs, back to the aforementioned starwheel 24, and on to the next downstream starwheel 26. Generally, each processing module 14 is structured to partially form the can body 1 so as to gradually reduce the cross-sectional area of the can body first end 6 (
Referring to
Referring to
Continuing to refer to
Binding in the gear train 50 resulting from the multiple drive points may be avoided in a number of ways. In one example approach, during setup (timing) of the machine, the left-most drive sub-module 60 shown in
As shown in
While the example distributed drive assembly 58 shown in
As another example,
From the foregoing example embodiments it is thus to be appreciated that embodiments of the concepts disclosed herein provide arrangements for driving necker machines that improve upon conventional arrangements by distributing the driving forces along the gear train while utilizing only a single drive motor. By better distributing the forces along the gear train, gears of lesser strength (e.g., thinner and/or formed from alternate materials (e.g., polymer, composite, etc.) may be employed in the gear train thus reducing costs of the gear train while improving reliability.
While specific embodiments of the disclosed concepts have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of disclosed concepts which are to be given the full breadth of the claims appended and any and all equivalents thereof.
