Patent Application
20240335871
The present invention relates generally to the field of forming or processing an article, such as a container. More specifically, the invention relates to an apparatus for handling and processing a metal container, such as an aluminum beverage container or a preform thereof.
Conventional ram systems have traditionally been used in machinery for processing containers, such as extruded steel or aluminum beverage containers or preforms thereof. For example, such conventional ram systems are used in machinery for various steps in processes for producing aluminum beverage containers from aluminum container preforms, and even in steps for handling the aluminum beverage containers thereafter. As a matter of convenience, reference herein to a container can interchangeably refer to a container or a preform used in the process of producing the container. Such conventional container processing machinery with conventional ram systems can be used at maximum output speeds of about 3600 containers per minute with containers of a certain size, generally referred to herein as “small containers.” Such small containers are generally known in the industry as 211 diameter containers, which have a diameter of about 66 millimeters (mm) and a height of less than about 190 mm. Such small containers allow for smaller physical dimensions in the conventional ram systems, but also smaller operational dimensions in the conventional ram systems. For example, the stroke length of ram systems for use with small containers is about 35 centimeters (cm) to about 44 cm.
As the size of the containers increases, so too do the challenges of processing the containers. For example, conventional ram systems as a whole, or elements thereof, can be re-sized to handle the larger dimensions of “large containers.” Such large containers are generally known in the industry as 300 containers, which have diameters of about 66 mm or larger and a height of about 88 mm or larger, such as containers with a diameter of about 70 mm to about 87 mm, a height of about 88 mm to about 211 mm. Stroke lengths for these large containers typically are about 6.4 cm or larger. However, the speed at which the large containers can be processed by the re-sized conventional ram systems cannot similarly increase because of the increased loads experienced by the ram systems at the higher speeds. As a result, conventional container processing machinery processing large containers using conventional ram systems are restricted to a maximum output speed of about 1800 containers per minute (CPM), with typical speeds of about 1000 CPM to about 1800 CPM. A more detailed explanation of the limitations of conventional ram systems for use with large containers is described below with respect to
During operation of the ram system 100, the knock-out ram 108 translates relative to the bushing 106 in a direction parallel to the line 111, which allows the knock-out ram assembly 102 to retain and release a container (not shown) within the ram system 100. The additional elements necessary for the operation of the knock-out ram assembly 102, along with a general description of the operation thereof, is known to those skilled in the art and is not discussed herein as a matter of convenience.
Similar to the knock-out ram assembly 102, the push ram assembly 104 includes a bushing 112 surrounding a push ram 114. Attached to the push ram 114 facing the knock-out ram assembly 102 is a push plate 116. The push plate 116 can be made out of metal, such as tool steel, and weigh about 0.12 kg to about 0.18 kg. During operation of the ram system 100, the push ram 114 translates relative to the bushing 112 in a direction parallel to the line 111, which allows the push ram assembly 104 to retain and release a container (not shown) within the ram system 100 in combination with the knock-out ram assembly 102. The additional elements necessary for the operation of the push ram assembly 104, along with a general description of the operation thereof, is known to those skilled in the art and is not discussed herein as a matter of convenience.
Referring next to the push ram assembly 104, the push ram 114 extends through the bushing 112, as described above. The push plate 116 is connected to the push ram 114 so that it faces the knock-out ram assembly 102. The push ram 114 includes a recess 126 that is sized to accommodate the push plate 116 and a retainer 128 that fastens the push plate 116 to the push ram 114. The line 122 represents the outer diameter of the push ram 114 where it extends through the bushing 112. The outer diameter is substantially the same as the inner diameter of the bushing 112, except for a minimal difference that allows the push ram 114 to translate within the bushing 112. For example, the outer diameter of the push ram 114 can be about 50 mm. The line 124 represents the smallest outer diameter of the bushing 112 through which the push ram 114 extends. For example, the outer diameter of the busing can be about 70 mm.
Referring back to the knock-out ram assembly 102, the knock-out 110 is coupled to the knock-out ram 108. Surrounding the outside of the knock-out 110 is a die 200 used in the processing of containers (not shown) retained in the ram system 100. The knock-out 110 surrounds a knock-out retainer 202 connected to the knock-out ram 108. An inwardly facing threaded portion 214 of the knock-out retainer 202 engages a corresponding outwardly facing threaded portion 216 of the knock-out ram 108. The knock-out retainer 202 retains the knock-out 110 on the knock-out ram 108.
As discussed above, the knock-out ram assembly 102 can be configured to allow for large containers. For example, the dimensions of the aforementioned die 200, knock-out 110, and knock-out retainer 202 can be increased to accommodate the larger dimensions of the large containers. Indeed, the conventional ram system 100 shown in
Beyond the weight limitations, other limitations exist in the conventional ram system 100 shown in
Specifically, and as shown in
The conventional push ram assembly 104 suffers from similar limitations based on modifying the push ram assembly 104 to handle large containers. For example, the larger dimensions of conventional push ram assemblies 104 sized to accept large containers results in weights and weight distributions that prevent running the conventional push ram assemblies 104 at high processing speeds.
Accordingly, needs exist for ram systems used in the processing of containers that do not suffer from the above limitations, while still accommodating large containers.
One exemplary embodiment of the invention relates to a knock-out ram assembly that includes a bushing and a knock-out ram extending through the bushing. The knock-out ram is configured to translate relative to the bushing. The knock-out ram assembly further includes a die coupled to the bushing at one end of the knock-out ram assembly. A knock-out retainer assembly is coupled to the knock-out ram at the one end. The knock-out retainer assembly includes a retainer and a filler body. The knock-out ram assembly further includes a knock-out retained against the knock-out ram at the one end by the knock-out retainer assembly.
An aspect of the assembly includes a retaining ring and a bias spring. The retaining ring and the bias spring maintain the filler body biased under tension on the retainer.
Another aspect of the assembly includes the filler body forming an interference fit with the knock-out such that there is no radial gap between the filler body and the knock-out.
Another aspect of the assembly includes the knock-out retainer assembly weighing about 0.37 kg to about 0.46 kg.
Another aspect of the assembly includes proximal ends of the knock-out retainer assembly and the knock-out being generally flush.
Another aspect of the assembly includes the retainer having a tapered nozzle. A further aspect is that a conduit passes through the knock-out ram and the knock-out retainer assembly for pressurizing an area defined by the die, knock-out retainer assembly, and the knock-out during use of the knock-out ram assembly. A further aspect includes the filler body having a taper that complements the tapered nozzle.
Another aspect of the assembly includes the knock-out ram including an inwardly facing threaded portion, and the retainer including an outwardly facing threaded portion. The inwardly facing threaded portion engages the outwardly facing threaded portion to couple the knock-out retainer assembly to the knock-out ram.
Another aspect of the assembly includes the knock-out having an annular groove facing the bushing.
Another aspect of the assembly includes an outer diameter of the knock-out ram within the bushing being about 34 mm to about 42 mm.
Another aspect of the assembly includes the filler body being formed of a polymer.
Another aspect of the assembly includes the knock-out ram assembly being configured to process containers having a diameter of about 66 mm to about 87 mm, a height of about 88 mm to about 211 mm, or a combination thereof.
Another exemplary embodiment of the invention relates to a ram system having a knock-out ram assembly and a push ram assembly. The knock-out ram assembly includes a first bushing and a knock-out ram extending through the first bushing. The knock-out ram is configured to translate relative to the first bushing. The knock-out ram assembly further includes a die coupled to the first bushing at one end of the knock-out ram assembly. The knock-out ram assembly further includes a knock-out retainer assembly coupled to the knock-out ram at the one end. The knock-out retainer assembly includes a retainer and a filler body. The knock-out ram assembly further includes a knock-out retained against the knock-out ram at the one end by the knock-out retainer assembly. The push ram assembly includes a second bushing and a push ram extending through second first bushing. The push ram is configured to translate relative to the second bushing. The push ram assembly further includes a push plate coupled to the push ram facing the knock-out ram assembly. The knock-out ram assembly and the push ram assembly are configured to cooperate together for retaining and releasing a container.
An aspect of the system includes the push ram being hollow beyond where the push plate connects to the push ram.
Another aspect of the system includes the ram system being configured to process containers having a diameter of about 66 mm to about 87 mm, a height of about 88 mm to about 211 mm, or a combination thereof, and the push ram weighs about 3.9 kg to about 4.8 kg.
Another aspect of the system includes the push plate being a single piece.
Another aspect of the system includes the filler body forming an interference fit with the knock-out such that there is no radial gap between the filler body and the knock-out.
Another aspect of the system includes proximal ends of the knock-out retainer assembly and the knock-out being generally flush.
Another aspect of the system includes the retainer having a tapered nozzle and the filler body having a taper that complements the tapered nozzle.
It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention as claimed.
These and other features, aspects, and advantages of the present invention will become apparent from the following description, appended claims, and the accompanying exemplary embodiments shown in the drawings, which are briefly described below.
While the invention is susceptible to various modifications and alternative forms, specific forms thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that it is not intended to limit the invention to the particular forms disclosed, but, on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.
Objects of the present invention are directed to a ram system that can be used for processing large containers within container processing machinery running at speeds traditionally only suitable for small containers.
During operation of the ram system 400, the knock-out ram 408 translates relative to the bushing 406 in a direction parallel to the line 411, which allows the knock-out ram assembly 402 to retain and release a container (not shown) within the ram system 400. The additional elements necessary for the operation of the knock-out ram assembly 402, along with a general description of the operation thereof, is known to those of ordinary skill in the art and is not discussed herein for convenience.
Similar to the knock-out ram assembly 402, the push ram assembly 404 includes a bushing 412 surrounding a push ram 414. Attached to the push ram 414 and configured to face the knock-out ram assembly 402 is a push plate 416. The push plate 416 can be made out of metal, such as tool steel, or a ceramic, and weigh about 0.3 kg. In one or more embodiments, the push plate 416 may be fixed, i.e., not adjustable like conventional push plates, to save additional weight. Preferably, the push plate 416 is made from a single piece of, for example, metal or ceramic.
During operation of the ram system 400, the push ram 414 translates relative to the bushing 412 in a direction parallel to the line 411, which allows the push ram assembly 404 to retain and release a container (not shown) within the ram system 400. The additional elements necessary for the operation of the push ram assembly 404, along with a general description of the operation thereof, is known to those of ordinary skill in the art and is not discussed herein for convenience.
While the overall setup of the ram system 400 is similar to the conventional ram system 100, differences described below allow the inventive ram system 400 to operate within container processing machinery at increased speeds and provide various processing efficiencies while processing the above-described large containers.
The line 518 represents the outer diameter of the knock-out ram 408 through the bushing 406, which is substantially the same as the inner diameter of the bushing 406, except for a minimal difference that allows the knock-out ram 408 to translate within the bushing 406. The outer diameter of the knock-out ram 408 can be about 34 mm to about 42 mm, such as about 38 mm. The line 520 represents the smallest outer diameter of the bushing 406, such as about 70 mm.
Referring next to the push ram assembly 404, the push ram 414 extends through the bushing 412, as described above. The push plate 416 is connected to the push ram 414 so that it faces the knock-out ram assembly 402 during use of the ram system 400 in container processing machinery. The line 522 represents the outer diameter of the push ram 414 through the bushing 412, which is substantially the same as the inner diameter of the bushing 412, except for a minimal difference that allows the push ram 414 to translate within the bushing 412. The outer diameter of the push ram 414 can be about 45 mm to about 56 mm, such as about 50 mm. The line 524 represents the smallest outer diameter of the bushing 412. The outer diameter of the bushing 412 can be about 70 mm.
Referring back to the knock-out ram assembly 402, surrounding the knock-out 410 is a die 500 used for processing containers (not shown) retained in the ram system 400. Although labeled as die 500, the die 500 according to an embodiment of the present invention can be the same die 200 as described above within the conventional ram system 100. For example, the shape, the materials, etc. can be the same as the conventional die 200.
The conventional knock-out 110 within the conventional ram system 100 is made of metal, such as steel and, particularly, tool steel. However, the knock-out 410 of the ram system 400 instead is made of a ceramic. The knock-out 410 includes an annular groove 418 where the knock-out 410 interfaces with the knock-out ram 408. The annular groove 418 is formed in the knock-out 410 to reduce the weight of the knock-out 410, as further described below with respect to
A knock-out retainer assembly 502 is connected to the knock-out ram 408 via a threaded portion 516 on the knock-out ram 408 that engages a threaded portion on the knock-out retainer assembly 502 (
The knock-out ram assembly 402 includes a conduit 510 through the knock-out ram 408 and a conduit 512 through the knock-out retainer assembly 502. The combined conduits 510 and 512 pressurize the knock-out ram assembly 402 during use to retain a container (not shown). The lack of equivalent spaces in the knock-out ram assembly 402 as the areas 206 and 208 in the conventional knock-out ram assembly 102 reduces the pressurization requirements during use of the knock-out ram assembly 402. The reduced requirements allow large containers to be processed within container processing machinery using the knock-out ram assembly 402 at speeds similar to speeds used for small containers, such as at about 2400 containers per minute rather than about 1800 containers per minute.
Still further, despite the reduced amount of empty space, the weight of the knock-out retainer assembly 502 is the same or even weight as the conventional knock-out retainer 202. For example, the inventive knock-out retainer assembly 502 weighs about 0.37 kilograms (kg) to about 0.46 kg, such as 0.40 kg. In contrast, the conventional knock-out retainer 202 weighs about 0.45 kg. Thus, the bulk density of the knock-out retainer assembly 502 assembly is less than the bulk density of the conventional knock-out retainer 202. The difference is primarily based on the different materials used to form the knock-out retainer assembly 502 versus the conventional knock-out retainer 202. For example, the knock-out retainer 202 is formed of metal, such as steel and, particularly, tool steel. In contrast, the inventive knock-out retainer assembly 502 is formed of multiple different materials to save weight, as further described below with respect to
Referring back to the knock-out ram 408, as described above, the outer diameter represented by the line 518 is smaller than the outer diameter of the conventional knock-out ram 108, represented by the line 118 in
Referring to the push ram assembly 404, the outer diameters of the push ram 414 and the conventional push ram 114 can be substantially similar. However, the push ram 414 is substantially hollow beyond where the push plate 416 connects to the push ram 414 along a majority of the push ram 414 based on the presence of a hollow portion 514. In contrast, and referring back to
Referring to
The retainer 900 includes a nozzle 910 through which the conduit 512 (
The retainer 900 can be formed of metal, such as steel and, particularly, tool steel. In contrast, the primary role of the filler body 904 is to occupy space so that less space must be pressurized during use of the knock-out ram assembly 402. Accordingly, the filler body 904 can be formed of a material that is lighter than steel, such as a polymer. In one or more embodiments, the material can be Nylon, Delrin, acrylonitrile butadiene styrene (ABS), polypropylene, and the like. Thus, despite its overall size, the filler body 904 can weigh about 0.1 kg to about 0.2 kg, depending on the size of the corresponding necking stages associated with the filler body 904. The retainer 900 can weigh about 0.19 kg.
Based on the foregoing differences in weight, relocation of weight, and reduced empty space, the ram system of the present invention can handle large containers at speeds traditionally reserved for small containers within container processing machinery. For example, where conventional container processing machinery must run at about 1800 containers per minute as a result of the increased size of the containers of the included conventional ram systems, container processing machinery with the ram system of the present invention can instead run at about 2400 containers per minute or even higher. The increased speeds result in increased economics of the container processing machinery because the container processing machinery can produce more containers for a given amount of time than the conventional processing machinery. The container processing machinery of the present invention can also meet a customer's demands with fewer machines and/or container lines.
Each of these embodiments and obvious variations thereof are contemplated as falling within the spirit and scope of the claimed invention, which is set forth in the following claims. Moreover, the present concepts expressly include any and all combinations and sub-combinations of the preceding elements and aspects.
As utilized herein, the terms “approximately,” “about,” “substantially”, “generally”, and similar terms are intended to have a broad meaning in harmony with the common and accepted usage by those of ordinary skill in the art to which the subject matter of this disclosure pertains. It should be understood by those of skill in the art who review this disclosure that these terms are intended to allow a description of certain features described and claimed without restricting the scope of these features to the precise numerical ranges provided. Accordingly, these terms should be interpreted as indicating that insubstantial or inconsequential modifications or alterations of the subject matter described and claimed are considered to be within the scope of the invention as recited in the appended claims.
It should be noted that the terms “exemplary” and “example” as used herein to describe various embodiments are intended to indicate that such embodiments are possible examples, representations, and/or illustrations of possible embodiments (and such terms are not intended to connote that such embodiments are necessarily extraordinary or superlative examples).
Any references herein to the positions of elements (e.g., “top,” “bottom,” “above,” “below,” etc.) are merely used to describe the orientation of various elements in the Figures. It should be noted that the orientation of various elements may differ according to other exemplary embodiments, and that such variations are intended to be encompassed by the present disclosure.
Although only a few embodiments have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. For example, elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangement of the various exemplary embodiments without departing from the scope of the present invention.
This application claims the benefit or and priority to U.S. Provisional Patent Application No. 63/229,887, filed Aug. 5, 2021, and titled, “RAM SYSTEM AND KNOCK-OUT RAM ASSEMBLY FOR PROCESSING CONTAINERS,” which is hereby incorporated by reference herein in its entirety.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2022/039489 | 8/4/2022 | WO |
| Number | Date | Country | |
|---|---|---|---|
| 63229887 | Aug 2021 | US |
