Patent Application
20240359227
The disclosed concept relates generally to necker machines and, more particularly, to necker machines including a base reformer assembly having an adjustable cam assembly utilizing a 3-dimensional track groove.
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. After forming, the can body base includes a concave dome extending into the enclosed space defined by 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, inspecting, and placed on pallets which are shipped to the filler. At the filler, the cans are taken off of the pallets, filled, have can ends coupled to them and then the filled cans are repackaged in six packs and/or twelve pack cases, etc.
As part of the forming process, some can bodies are further formed in a necker machine. Necker machines are structured to reduce the diameter/radius of the can body at the open end. That is, the open end is reduced relative to the diameter/radius of other portions of the can body sidewall. Typically, a necker machine processes over 3000 can bodies per minute. The necker machine includes a number of processing and/or forming stations disposed in series. Further, each forming station processes multiple can bodies at a time. In an exemplary embodiment, a forming station includes twelve forming units. When a can body is disposed at a forming unit, that forming unit moves over a path while forming the can body. The forming unit then ejects the can body and is moved back to the initial position to receive another can body. It is understood that the other units at the forming station follow the same path and operate in a similar manner. Thus, at such a station, there are a number of can bodies at different stages of the forming being performed with a more limited number of forming units receiving/ejecting a can body or moving to a position to receive another can body.
Further, the processing and/or forming stations are disposed adjacent to each other and a transfer assembly moves a can body between adjacent processing and/or forming stations. As the can bodies move through the necker machine, the can bodies stay, generally, in the same plane. That is, when viewed from the front side of the necker machine, the can body moves, for example, left to right while remaining within the same general plane. This configuration allows the use of “starwheels” to move the can body between forming stations rapidly and without the need to move the can bodies in/out of the general plane of motion.
This configuration, however, also means that the forming assemblies need to operate in a limited space or plane. This, in turn, means that the forming assemblies have a limited space in which the forming elements are disposed. That is, generally, the forming assembly is disposed between the front of the necker machine (or the drive assembly) and the plane in which the can bodies move. Typically, this space is about 18 inches between the front of the necker machine and the plane in which the can bodies move. Thus, each forming assembly has a limited length in a direction generally perpendicular to the plane in which the can bodies move. This configuration leads to known problems.
That is, the forming assemblies must be configured with the forming elements and the drive elements substantially within the limited length/space allowed as described above. This, in turn, means that many of the forming/drive elements are smaller than would be desired. That is, when forming 3000 can bodies per minute, the forming/drive elements are subject to wear. Thus, it is generally desirable to have large and robust elements but, due to the limited space, these elements are often smaller than desired. Thus, these elements often need maintenance or need to be replaced. This is a problem.
For example, one station of the necker machine is, typically, a base reformer. The base reformer station utilizes a die to reform, i.e., reshape, the shape of the can body base. As is known, the bodymaker, discussed above, forms a can body with an inwardly domed portion having an annular ring disposed thereabout. The base reformer station reforms the annular ring by modifying the internal base profile of a can body to provide an increase in body strength at the base. This allows lower gauge thicknesses to be used for the can body resulting in a reduction in metal usage. In the prior art, the base reformer included a roller die that was configured to fit within the space defined by the can body dome. A can body is transferred to a base reformer unit when the forming die, hereinafter “the reforming die,” is disposed at a generally central location relative to the base. The reforming die has a smaller cross-sectional area than the dome; thus, the reforming die was disposed within, and did not contact, the can body base. As the base reformer unit moved over its path, as described above, the reforming die moved radially outwardly to contact and reform the can body base. After the base reformer unit reformed the base, the reforming die returned to a central position and the can was ejected and moved on to a subsequent forming station.
Various drive assemblies were included in each base reformer unit. For example, a cam actuated drive assembly moved the reforming die radially from the central location to engagement with the can body base. Then, a drive system utilizing gears was used to rotate the reforming die about the can body base. Given the space available for such a drive assembly, the gears, and especially the teeth of the gears, are examples of elements having a size prone to wear. That is, such drive assembly elements, as well as other elements, are the types of elements that need frequent maintenance and replacement. Such elements are a problem.
Further, given the limited space for the base reformer unit, such units do not include certain desirable elements/assemblies. For example, the reforming die is positioned and maintained in a selected plane by bushings. That is, at a location offset from the forming portion of the reforming die, i.e., the portion that contacts the can body base, the reforming die included an outwardly extending flange. This flange was disposed between two substantially parallel torpid bushings. In some embodiments, the friction between the reforming die and the bushings was further reduced by a lubricant, e.g., grease. The bushings, however, were exposed to the industrial atmosphere when a can body was not disposed on the base reformer unit. Thus, the bushing and/or the lubricant was/were exposed to contamination. This is a problem. Moreover, constructs such as, but not limited to, sealed thrust bearings were not used in place of such bushings because of the limited available space, as described above. This is also a problem.
It is noted that the reforming die, which was typically a generally cylindrical roller die, had a radius that was much smaller than the dome radius. As such, the reforming dic did not trap, or otherwise interfere, with movement of the can body following base reformation. As such, the known base reformer assemblies did not require an additional construct or constructs to assist when moving the can body from the base reformer assembly. When the reforming die has a larger radius, i.e., a radius that is smaller than, but nearly the same size as, the dome radius, there is a potential for interference between the reforming die and can body. That is, the can body has the potential of becoming loosely trapped between the reforming die and the chuck.
Such problems/shortcomings in the prior art were generally addressed by the reformer assembly disclosed in U.S. Pat. No. 11,420,242 B2 (hereinafter the “'242 patent”, the contents of which are incorporated herein by reference), issued to the same Assignee as the present application. The reformer assembly described in the '242 patent utilizes a cam arrangement having a roller die unit actuating assembly 10, such as shown in
There is, therefore, a need for a base reformer assembly, and/or a base reformer roller die unit/cam plate arrangement that provides for adjustability without requiring removal and installation of a new cam plate, and even more preferably adjustability that can be carried out generally on the fly with the reformer and associated machinery operating at full, or as near as full, capacity as possible.
These needs, and others, are met by embodiments of the disclosed concept that provide for adjustment of a roller die in a base reformer. As one aspect of the disclosed concept, a cam arrangement is provided. The cam arrangement comprises: a cam plate comprising: a body having a planar face; a number of cam channels defined in the body, each cam channel extending into the body from the planar face and defined, in-part, by a pair of opposing sidewalls, and a number of cam followers, each cam follower having a roller assembly comprising an upper roller member and a lower roller member, wherein the upper roller member is engaged with a first sidewall of the pair of opposing sidewalls at a depth into the channel from the planar face, and wherein the lower roller member is engaged with a second sidewall, opposite the first sidewall, of the pair of opposing sidewalls at the depth into the channel from the planar face.
At least one cam channel of the number of cam channels may have a number of contoured portions wherein the opposing sidewalls extend obliquely to the planar surface.
The roller assembly may be structured to be adjustably positioned at a plurality of different depths within the channel, wherein each depth of the plurality corresponds to a different cam path.
The number of cam channels may comprise a plurality of cam channels. The cam arrangement may further comprise a second cam follower having a roller assembly comprising an upper roller member and a lower roller member, wherein the upper roller member of the second cam follower is engaged with a first sidewall of the pair of opposing sidewalls of a second cam channel at a second depth into the channel from the planar face, and wherein the lower roller member is engaged with a second sidewall, opposite the first sidewall, of the pair of opposing sidewalls of the second cam channel at the second depth into the channel from the planar face.
The cam follower may comprise a stem member having an upper portion disposed about a first longitudinal axis and a lower portion disposed about a second longitudinal axis at an angle relative to the first longitudinal axis, and wherein the roller assembly is coupled to the lower portion and rotates about the second longitudinal axis.
The upper roller member and the lower roller member may each comprise a sidewall engaging surface shaped as a portion of a hemisphere.
The upper roller member and the lower roller member may each comprise a sidewall engaging surface shaped as a strip-like portion of a hemisphere.
The cam arrangement may further comprise an actuator coupled to at least one of the cam plate and/or a cam follower of the number of cam followers, the actuator being structured to adjust the depth at which the upper roller member is engaged with the first sidewall of the pair of opposing sidewalls and the depth at which the lower roller member is engaged with the second sidewall of the pair of opposing sidewalls.
As another aspect of the disclosed concept a base reformer unit for a necking machine for performing shaping operations on a can body is provided. The base reformer unit comprises: a housing assembly structured to be fixedly coupled to a frame assembly of the necking machine; a drive shaft rotatably coupled to the housing assembly and structured to be rotated by a drive assembly of the necking machine; and a base reformer assembly comprising: a support plate; a number of base reformer roller die units; a number of roller die unit actuating assemblies; and a cam arrangement such as previously described.
As yet a further aspect of the disclosed concept a necker machine for use in performing shaping operations on a can body is provided. The necker machine comprises: a frame assembly; a drive assembly; and a base reformer unit such as previously described.
These and other objects, features, and characteristics of the disclosed concept, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economics 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 provided for the purpose of illustration and description only and are not intended as a definition of the limits of the concept.
A full understanding of the disclosed concept can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:
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, number of components used, embodiment configurations and other physical characteristics related to the embodiments disclosed herein are not to be considered as 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 intended to be 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, 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, “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, 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, 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 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., without limitation, liquid, food, any other suitable substance), and expressly includes, but is not limited to, beverage cans, such as beer and soda/pop cans, as well as food cans.
As used herein, a “can body” includes a base and a depending, or upwardly depending, sidewall. The “can body” is unitary. In this configuration, the “can body” defines a generally enclosed space. Thus, the “can body,” i.e., the base and sidewall, also include(s) an outer surface and an inner surface. That is, for example, a “can body” includes a sidewall inner surface and a sidewall outer surface.
As used herein, to “form” metal means to change the shape of a metal construct in a predetermined manner.
As used herein, a “cam channel” means a groove, or similar construct, wherein at least one surface defining the channel is structured to be a cam surface. As used herein, a “side cam channel” means a “cam channel” wherein a surface defining a side (or side portion) of the channel, as opposed to the bottom surface (or bottom portion) of the channel, is structured to be a cam surface. As used herein, a “dual-side cam channel” means a “cam channel” including generally opposed and generally parallel sides and wherein both sides of the “cam channel” are structured to be a cam surface.
As used herein, a “dual-level” cam channel means a “dual-side cam channel” wherein one side of the cam channel defines a first cam surface that moves a cam follower in one direction and the other side of the cam channel defines a second cam surface that moves a cam follower in the other direction. For example, if the cam channel is generally straight, the first cam surface moves a cam follower laterally to the right and the second cam surface moves a cam follower laterally to the left. Alternatively, if the cam channel is generally circular, the first cam surface moves a cam follower radially outwardly and the second cam surface moves a cam follower radially inwardly. Further, as used herein, in a “dual-level” cam channel the first cam surface is at a first elevation relative to the cam channel bottom surface and the second cam surface is at a second elevation relative to the cam channel bottom surface. Further, in this configuration, the surface opposite the first cam surface and the surface opposite the second cam surface do not affect the cam follower and, as such, are structured to be spaced from a cam follower that engages the first/second cam surface. Alternatively, the surface opposite the first cam surface and the surface opposite the second cam surface are absent. The lack of a surface opposite a first/second cam surface in a “dual-level” cam channel does not change the nature of the channel as a “dual-side cam channel.” That is, there are still two opposed cam surfaces but the cam surfaces are at different elevations relative to each other. As used herein, and with respect to a cam surface of a cam channel, “elevation” is the distance relative to the cam channel bottom surface.
As used herein, “cooperative cam channels” means a plurality of cam channels structured to interact with a linkage having at least two elongated linkage members, a plurality of cam followers wherein the interaction between the cam channels, the cam followers, and the linkage move a portion of a linkage member over a selected, i.e., an intended, path. As used herein, a “portion of a linkage member” means an identifiable portion such as, but not limited to, an end of the linkage member. Further, as used herein, the “portion of a linkage member” that moves over the selected path is also identified as the “actuated element.” Thus, as used herein, all “cooperative cam channels” inherently have a number of associated “actuated element(s).” As used herein, “circular cooperative cam channels” means “cooperative cam channels” that move a portion of a linkage member over a generally circular path. As used herein, “spiral/circular cooperative cam channels” means “cooperative cam channels” that move a portion of a linkage member over a path that initially spirals outwardly from an origin to a selected radius, follows a circular path for at least one revolution, then spirals inwardly to the origin.
An example necker machine 100 in accordance with an example embodiment of the disclosed concept is shown in
The processing stations 106 are disposed adjacent to each other and in series. That is, the can bodies 102 being processed by the necker machine 100 each move from an upstream location through a series of processing stations 106 in the same sequence. The can bodies 102 follow a path, hereinafter, the “work path 112” (
A can body 102 is processed and/or formed (or partially formed) as the can body 102 moves across each processing station 106. Generally, the processing/forming occurs in/at a turret 114 of each processing station 106. That is, the term “turret 114” identifies a generic turret. Each processing station 106 includes a non-vacuum starwheel 116. As used herein, a “non-vacuum starwheel” means a starwheel that does not include, or is not associated with, a vacuum assembly that is structured to apply a vacuum to pockets (not numbered) thereof that are each structured to temporarily support a can body 102. Further, each processing station 106 typically includes one turret 114 and one non-vacuum starwheel 116 or another support for the can bodies 102.
The transfer assembly 108 is structured to move the can bodies 102 between adjacent processing stations 106. To accomplish this, the necker machine 100 includes a frame assembly 120 to which the plurality of processing stations 106 are removably coupled. Alternatively, the frame assembly 120 includes elements incorporated into each of the plurality of processing stations 106 so that the plurality of processing stations 106 are structured to be temporarily coupled to each other. The frame assembly 120 has an upstream end 122 and a downstream end 124. Further, the frame assembly 120 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.
The specific nature of the processing stations 106 upstream or downstream of a base reformer station 130 are not relevant to the present disclosure. It is understood that the transfer assembly 108 feeds a series of can bodies 102, one at a time, to the base reformer station 130. It is to be understood that in general the base reformer station 130 operates in the same manner as that described in the '242 patent except for the adjustability feature/arrangement described further below, accordingly, only a brief description of the base reformer station 130 is provided herein. Referring to
Continuing to refer to
As noted above, each roller die unit 144 is driven/controlled by a corresponding roller die unit actuating assembly 145. Meanwhile, each roller die unit actuating assembly 145 is driven/controlled by first and second cam followers 180 thereof interacting with first and second channels 162 and 164 of the cam plate 146. Embodiments of the disclosed concept address shortcomings of prior solutions, such as, for example, without limitation, provided by the arrangements described in the '242 patent and briefly discussed in the Background section herein, by providing arrangements which allow for precise adjustments to the path of a roller die of a roller die unit 144 without needing to change the cam plate 146. Such arrangements allow for such adjustments to be carried out while the necker machine 100 is running, such as at a slow jogging speed, an operating speed, or other suitable speed. Such adjustability is generally accomplished by replacing the prior art cam plate 12 having cam channels 18, 20 that each define a single cam path (such as shown in
Referring to
From the sectional view shown in
In order to address/avoid such problems/incompatibility of a conventional cam follower arrangement in a cam channel having contoured sidewalls such as described herein, the example cam follower 180 shown in
From the detailed sectional view shown in
From the foregoing it is thus to be appreciated that embodiments of the disclosed concept provide arrangements which allow for the path travelled by a reformer die of a reformer unit to be adjusted simply by adjusting the depth of a cam follower, such as cam follower 180, within a contoured cam channel, such as cam channels 162 and/or 164 of cam plate 146 of
While specific embodiments of the disclosed concept 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 concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.
In the claims, any reference signs placed between parentheses shall not be construed as limiting the claim. The word “comprising” or “including” does not exclude the presence of elements or steps other than those listed in a claim. In a device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The word “a” or “an” preceding an element does not exclude the presence of a plurality of such elements. In any device claim enumerating several means, several of these means may be embodied by one and the same item of hardware. The mere fact that certain elements are recited in mutually different dependent claims does not indicate that these elements cannot be used in combination.
This application claims priority to U.S. patent application Ser. No. 63/462,662, filed Apr. 28, 2023, titled “Reformer With 3-Dimensional Track Groove Cam Assembly.”
| Number | Date | Country | |
|---|---|---|---|
| 63462662 | Apr 2023 | US |
