Abstract:
The invention includes an air manifold comprising at least one port adapted for receiving high pressure air from a compressor, at least one port adapted for receiving low pressure air from a compressor, at least one port adapted for bleeding high pressure air from a container, at least one port adapted for reusing high pressure bleed air. The port for reusing high pressure air receiving high pressure air from the port adapted for bleeding high pressure air. The air manifold also includes at least one port adapted for bleeding low pressure air from a container and at least one port adapted for reusing low pressure bleed air. The port for reusing low pressure air receiving low pressure air from the port adapted for bleeding low pressure air. The present invention also includes an air distribution system and a necking machine which include the manifold as well as a method of necking a can.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention is generally related to two piece can making equipment, and more specifically related to an air manifold for can making equipment, and a necking machine incorporating the air manifold.  
         BACKGROUND OF THE INVENTION  
         [0002]    Static die necking is a process whereby the open ends of can bodies are provided with a neck of reduced diameter utilizing a necking tool having reciprocating concentric necking die and pilot assemblies that are mounted within a rotating necking turret and movable longitudinally under the action of a cam follower bracket to which the necking die assembly is mounted. The cam follower bracket thereby rotates with the turret while engaging a cam rail mounted adjacent and longitudinally spaced from the rear face of the necking turret. A can body is maintained in concentric alignment with the open end thereof facing the necking tool of the concentric die and pilot assemblies for rotation therewith. The reciprocating pilot assembly is spring loaded forwardly from the reciprocating die member. The forward portions of the die member and pilot assembly are intended to enter the open end of the can body to form the neck of the can.  
           [0003]    More specifically, the die member is driven forwardly and, through its spring loaded interconnection with the pilot assembly, drives the pilot assembly forwardly toward the open end of the can. The outer end of the pilot assembly enters the open end of the can in advance of the die member to provide an anvil surface against which the die can work. The forward advance of the pilot assembly is stopped by the engagement of a homing surface on the necking turret with an outwardly projecting rear portion of the pilot assembly, slightly before the forward portion of the die member engages the open end of the can. As the die member continues to be driven forwardly by the cam, its die forming surface deforms the open end of the can against the anvil surface of the pilot assembly to provide a necked-in end to the can body.  
           [0004]    A necking machine of the type discussed above is disclosed, for example, in U.S. Pat. Nos. 4,457,158 and 4,693,108. In the latter &#39;108 patent, each necking station also has a container pressurizing means in the form of an annular chamber formed in the pilot assembly. The container pressurizing means acts as a holding chamber prior to transmitting the pressurized fluid into the container from a large central reservoir located in the necking turret. In the type of static die necking discussed above to which the present invention pertains, pressurized fluid internally of the container is critical to strengthen the column load force of the side wall of the container during the necking process. There are particular problems inherent in introducing sufficient pressurized fluid into the container as the speed of production is increased. Further, the cost of pressurized air has risen to be a significant percentage of the cost of manufacturing.  
           [0005]    A necking machine addressing these problems is disclosed in PCT/US97/05635. This necking machine includes a manifold, illustrated schematically in FIG. 1, adapted to supply air at different pressures to the can. Specifically, the manifold includes ports which supply low, medium and high pressure air to the can. The manifold also includes low, medium and high pressure bleed ports which recycle air from the formed can back to succeeding cans to be formed. By recycling air, this design reduces the total amount of air necessary in the forming process. Although this necking machine represents an improvement over earlier necking machines, the use of three distinct pressure supplies and three recycle streams results in a much more complicated necking machine.  
           [0006]    Therefore, it would be advantageous to have a relatively simple manifold, necking machine, and method of necking a can which supplies sufficient air to maintain the can under pressure while necking, yet requires less air than conventional devices and methods.  
         SUMMARY OF THE INVENTION  
         [0007]    Briefly, in one embodiment, the present invention includes an air manifold adapted for use in a can necking module comprising at least one port adapted to supply low pressure air to a can prior to necking, at least one port adapted to supply high pressure air to a can prior to necking at least one port adapted for bleeding high pressure air from a can after necking, at least one port adapted for bleeding low pressure air from a can after necking and not having ports adapted to supply or bleed air at pressures intermediate between the high and low pressures.  
           [0008]    The present invention also includes a necking module comprising an air manifold having at least one port adapted to supply low pressure air to a can prior to necking, at least one port adapted to supply high pressure air to a can prior to necking, at least one port adapted for bleeding high pressure air from a can after necking, at least one port adapted for bleeding low pressure air from a can after necking and not having ports adapted to supply or bleed air at pressures intermediate between the high and low pressures, a necking die and a rotor.  
           [0009]    In addition, the present invention includes an air distribution system for can necking comprising an air compressor, a high pressure line, a low pressure line; and a least one necker module having an air manifold including at least one port adapted to supply low pressure air to a can prior to necking, at least one port adapted to supply high pressure air to a can prior to necking, at least one port adapted for bleeding high pressure air from a can after necking, at least one port adapted for bleeding low pressure air from a can after necking and not having ports adapted to supply or bleed air at pressures intermediate between the high and low pressures.  
           [0010]    The present invention also includes a method of necking a can comprising the steps of supplying a first can to a necking module including an air manifold having ports adapted for low pressure air, ports adapted for high pressure air and not having ports at pressures intermediate between the high and low pressures, charging a first can with low pressure bleed air through a first reuse port, charging the first can with high pressure bleed air through a second reuse port, charging the first can with high pressure air from a compressor through at least one feed port, inserting the first can into a necking die, necking the first can, bleeding high pressure air from the first can to at least one succeeding can through a first regen port and bleeding low pressure air from the first can to at least one succeeding can through a second regen port.  
           [0011]    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. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0012]    The foregoing and other features, aspects and advantages of the present invention will become apparent from the following description, appended claims and the exemplary embodiments shown in the drawings, which are briefly described below.  
         [0013]    [0013]FIG. 1 is a schematic diagram of a prior art air manifold and a prior art air distribution system using the manifold.  
         [0014]    [0014]FIG. 2 is a plan view of an air manifold according to the present invention.  
         [0015]    [0015]FIG. 3 is a perspective view of a necking module according to the present invention.  
         [0016]    [0016]FIG. 4 is plan view of the necking module of FIG. 2.  
         [0017]    [0017]FIG. 5 is a schematic diagram of an air distribution system according to the present invention.  
         [0018]    [0018]FIG. 6 is an exploded view of a manifold assembly according to the present invention.  
         [0019]    [0019]FIG. 7 is a partial cut away view of a necking module according to the present invention.  
         [0020]    [0020]FIG. 8 is a partial cut away view of a manifold assembly according to the present invention.  
         [0021]    [0021]FIG. 9 is a schematic representation of the air manifold in relation to the port holes on a rotor during operation of a necking module of the present invention. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0022]    The present inventor has discovered that it is possible to fabricate a relatively simple necking machine for can manufacture which supplies sufficient air to maintain the can under pressure while necking and which requires less air than conventional devices and methods. This discovery is accomplished with a novel air manifold which provides for the use of high and low pressure recycled air. In addition, this discovery has resulted in a novel manifold, a novel necking machine, a novel air distribution system for the necking machine and a novel method of necking.  
         [0023]    [0023]FIG. 2 illustrates an air manifold  248  according a preferred embodiment of the invention. The air manifold  248  is generally arcuate or horseshoe shaped, spanning an angle of approximately 180 degrees. The air manifold includes eight ports: a first reuse port  20 ; a second reuse port  22 ; a first high pressure feed  24 ; a second high pressure feed  26 ; a monitoring port  28 ; a first regen port  30 ; a second regen port  32  and a low pressure feed port  34 . Additionally, several of the ports comprise arcuate slots  300 A- 300 F. The use and design of the various ports and slots and advantages of the preferred embodiment of the invention are described in more detail below.  
         [0024]    The preferred necking module  12  of the present invention is illustrated in FIGS. 3 and 4. The air manifold  248  of the present invention is designed to be used in so that it reduces the amount of air needed during necking. The reduction in air in the present invention is achieved with the conservation and recycling of internally applied air pressure to the cans during forming in the necking module  12 . The necking module  12  comprises a transfer star wheel  48  having twelve vacuum assisted transfer pockets  50  and a main star wheel  40  having twelve pockets  42 . When a can is transferred to the main star wheel  40 , it is contacted by a pusher pad  64  and driven forward into a necking die  41  by push ram  60 . The necking die is mounted on a turret assembly (not shown), which rotates in concert with the main star wheel  40 . Also rotating in concert is an air distribution rotor  156  which distributes air from the manifold  248  to the can.  
         [0025]    The operation of air manifold  248  and necking module  12  is best understood in conjunction with the preferred air distribution system  10 . A schematic diagram of the preferred air distribution system  10  of the present invention is illustrated in FIG. 5. Air distribution system  10  comprises an air compressor  238  which provides a main air supply pressure of nominally 60 psig. The incoming supply is filtered in a filter  240  before being split to different pressure regulators: a high pressure regulator  242  and a low pressure regulator  246 . The air pressures are then fed to a horseshoe shaped manifold  248  in an air manifold assembly (not shown) via high and low pressure headers  250 ,  254 . Preferably, the high pressure is between 20 and 50 psig and the low pressure is between 1 and 10 psig. Typically, the high pressure header  250  is maintained at 30 psig and the low pressure header  254  is maintained at 5 psig. Each supply is regulated and a dial gives the actual pressures.  
         [0026]    Air is transferred from the incoming supply headers  250 , and  254  to each die necking module  12  through modified ABS tubing. Header  250  carries the high pressure air and divides into two polyflow (reinforced polyethylene) hoses  256  connected to the air manifold  248 . Header  254  carries the low pressure air and is connected to the air manifold  248  through polyflow hose  260 . This air distribution arrangement is repeated identically for each necking module  12  in system  10 .  
         [0027]    Typically, with the manifold  248  and the air distribution system  10  of the present invention, each of the die necking modules  12  requires a volume of 50 SCFM air flow from the high pressure compressor  238 . This is a much reduced volumetric flow rate compared to conventional machines. This reduction is accomplished by provision of the air pressure manifold  248  coupled to the necking die turret (not shown). The necking die turret provides an overlapping stepped increased air pressure into each of the cans in its pocket  42  on the turret star wheel  40 . This is accomplished as the star wheel  40  rotates into the full die insertion position at top dead center (TDC) of each turret along with recapture or feedback from air released from the inside of each can prior to transfer.  
         [0028]    More specifically, low pressure air is initially supplied into the can via the first reuse port  20  (see FIG. 5) as it is picked up from the transfer star wheel  48  and rotated upward. This low pressure air seats the can against the pusher pad  64  and in the pocket  42  of the main star wheel  40  (see FIG. 4). As each can begins entry into the die, air pressure fed through the center of the die into the can is increased to a high pressure. Air pressure is increased to a high pressure to prevent buckling as the die begins necking the can. It is increased as the can is further pressed into the die so that as the can approaches TDC it has full internal support. As the main star wheel  40  continues to rotate beyond TDC, the particular necking operation is now complete and the pusher pad  64  begins to retract. The high pressure air supplied into the can is isolated. The high pressure air in the can pushes the can against the retracting pusher pad  64  and away from the die. During this period, the internal air pressure in the can is bled back to the first regen port  30  and the second regen port  32  rather than releasing it to ambient. After the can is pushed back out of the die as the main star wheel  40  rotates, low pressure air is applied from port  34  to hold the can against the pusher pad  64  until just prior to the can being picked up by the transfer star wheel  48  with the aid of vacuum for transfer of the can to the next module  12  (see FIG. 3).  
         [0029]    This recapture of air pressure from the high pressure applied at TDC of the turret  40  is, in essence, a pressure feedback system which conserves the use of pressurized air which provides internal can support during the necking operations. The exhausting high pressure air from within the can is directed to a high pressure reuse surge tank and to a low pressure reuse surge tank.  
         [0030]    More particularly, air at low pressure is supplied to the interior of a can via the first reuse port  20  as it is picked up in the can pocket of the turret star wheel  40  from the transfer star wheel  48  (see FIGS. 3 and 5). This low pressure air blown into the can pushes the can firmly against the pusher pad  64 , properly locating the can for the operation to come. As the turret  40  rotates upward toward TDC, the air pressure is changed to a high pressure to prime the can as it enters the necker tooling. Prior to TDC, high pressure air is supplied into the can via the second reuse port  22  and two high pressure feed ports  24 ,  26  to provide lateral internal support to the thin side wall of the can during the die forming. Then, as the turret  40  rotates past TDC, the can is no longer being necked. Consequently, the high pressure is no longer needed and the high pressure supply is isolated from the can. The high pressure then bleeds from the can back to the high and low pressure reuse surge tanks via regen ports  30 ,  32 . This bleed back process recoups about 50% of the air volume which would otherwise be required to operate the system. Finally, low pressure air is provided via port  34  to blow the can back from the die prior to the transfer star wheel picking up the can to transfer it to the next stage.  
         [0031]    Also included in the manifold  248  is a monitoring port  28 . Monitoring port  28  is typically not used in production, however, it can be accessed to monitor the performance of the manifold  248  and air distribution system  10 . Monitoring is accomplished by sampling the air pressure and determining whether the pressure is within a suitable range.  
         [0032]    [0032]FIG. 6 illustrates an exploded view of the manifold assembly  154  while FIG. 7 shows the relationship between the manifold assembly  154  and the die/knockout ram module  38 . The air manifold assembly  154  comprises an annular manifold plate  262 , a cam sleeve  56 , a horseshoe shaped flat manifold  248 , a horseshoe shaped manifold support  282  which is in turn clamped to the manifold plate  262 , and the air distribution rotor  156  fastened to the air distribution sleeve  148  on the main shaft (not shown). The assembly  154  also includes seven hollow piston tubes  288 , with pistons  278  fixed to the ends. The pistons  278  are in piston chambers  280  in the manifold support  282 . The design and use of the pistons  278  will be discussed in more detail below.  
         [0033]    The horseshoe shape of the manifold  248  and the manifold support  282  allows the assembly to be removed from the main shaft without a major disassembly operation. The manifold  248  in one embodiment is made of steel and has a face plate  294  of a low friction, high wear resistance surface material bonded to its rear face  292 . The face plate is bonded thereto to minimize friction and wear between the manifold and the front face  268  of the rotor  156  during module operations. By way of example, this face plate could be made of Turcite™. In the example embodiment shown, the manifold  248  has eight threaded radial bores  296  spaced about the periphery of the manifold. Seven of these bores intersect with the ports  20 - 34 . Note that the present invention has broad application and is not limited by this specific example.  
         [0034]    The front end portion of the distribution sleeve  148  has a radial flange  272  which has twelve threaded ports  274  which connect with the bottom ends of axial bores  270  and  271 . A flexible polyflow (reinforced polyethylene) hose  276  connects each port  274  to one of the die/knockout ram modules  38 . Additionally, the assembly is held together by three bolts  144 . The ram modules  38  are discussed in more detail below.  
         [0035]    [0035]FIG. 8 is a face view of the manifold  248  showing the seven air hoses  256 ,  258  and  260  connected to their appropriate bores  296  via fittings  298 . The ports  20 - 34  connect with elongated timing slots  300 A- 300 F in the face  292  of the manifold  248 . These arcuate slots  300 A- 300 F mate with the ports of the bores  266  in the front face  268  of the rotor  156  as the rotor rotates (see FIG. 7). Timing is accomplished by selecting different values for the lengths of the timing slots  300 A- 300 F. The length of the various slots  300 A- 300 F may be chosen independently. Thus, one or a plurality of the slots  300 A- 300 F may have different lengths and great control can be exercised over the timing of the module  12 .  
         [0036]    As the main shaft rotates, each bore  266  intersects with the one of the slots  300  to distribute either low pressure, high pressure or no pressure through the rotor  156 , the bore  270 , port  274 , hose  276  into the module  38  and ultimately into the can in the pocket  42  on the main star wheel  40 . Thus, the manifold  248  provides air pressure application timing during the necking process of each can while it is on the main turret. The rotational position of the manifold  248  may be adjusted to fine tune this timing by loosening the clamps  284  and rotating the manifold  248  and manifold support  282  clockwise or counterclockwise.  
         [0037]    In operation, as a can is fed into the main star wheel  40 , low air pressure is fed through the knockout ram  54  of the die/knockout ram module  38  into the can (see FIG. 7). This stabilizes the can against the pusher pad  64  as the can is transferred from the pocket  50  of the transfer star wheel  48  into the pocket  42  on the main star wheel  40  of the main turret  36  (see FIG. 4). Increased pressure is then applied as the can enters the throat of the die. This air primes the can with air pressure prior to forming. By using recycled air, there is only a limited waste of compressed air. A further benefit of this supply is that it centers the can in the throat of the die as air is forced out between the outside diameter of the can and the throat of the die.  
         [0038]    High pressure is then injected once the can is located in the die. The high pressure air supports the can during the die necking operation. Further, the can pressing against the die form acts as a seal for this high air pressure. At the top of the cycle, there is no additional high pressure feed. As the can leaves the die, residual pressure suffices to strip the can. At the end of the cycle, the low pressure feed stabilizes the can against the push pad prior to discharge of the can into the transfer star wheel and ensures ejection of the can from the knockout.  
         [0039]    [0039]FIG. 9 shows diagrammatically how the air system is configured and how it functions. The high and low pressure headers  250  and  254  feed three air hoses to the air manifold assembly: low pressure line  260  and two high pressure lines  256 . These lines in turn feed into the circumferential slots  300 C and  300 F which are on the same pitch circle as the twelve bore openings  266  in the mating face  268  of the rotor  156  (see FIG. 7). Each of these bores ultimately feed through a central bore  308  through the knockout ram  54 .  
         [0040]    The diagram in FIG. 9 shows how the rotor ports move through the different air supplies. Each numbered circle represents a can on the turret and its port or opening on the front face  268  of the rotor  156 . Each horizontal row  800 - 826  represents a different angular position of the rotor  156  as a can passes from the first slot  300 A through the last slot  300 F. The first slot  300 A is sized so that only one rotor port is in the initial feed at any one time. However, as can one is entering the initial low pressure slot  300 A (signified by the hashed vertical strip beneath its corresponding slot  300 A) another can (can No.  8 ) is leaving the second regen port slot  300 E on the far right. This allows for air to feed between the two ports  20 ,  32 , reducing waste.  
         [0041]    A can, i.e., its port  266 , will enter the second reuse slot  300 B as the port  266  trailing it will enter the first reuse slot  300 A (see line  804 ). Can No.  10  on the trailing side has already primed the surge tank via the first regen port  30  when can No. 1 is connected to the second reuse port  22 .  
         [0042]    A key feature of the air supply manifold  248  is that the configuration of the slots  300 A- 300 E in the manifold  248  allows air to be re-used. Note that when the port  266  on the rotor  156  passes out of the second high pressure slot  300 C, the path is blocked (see line  814 ). The can, at this time, is firmly sealed in the die/knockout ram module  38 . When this port  266  reaches the first regen slot, high pressure still resides within the can and passages (line  816 ). Consequently, air is actually fed from the can and passages back into the high pressure reuse surge tank rather than to atmosphere. This residual air in the can will also bleed back into the reuse supply channel on the in-feed side (second reuse port  22 ).  
         [0043]    As the turret and rotor  156  further rotates to position this particular port in line with the second regen slot, the residual pressure in the can and passages feeds back into a second surge tank (not shown) from whence it can supply the first reuse port  20 . This feature provides a substantial savings in air volume required for system operation, on the order of at least 50% less air volume than in comparable conventional machines.  
         [0044]    Another feature of the preferred embodiment of the invention is the ability of the manifold  248  to bleed off a small portion of air and use it to seal itself to the rotor  156 . The seven piston tubes  288 , with pistons  278  fixed to the ends, are press fitted in ports  20 - 34 . The positioning of the piston tubes  288  thus correlate with the positions of the slots  300  through the pad  294  on the working face  292  (see FIG. 8). These pistons fit in the piston chambers  280  in the manifold support  282 . As air is transmitted through the manifold  248 , the majority of the air is fed into the slots  300 , into the ports  266  on the rotor  156  and then into the knockout rams  54 . Air is also fed back through each of the piston tubes  288  into the piston chamber  280 . This feedback then forces the piston faces, and thus the manifold  248 , onto the working face  268  of the rotor  156  to create an air tight seal. There are also springs (not shown) adjacent to four of the chambers  280  to press the manifold  248  against the rotor  156  if no cans are present. Note also that there are different loads exerted between the manifold  248  and the rotor  156  via the pistons around the manifold, depending on the pressure of the air being metered through each slot  300 . This has the effect of applying the most load to the areas of the rotor  156  where the greatest sealing forces are required, i.e., in the areas of high pressure. Once air flow starts, the air pressure under each piston seals the manifold face.  
         [0045]    The piston bores  280  are deep enough to allow for a 0.400″ adjustment of neck depth. There will always be a seal between the manifold  248  and the rotor  156 , irrespective of the position of the rotor relative to the manifold plate  262 . In a preferred embodiment, the spacing between the slots is about 0.040″ smaller than the diameter of the opening of the ports in the rotor  156 . This is to prevent can collapse due to no internal air pressure being present at machine start-up, i.e., it is not possible for any rotor ports to be starved of air.  
         [0046]    The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The drawings and description were chosen in order to explain the principles of the invention and its practical application. It is intended that the scope of the invention be defined by the claims appended hereto, and their equivalents.