Vacuum Manifold Having Dual Timing Adjustability for Process Turret

The disclosed concept relates generally to apparatus for manufacturing containers, such as necker machines for necking can bodies and, more particularly, to vacuum manifold assemblies for use with process turrets of such apparatus.

Metal beverage cans are designed and manufactured to withstand high internal pressure-typically 90-100 psi. Can bodies are commonly formed from a metal blank that is first drawn into a cup. The sides of the cup are ironed to a desired can wall thickness and height and the bottom of the cup is formed into a dome. After the can is filled, a can end is placed onto the open can end and affixed with a seaming process.

It has been the conventional practice to reduce the diameter at the top of the can in a process referred to as necking. Cans may be necked in a “spin necking” process in which cans are rotated with rollers that reduce the diameter of the neck. Most cans are necked in a “die necking” process in which cans are longitudinally pushed into dies to gently reduce the neck diameter over several stages. For example, reducing the diameter of a can neck from a conventional body diameter of 2 11/16th inches to 2 2/16th inches (that is, from a 211 to a 202 size) typically requires multiple necking stages, often 12.

Each of the necking stages are typically carried out in a station that includes a main process turret that includes a starwheel for holding the can bodies, a die assembly that includes the tooling for reducing the diameter of the open end of the can, and a pusher ram having a pusher pad which couples to the can via vacuum prior to pushing the can into the die tooling. Each necking stage also typically includes a transfer turret assembly that receives can bodies from a previous or upstream stage and delivers the can bodies to the aforementioned process turret which, after processing, delivers the cans to the transfer turret of an adjacent downstream station.

While the vacuum start and abatement locations for transferring cans to/from a process turret may provide for accurate transfers at a given rotational speed, the capability to operate die necking processes at different speeds has become desirable to control the quantity of can bodies produced over a given period of time. Unfortunately, changing the rotational speed of the process turret can remove the exit and intake pockets from proper operational alignment due to the resulting change(s) in transfer times, which can cause can bodies to be dropped or crushed during operation, and may use the vacuum ineffectively by providing a period during which vacuum force is applied but no can is located near the pusher pad or a period in which vacuum force is applied too long thus inhibiting transfer of the can from the pusher pad.

Embodiments of the disclosed concept address shortcomings in conventional arrangements by providing robust solutions for independently adjusting on and off vacuum timing in a transfer turret for different operating speeds. As one aspect of the disclosed concept, a vacuum manifold assembly for use in a station of a necker machine is provided. The vacuum manifold assembly comprises: a housing of annular shape positioned about a central axis, the housing being structured to be fixedly coupled to a fixed subframe adjacent a rotatable process turret of the station, the housing comprising: a first end face disposed perpendicular to the central axis; an annular trough defined in the housing spaced about the central axis, the annular trough extending a depth into the housing axially along the central axis from a trough top at the first end face to a trough base; and a number of vacuum inlets defined in the housing and opening into the annular trough, each vacuum inlet being structured to communicate a vacuum to the trough from a source of vacuum pressure; a first adjustment member positioned in the trough and adjustably coupled to the housing among a first plurality of positions, the first adjustment member having an end face sized and configured to close off a first portion of the trough; and a second adjustment member positioned in the trough and adjustably coupled to the housing among a second plurality of positions independent of the first adjustment member, the second adjustment member having an end face sized and configured to close off a second portion of the trough, wherein the first end face of the housing is structured to sealingly engage with the rotatable process turret such that the top of the trough is sealed by the rotatable process turret, wherein the end face of the first adjustment member and the end face of the second adjustment member delineate the trough into two portions: an active vacuum zone and an inactive vacuum zone, the active vacuum zone being the portion of the trough between the end face of the first adjustment member and the end face of the second adjustment member having the number of vacuum inlets opening therein, wherein an angular starting point of the active vacuum zone is adjustable by adjusting the positioning of the first adjustment member, and wherein an angular ending point of the active vacuum zone is adjustable by adjusting the positioning of the second adjustment member.

The housing may comprise a backer plate and a manifold plate coupled to the backer plate, the manifold plate may comprise the first end surface and define the trough, and the first adjustment member and the second adjustment member may be adjustably coupled to the backer plate.

The number of vacuum inlets may open into the base of the trough.

The number of vacuum inlets may comprise a plurality of vacuum inlets circumferentially spaced along the vacuum zone.

The housing may comprise an outward extending flange opposite the first end face, wherein the housing is structured to be fixedly coupled to the fixed subframe of the station via the outward extending flange.

As another aspect of the disclosed concept a station for use in a necker machine is provided. The station comprises: a subframe; a process turret rotatably coupled to the subframe and structured to be rotated about a rotation axis by a drive assembly of the necker machine, the process turret having a plurality of vacuum conduits defined therein, each vacuum conduit extending from a respective opening defined in an end face of the process turret positioned perpendicular to the rotation axis to an arrangement for receiving a can body for processing; and a vacuum manifold assembly comprising: a housing of annular shape positioned about a central axis aligned with the rotation axis of the process turret, the housing fixedly coupled to the subframe adjacent the end face of the process turret, the housing comprising: a first end face disposed perpendicular to the central axis; an annular trough defined in the housing spaced about the central axis, the annular trough extending a depth into the housing axially along the central axis from a trough top at the first end face to a trough base; and a number of vacuum inlets defined in the housing and opening into the annular trough, each vacuum inlet being structured to communicate a vacuum to the trough from a source of vacuum pressure; a first adjustment member positioned in the trough and adjustably coupled to the housing among a first plurality of positions, the first adjustment member having an end face sized and configured to close off a first portion of the trough; and a second adjustment member positioned in the trough and adjustably coupled to the housing among a second plurality of positions independent of the first adjustment member, the second adjustment member having an end face sized and configured to close off a second portion of the trough, wherein the first end face of the housing is sealingly engaged with the end face of the process turret such that the top of the trough is sealed by the process turret, wherein the end face of the first adjustment member and the end face of the second adjustment member delineate the trough into two portions: an active vacuum zone and an inactive vacuum zone, the active vacuum zone being the portion of the trough between the end face of the first adjustment member and the end face of the second adjustment member having the number of vacuum inlets opening therein, wherein an angular starting point of the active vacuum zone is adjustable by adjusting the positioning of the first adjustment member, wherein an angular ending point of the active vacuum zone is adjustable by adjusting the positioning of the second adjustment member, and wherein the respective openings of the vacuum conduits of the process turret aligned with the active vacuum zone communicate the vacuum to the arrangement for receiving the can body for processing associated therewith.

The housing may comprise a backer plate and a manifold plate coupled to the backer plate, the manifold plate may comprise the first end surface and define the trough, and the first adjustment member and the second adjustment member may be adjustably coupled to the backer plate. The number of vacuum inlets may open into the base of the trough. The number of vacuum inlets may comprise a plurality of vacuum inlets circumferentially spaced along the vacuum zone. The housing may comprise an outward extending flange opposite the first end face, the housing may be structured to be fixedly coupled to the fixed subframe of the station via the outward extending flange.

As yet a further aspect of the disclosed concept, a necker machine for use in forming can bodies is provided. The necker machine comprises: a drive assembly; and a plurality of stations, wherein one or more of the plurality of stations comprises a station 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 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 provided for the purpose of illustration and description only and are not intended as a definition of the limits of the disclosed concept.

It is to be appreciated that the specific elements illustrated in the drawings and described herein are simply exemplary embodiments of the disclosed concept. Accordingly, specific dimensions, orientations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.

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

As used herein, the 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 employed herein, the term “can” refers 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 cans, as well as cans used for food.

As used herein, “coupled” means a link between two or more elements, whether direct or indirect, so long as a link occurs. 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, “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, “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. The fixed components may, or may not, be directly coupled.

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

As used herein, “associated” means that the identified components are related to each other, contact each other, and/or interact with each other. For example, an automobile has four tires and four hubs, each hub is “associated” with a specific tire.

As used herein, “engage,” when used in reference to gears or other components having teeth, means that the teeth of the gears interface with each other and the rotation of one gear causes the other gear to rotate as well.

As employed herein, the term “number” shall mean one or an integer greater than one (i.e., a plurality).

A necker machine, such as shown in the example embodiment of. is structured to reduce the diameter of a portion of a can body. Necker machineis of similar construction and operates in a similar manner as necker machines such as, for example, without limitation, described in U.S. Pat. Nos. 11,370,015 and 11,565,303 commonly assigned to the same assignee as the present application except for the vacuum manifold arrangements described herein and components related thereto. Accordingly, only a general overview of major components of necker machineand the general operation thereof is provided herein.

The necker machineincludes a plurality of stations including an infeed stationhaving an infeed assemblyfor receiving can bodiesto the necker machine, an outfeed stationhaving an outfeed assemblyfor passing can bodies from the necker machine, and a plurality of processing/forming stationspositioned therebetween for carrying out processing steps on the can bodies passing along the necker machine. The necker machinefurther includes a transfer assembly, and a drive assembly shown generally at. Hereinafter, processing/forming stationsare identified by the term “processing stations” and refer to generic processing stations. As is known, the processing stationsare disposed adjacent to each other and in series. That is, the can bodiesbeing processed by the necker machineeach move from an upstream location starting at the infeed stationand through a series of processing stationsin the same sequence before exiting via the outfeed station. The can bodiesfollow a path, hereinafter, the “work path” (). That is, the necker machinedefines the work pathwherein can bodiesmove from an “upstream” location (i.e., closer to the infeed station) to a “downstream” location (i.e., closer to the outfeed station). Hereinafter, infeed station, outfeed station, and processing stationsare also referred to individually as a “station”, and/or collectively as “stations”, of the necker machine. With regard to elements that define the work path, each of those elements have an “upstream” end and a “downstream end” wherein the can bodiesmove from the “upstream” end to the “downstream end.” Thus, as used herein, the nature/identification of an element, assembly, sub-assembly, etc. as an “upstream” or “downstream” element or assembly, or, being in an “upstream” or “downstream” location, is inherent. Further, as used herein, the nature/identification of an element, assembly, sub-assembly, etc. as an “upstream” or “downstream” element or assembly, or, being in an “upstream” or “downstream” location, is a relative term.

Each processing stationhas a similar width W () and the can bodyis processed and/or formed (or partially formed), i.e., “necked”, as the can bodymoves generally across the width W. Generally, the processing/forming in each processing stationoccurs in/on a process turretthat includes a process shaft. The process shaft, and thus the process turret, is structured to be rotated about a rotation axisby the drive assembly of the necker machine. Each processing stationincludes a non-vacuum starwheel. 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 the starwheel pockets. Further, each processing stationtypically includes one turretand one non-vacuum starwheel.

It is noted that the plurality of processing stationsare structured to neck different types of can bodiesand/or to neck can bodies in different configurations. Thus, the plurality of processing stationsare structured to be added and removed from the necker machinedepending upon the need. To accomplish this, the necker machineincludes a frame assembly (shown generally at) to which the plurality of processing stationsand the infeed and outfeed stationsandare removably coupled. Alternatively, the frame assemblyincludes elements incorporated into each of the plurality of processing stationsand infeed and outfeed stationsandso that the plurality of processing stationsand infeed and outfeed assembliesandare structured to be temporarily coupled to each other.

The frame assemblyhas an upstream endand a downstream end. Further, the frame assemblyincludes 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.” Generally, each processing stationis structured to partially form (i.e., neck) the can bodyso as to reduce the cross-sectional area of an open end of a can bodya predetermined amount. The processing stationsinclude some elements that are unique to a single processing station, such as, but not limited to, a specific die. Other elements of the processing stationsare common to all, or most, of the processing stations.

The transfer assemblyis structured to move the can bodiesbetween adjacent processing stations, and typically between process turretsof adjacent processing stations. As shown in the example embodiment of, the transfer assemblyincludes a plurality of transfer turrets. Each transfer turretincludes a transfer starwheelrotatable about a rotation axis. The transfer starwheelis configured to transfer can bodiesto/from a given processing stationor between processing stationsas the starwheelrotates about axisin a direction as shown by arrow. Although shown as rotating in a counter-clockwise direction (i.e., a right-handed machine) in the example discussed herein, it is to be appreciated that arrangements of the disclosed concept may be likewise applied to arrangements rotating in a clockwise direction (i.e., a left-handed machine) without varying the scope of the disclosed concept. The transfer starwheelis generally circular in shape and includes a plurality of peripheral pocketsdisposed about an outer periphery (not numbered) of the transfer starwheel. Each pocketis adapted to receive a can bodyand includes a vacuum port (not numbered) for conveying a vacuum pressure/force to hold a can bodyin each pocketof the transfer starwheelwhile each can bodyis transported by the transfer starwheelfrom an infeed point IP (shown generally in) of the transfer starwheelwherein a can bodyis received in a particular pocket from an upstream process turret(or other arrangement), to an outfeed point OP (also shown generally in) wherein the can bodypreviously received in the particular pocket is released/transferred from the pocket to a downstream process turret(or other arrangement).

Referring now to, an example processing stationin the form of a necking station having a vacuum manifold assemblyin accordance with an example embodiment of the disclosed concept will now be discussed. As previously discussed, processing stationincludes process turretincluding the process shaftthat is structured to be rotated about the rotation axis. More particularly, the process turret/shaftis/are rotatably coupled to a subframeof the processing stationthat is fixedly coupled with the frame assembly(previously discussed) and/or forms a part of the frame assembly. The process turretreceives can bodiesfrom the transfer starwheelof transfer turret. Like other conventional arrangements, during such transfer each can bodymoves from being held in a pocketof the transfer starwheelby a vacuum arrangement thereof to being held by another vacuum arrangement to a push padof a pusher assembly(only one is shown in the example of) which engages and disengages the can body with a necking die (not numbered) of the processing turret. As shown in the detail view of, the process turretincludes a plurality of vacuum conduits (not numbered) defined therein, of the process turretthat is positioned perpendicular to the rotation axiseach vacuum conduit extending from a respective openingdefined in an end faceto an arrangement for receiving a can body for processing (e.g., push pad).

The vacuum manifold assemblyreceives vacuum pressure from a vacuum source (not numbered) via a number of conduits(e.g., hoses) and controls the angular locations during rotation about the rotation axisthat the openingsprovided in end face(and thus the conduits extending therefrom) are initially subjected to, and when they subsequently are isolated from, vacuum pressure. Referring now to, the vacuum manifold assemblyincludes a housingof annular shape positioned about a central axis. Housingis structured to be fixedly coupled to subframeadjacent rotatable end faceof process turret(as discussed further below) with the central axisaligned with the rotation axisof the process turret. Housingis formed from a suitable metal or other rigid material and includes a first (inner) end facedisposed perpendicular to the central axisand an opposite second (outer) end face. A number of vacuum portsare provided on the second end facefor coupling with the conduitspreviously discussed. Housingfurther includes an annular troughdefined in the housingand spaced about the central axis. The annular troughextends a depth d into the housingaxially along the central axisfrom a trough topat the first end faceto a trough base. Housingfurther includes a number of vacuum inletsdefined in the housing and opening into the annular trough. Each vacuum inletis structured to communicate a vacuum to the troughfrom a conduit(shown in hidden line in) defined within housingextending from a corresponding vacuum port(which receives vacuum from a vacuum source via a conduitsuch as previously discussed). In an example embodiment, the number of vacuum inletsopen into the tough base. In an example embodiment, the number of vacuum inletscomprise a plurality of vacuum inlets circumferentially spaced along a portion of the trough.

Continuing to refer to, vacuum manifold assemblyfurther includes a first adjustment memberand a second adjustment member. The first adjustment memberis positioned in the troughand adjustably coupled to the housingamong a first plurality of positions. The first adjustment memberincludes an end facethat is sized and configured to close off (i.e., functions generally as a dam) a first portion of the trough. In the example embodiment shown in, the first adjustment memberincludes a base portionand an upright portionwith the base portionhaving an elongated arcuate slotdefined therein for receiving a fastening elementtherethough (e.g., an Allen bolt or other suitable fastener) for adjustably coupling the first adjustment memberto the housing. In such example, the upright portionincludes the end face. The second adjustment memberis positioned in the troughand adjustably coupled to the housingamong a second plurality of positions independent of the first adjustment member. The second adjustment memberincludes an end facethat is sized and configured to close off (i.e., functions generally as a dam) a second portion of the trough. In the example embodiment shown inthe second adjustment memberis generally a block of uniform thickness having a first slotand a second slotdefined therein for receiving fastening elementsandtherethough (e.g., Allen bolts or other suitable fasteners) for adjustably coupling the second adjustment memberto the housing. It is to be appreciated that such particular examples of first and second adjustment members are provided for exemplary purposes only and that variations thereof may be employed without varying from the scope of the disclosed concept. It is also to be appreciated that in such example embodiment the housingis a multi-piece assembly including a backer plateA, a manifold plateB which includes the first end surfaceand defines the troughand is coupled to the backer plateA, and a mounting bodyC which includes an outward extending flangefor fixedly coupling the housingto the subframeof the station. In such arrangement the first adjustment memberand the second adjustment memberare adjustably coupled to the backer plateA.

When the vacuum manifold assemblyis installed on the process station(i.e., when housingis fixedly coupled to subframeadjacent rotatable end faceof process turret) such as shown in, the first end faceof the housingis sealingly engaged with the end faceof the process turretsuch that the topof the troughis sealed by the end faceof the process turret, thus creating a vacuum manifold in the troughbounded by the first and second end facesandof the first and second adjustment membersand. In other words, the end faceof the first adjustment memberand the end faceof the second adjustment memberdelineate the troughinto two portions: an active vacuum zoneand an inactive vacuum zone; the active vacuum zonebeing the portion of the troughbetween the end faceof the first adjustment memberand the end faceof the second adjustment memberhaving the number of vacuum inletsopening therein. It is to be appreciated that such arrangement provides for an angular starting point (i.e., end faceof first adjustment member) of the active vacuum zoneto be adjustable by adjusting the positioning of the first adjustment member; and for an angular ending point (i.e., end faceof the second adjustment member) of the active vacuum zoneto be adjustable by adjusting the positioning of the second adjustment member. During operation of the process turret, the respective openingsof the vacuum conduits of the process turretthat are aligned with the active vacuum zonecommunicate the vacuum to the arrangement for receiving the can body (i.e., push pad) for processing associated therewith, while the respective openingof the vacuum conduits of the process turretthat are not aligned with the active vacuum zoneand instead are aligned with the inactive vacuum zone do not communicate a vacuum to the arrangement associated therewith.

illustrate another example of a vacuum manifold assembly′ having the same functionality as vacuum manifold assemblyemployed in conjunction with a waxer arrangementof an infeed stationfor a necker machinesuch as previously discussed in regard to.

From the foregoing examples it is thus to be appreciated that embodiments of the disclosed concept provide arrangements that allow independent adjustment of both the infeed and outfeed vacuum timing on a process turret on a necker machine to ensure that: can bodies are fully suctioned to the process turret push pad while the can is aligned with the push pad at the transfer point into the process turret, can bodies are fully suctioned to the process turret push pad before the necking process begins, and that can bodies are released from push pad suction in time for proper transfer out of the process turret onto the proceeding transfer turret. As the speed of the necking machine increases, adjustment of vacuum timing allows the effective “on” and “off” time of the vacuum to stay the same relative to the transfer point between the transfer turret and the process turret. Such arrangement ensures consistent performance of the necker machine at various speeds.

While specific embodiments of the invention 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 any 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. The mere fact that certain elements are recited in mutually different dependent claims does not indicate that these elements cannot be used in combination.