Selectively Disengageable Drive Arrangement

This application claims priority to U.S. Patent Application Ser. No. 63/657,209, filed Jun. 7, 2024, entitled, Selectively Disengageable Drive Arrangement.

The disclosed concept relates generally to drive arrangements and, more particularly, to drive arrangements for necker machines. The disclosed concept further relates to necker machines having such drive arrangements.

Can bodies are, typically, formed in a bodymaker. That is, a bodymaker forms blanks such as, but not limited to, disks or cups into an elongated can body. A can body includes a base and a depending sidewall. The sidewall is open at the end opposite the base. The bodymaker, typically, includes a ram/punch that moves the blanks through a number of dies to form the can body. The can body is ejected from the ram/punch for further processing such as, but not limited to, trimming, washing, printing, flanging, and inspecting, before being placed on pallets which are then shipped to a filler. At the filler, the cans are taken off of the pallets, filled, have ends placed on them, and then are typically repackaged in various quantities (e.g., six packs, twelve pack or other multi-can cases, etc.) for sale to the consumer.

Some can bodies after being formed in a bodymaker are further formed in a die necking machine, commonly referred to as simply a necker machine. Necker machines are structured to reduce the cross-sectional area of a portion of a can body sidewall, i.e., at the open end of the sidewall. That is, prior to coupling a can end to the can body (and prior to filling), the diameter/radius of the can body sidewall open end is reduced relative to the diameter/radius of other portions of the can body sidewall. The necker machine includes a number of processing and/or forming modules disposed in series. That is, the processing and/or forming modules are disposed adjacent to each other and a transfer assembly moves a can body between adjacent processing and/or forming modules. As the can body moves through the processing and/or forming modules the can body is processed or formed.

Some die necking machine configurations require a large number of necking modules. The rotational position of each module must be kept in sync with adjacent modules, which is typically accomplished through the use of a gear train that effectively connects/drives all of the other modules. Such gear train is typically driven only at one end. The gear tooth load at the aforementioned driven end of the gear train is very high, whereas load on the opposite end of the gear train is low. This results in uneven gear wear along the gear train and requires the majority of gears in the train to be oversized which incurs additional and unnecessary expense.

These needs, and others, are met by embodiments of the disclosed concept which, in one aspect provides a drive arrangement for a necker machine having a frame assembly and a plurality of modules, each module having a number of drive shafts. The drive arrangement comprises: a plurality of control motors, each control motor of the plurality of control motors structured to be operatively engaged with a drive shaft of the number of drive shafts of a respective module of the plurality of modules, each control motor structured to be electrically connected to a power bus of a number of power buses; a control unit in communication with each control motor of the plurality of control motors, the control unit structured to control operation of each control motor of the plurality of control motors; and a number of voltage sensors in communication with the control unit, each voltage sensor structured to detect voltage in a corresponding power bus of the number of power buses, wherein the control unit is programmed to: monitor, via the number of voltage sensors, the voltage in each power bus of the number of power buses during operation of the necker machine.

The control unit may be further programmed to: determine that the voltage of at least one power bus of the number of power buses has dropped below a predetermined threshold; and begin a shutdown sequence of the plurality of control motors responsive to determining that the voltage has dropped below the predetermined threshold.

The control unit may be further programmed to bring the plurality of control motors to a stop in a timed positioning.

The control unit may be further programmed to: determine that the voltage of each power bus of the number of power buses has returned above the, or another, predetermined threshold;

and resume operation of the necker machine.

Each control motor may comprise a servo motor having an associated electrical drive electrically connected thereto, each electrical drive may be structured to drive the servo motor associated therewith; and the control unit may be in communication with the electrical drive of each servo motor.

The drive shaft to which each respective control motor is structured to be operatively engaged may be one of a primary drive shaft structured to drive a processing arrangement of a respective module of the plurality of modules or a secondary drive shaft structured to drive a transfer arrangement of the respective module.

The control unit may be structured to: electronically selectively couple the plurality of control motors such that a rotational timing position of each of the drive shafts to be operatively engaged therewith are locked in sync; and operate the plurality of control motors in a synchronized timed manner.

The control unit may be further structured to: electronically selectively uncouple a number of control motors of the plurality of control motors from other control motors of the plurality of control motors; and operate the number of control motors independently of the other control motors.

As another aspect of the disclosed concept, a necker machine is provided. The necker machine comprises: a frame assembly; a plurality of modules coupled to the frame assembly, each module having a number of drive shafts, and a drive arrangement comprising: a number of power buses; a plurality of control motors, each control motor of the plurality of control motors operatively engaged with a drive shaft of the number of drive shafts of a respective module of the plurality of modules, each control motor electrically connected to a power bus of the number of power buses; a control unit in communication with each control motor of the plurality of control motors, the control unit structured to control operation of each control motor of the plurality of control motors; and a number of voltage sensors in communication with the control unit, each voltage sensor structured to detect voltage in a corresponding power bus of the number of power buses, wherein the control unit is programmed to: monitor, via the number of voltage sensors, the voltage in each power bus of the number of power buses during operation of the necker machine.

The control unit may be further programmed to: determine that the voltage of at least one power bus of the number of power buses has dropped below a predetermined threshold; and begin a shutdown sequence of the plurality of control motors responsive to determining that the voltage has dropped below the predetermined threshold.

The control unit may be further programmed to bring the plurality of control motors to a stop in a timed positioning.

The control unit may be further programmed to: determine that the voltage of each power bus of the number of power buses has returned above the, or another, predetermined threshold; and resume operation of the necker machine.

Each control motor may comprise a servo motor having an associated electrical drive electrically connected thereto, each electrical drive structured to drive the servo motor associated therewith; and the control unit may be in communication with the electrical drive of each servo motor.

The drive shaft to which each respective control motor is operatively engaged may be one of a primary drive shaft structured to drive a processing arrangement of a respective module of the plurality of modules or a secondary drive shaft structured to drive a transfer arrangement of the respective module.

The control unit may be structured to: electronically selectively couple the plurality of control motors such that a rotational timing position of each of the drive shafts to be operatively engaged therewith are locked in sync; and operate the plurality of control motors in a synchronized timed manner.

The control unit may be further structured to: electronically selectively uncouple a number of control motors of the plurality of control motors from other control motors of the plurality of control motors; and operate the number of control motors independently of the other control motors.

The number of power buses may comprise a plurality of power buses.

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 will be appreciated that the specific elements illustrated in the figures herein and described in the following specification are simply exemplary embodiments of the disclosed concept, which are provided as non-limiting examples solely for the purpose of illustration. Therefore, specific dimensions, orientations, assembly, quantity of components used, embodiment configurations and other physical characteristics related to the embodiments disclosed herein are not to be considered limiting on the scope of the disclosed concept.

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

As used herein, the singular form of “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.

As used herein, “structured to [verb]” means that the identified element or assembly has a structure that is shaped, sized, disposed, coupled and/or configured to perform the identified verb. For example, a member that is “structured to move” is movably coupled to another element and includes elements that cause the member to move or the member is otherwise configured to move in response to other elements or assemblies. As such, as used herein, “structured to [verb]” recites structure and not function. Further, as used herein, “structured to [verb]” means that the identified element or assembly is intended to, and is designed to, perform the identified verb. Thus, an element that is merely capable of performing the identified verb but which is not intended to, and is not designed to, perform the identified verb is not “structured to [verb].”

As used herein, “associated” means that the elements are part of the same assembly and/or operate together, or, act upon/with each other in some manner. For example, an automobile has four tires and four hub caps. While all the elements are coupled as part of the automobile, it is understood that each hubcap is “associated” with a specific tire.

As used herein, a “coupling assembly” includes two or more couplings or coupling components. The components of a coupling or coupling assembly are generally not part of the same element or other component. As such, the components of a “coupling assembly” may not be described at the same time in the following description.

As used herein, a “coupling” or “coupling component(s)” is one or more component(s) of a coupling assembly. That is, a coupling assembly includes at least two components that are structured to be coupled together. It is understood that the components of a coupling assembly are compatible with each other. For example, in a coupling assembly, if one coupling component is a snap socket, the other coupling component is a snap plug, or, if one coupling component is a bolt, then the other coupling component is a nut or threaded bore. Further, a passage in an element is part of the “coupling” or “coupling component(s).” For example, in an assembly of two wooden boards coupled together by a nut and a bolt extending through passages in both boards, the nut, the bolt and the two passages are each a “coupling” or “coupling component.”

As used herein, a “fastener” is a separate component structured to couple two or more elements. Thus, for example, a bolt is a “fastener” but a tongue-and-groove coupling is not a “fastener.” That is, the tongue-and-groove elements are part of the elements being coupled and are not a separate component.

As used herein, the statement that two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, “directly coupled” means that two elements are coupled in direct contact with each other. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other. As used herein, “adjustably fixed” means that two components are coupled so as to move as one while maintaining a constant general orientation or position relative to each other while being able to move in a limited range or about a single axis. For example, a doorknob is “adjustably fixed” to a door in that the doorknob is rotatable, but generally the doorknob remains in a single position relative to the door. Further, a cartridge (nib and ink reservoir) in a retractable pen is “adjustably fixed” relative to the housing in that the cartridge moves between a retracted and extended position, but generally maintains its orientation relative to the housing. Accordingly, when two elements are coupled, all portions of those elements are coupled. A description, however, of a specific portion of a first element being coupled to a second element, e.g., an axle first end being coupled to a first wheel, means that the specific portion of the first element is disposed closer to the second element than the other portions thereof. Further, an object resting on another object held in place only by gravity is not “coupled” to the lower object unless the upper object is otherwise maintained substantially in place. That is, for example, a book on a table is not coupled thereto, but a book glued to a table is coupled thereto.

As used herein, the phrase “removably coupled” or “temporarily coupled” means that one component is coupled with another component in an essentially temporary manner. That is, the two components are coupled in such a way that the joining or separation of the components is easy and would not damage the components. For example, two components secured to each other with a limited number of readily accessible fasteners, i.e., fasteners that are not difficult to access, are “removably coupled” whereas two components that are welded together or joined by difficult to access fasteners are not “removably coupled.” A “difficult to access fastener” is one that requires the removal of one or more other components prior to accessing the fastener wherein the “other component” is not an access device such as, but not limited to, a door.

As used herein, “operatively coupled” means that a number of elements or assemblies, each of which is movable between a first position and a second position, or a first configuration and a second configuration, are coupled so that as the first element moves from one position/configuration to the other, the second element moves between positions/configurations as well. It is noted that a first element may be “operatively coupled” to another without the opposite being true.

As used herein, the statement that two or more parts or components “engage” one another means that the elements exert a force or bias against one another either directly or through one or more intermediate elements or components. Further, as used herein with regard to moving parts, a moving part may “engage” another element during the motion from one position to another and/or may “engage” another element once in the described position. Thus, it is understood that the statements, “when element A moves to element A first position, element A engages element B,” and “when element A is in element A first position, element A engages element B” are equivalent statements and mean that element A either engages element B while moving to element A first position and/or element A either engages element B while in element A first position.

As used herein, “operatively engage” means “engage and move.” That is, “operatively engage” when used in relation to a first component that is structured to move a movable or rotatable second component means that the first component applies a force sufficient to cause the second component to move. For example, a screwdriver may be placed into contact with a screw. When no force is applied to the screwdriver, the screwdriver is merely “temporarily coupled” to the screw. If an axial force is applied to the screwdriver, the screwdriver is pressed against the screw and “engages” the screw. However, when a rotational force is applied to the screwdriver, the screwdriver “operatively engages” the screw and causes the screw to rotate. Further, with electronic components, “operatively engage” means that one component controls another component by a control signal or current.

As used herein, “correspond” indicates that two structural components are sized and shaped to be similar to each other and may be coupled with a minimum amount of friction. Thus, an opening which “corresponds” to a member is sized slightly larger than the member so that the member may pass through the opening with a minimum amount of friction. This definition is modified if the two components are to fit “snugly” together. In that situation, the difference between the size of the components is even smaller whereby the amount of friction increases. If the element defining the opening and/or the component inserted into the opening are made from a deformable or compressible material, the opening may even be slightly smaller than the component being inserted into the opening. With regard to surfaces, shapes, and lines, two, or more, “corresponding” surfaces, shapes, or lines have generally the same size, shape, and contours.

As used herein, the 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 employed herein, the terms “can” and “container” are used substantially interchangeably to refer to any known or suitable container, which is structured to contain a substance (e.g., without limitation, liquid; food; any other suitable substance), and expressly includes, but is not limited to, beverage cans, such as beer and beverage cans, as well as food cans.

As used herein, “about” in a phrase such as “disposed about [an element, point or axis]” or “extend about [an element, point or axis]” or “[X] degrees about an [an element, point or axis],” means encircle, extend around, or measured around. When used in reference to a measurement or in a similar manner, “about” means “approximately,” i.e., in an approximate range relevant to the measurement as would be understood by one of ordinary skill in the art.

As used herein, a “drive assembly” means elements that are operatively coupled to the rotating shafts extending back to front in a processing module. A “drive assembly” does not include the rotating shafts extending back to front in a processing module.

As used herein, an “elongated” element inherently includes a longitudinal axis and/or longitudinal line extending in the direction of the elongation.

As used herein, “generally” means “in a general manner” relevant to the term being modified as would be understood by one of ordinary skill in the art.

As used herein, “substantially” means “for the most part” relevant to the term being modified as would be understood by one of ordinary skill in the art.

As used herein, “at” means on and/or near relevant to the term being modified as would be understood by one of ordinary skill in the art.

An example necker machinefor which a drive arrangement in accordance with the concepts disclosed herein may be employed is illustrated in. While a brief description of the general elements and operation of necker machineis provided herein, a detailed description of a similar necker machine and the operation thereof is provided in U.S. Pat. No. 11,370,015, the contents of which are incorporated by reference herein. Some other examples of necker machines for which drive arrangements in accordance with the concepts disclosed herein may be employed are described in, for example, without limitation, U.S. Pat. Nos. 8,464,567, 8,601,843, 9,095,888, 9,308,570, the contents of each being incorporated by reference herein.

As previously discussed in the Background above, the necker machineis structured to reduce the diameter of a portion of a can body, such as illustrated in. As used herein, to “neck” means to reduce the diameter/radius of a portion of a can body. That is, as shown in, a can bodyincludes a basewith an upwardly depending sidewall. The can body baseand can body sidewalldefine a generally enclosed space. In the embodiment discussed below, the can bodyis a generally circular and/or an elongated cylinder. It is understood that this is only one exemplary shape and that the can bodycan have other shapes. The can body has a longitudinal axis. The can body sidewallhas a first endand a second end. The can body baseis at the second end. The can body first endis open. The can body first endinitially has substantially the same radius/diameter as the can body sidewall. Following forming operations in the necker machine, the radius/diameter of the can body first endis smaller than the other portions of the radius/diameter at the can body sidewall.

Referring to, the necker machinegenerally includes a plurality of modules (shown generally at) coupled together in a side-by-side arrangement. While the example necker machineincludes six of such modules, it is to be appreciated that the quantity of modulesincluded in a given necker machine is generally dependent on details of the can body being processed/formed and the final desired geometry thereof and as such the quantity of modulesmay be varied without varying from the scope of the disclosed concept. The plurality of modulesincludes an infeed modulepositioned at a first end of the necker machine. The infeed moduleincludes an infeed assemblyfor receiving can bodies(e.g., see). The plurality of modulesalso includes a plurality of forming/processing modulesextending side by side in a series arrangement from the infeed module. The plurality of modulesconcludes with a discharge modulepositioned at the opposite end of the necker machine from the infeed modulesuch that the plurality of processing modulesare bounded by the infeed moduleand the discharge module. The discharge moduleincludes an exit assemblyfor discharging necked cans from the necker machine. Hereinafter, the processing/forming modulesare identified by the term “processing modules” and refer to generic processing modules. Each processing modulehas an overall width W () that is generally the same as all the other processing modules. Accordingly, it is to be appreciated that the length/space occupied by the necker machineis generally determined by the quantity of processing modulesutilized therein.

As is known, the processing modulesare disposed adjacent to each other and in series with the infeed moduleand discharge moduledisposed at opposite ends of the series of processing modules. That is, the can bodiesbeing processed by the necker machineeach move from an upstream location through a series of processing modulesin the same sequence. Movement of the can bodiesthrough the necker machineis carried out by a transfer assemblydriven by a drive arrangement() that are both included as portions of the necker machine.