U.S. patent application number 16/143766 was filed with the patent office on 2019-03-21 for forming apparatus.
The applicant listed for this patent is BELVAC PRODUCTION MACHINERY, INC.. Invention is credited to Terry Babbitt, Dennis Green, Nageswara Nagisetty.
Application Number | 20190084030 16/143766 |
Document ID | / |
Family ID | 48290406 |
Filed Date | 2019-03-21 |
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United States Patent
Application |
20190084030 |
Kind Code |
A1 |
Babbitt; Terry ; et
al. |
March 21, 2019 |
FORMING APPARATUS
Abstract
A rotatable forming apparatus and a method for modifying a shape
of a container. The rotatable forming apparatus includes a frame
and a forming turret assembly. The forming turret assembly connects
to the frame and includes a drive shaft, a fixed turret portion, a
turret starwheel, an axially moveable turret portion and forming
ram assemblies. The forming ram assemblies extend around and
connect to the axially movable turret portion. Each of the forming
ram assemblies includes cam followers, a forming die, a knockout
tooling device and a drive cylinder. The cam followers are
configured to follow a cam as the cam rotates. The forming die is
operatively connected to the cam followers such that the forming
die moves in the vertical direction while following the cam. The
drive cylinder causes axial movement of the knockout tooling device
and is configured to operate independently of the forming die.
Inventors: |
Babbitt; Terry; (Lynchburg,
VA) ; Nagisetty; Nageswara; (Lynchburg, VA) ;
Green; Dennis; (Lynchburg, VA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BELVAC PRODUCTION MACHINERY, INC. |
Lynchburg |
VA |
US |
|
|
Family ID: |
48290406 |
Appl. No.: |
16/143766 |
Filed: |
September 27, 2018 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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14357350 |
Oct 30, 2014 |
10166591 |
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PCT/US11/59866 |
Nov 9, 2011 |
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16143766 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B21D 51/2669 20130101;
B21D 51/2692 20130101; B21D 51/2646 20130101 |
International
Class: |
B21D 51/26 20060101
B21D051/26 |
Claims
1-17. (canceled)
18. A rotatable forming apparatus for modifying a shape of a
container, the apparatus comprising: a frame having a lower base
and an upper base; and a forming turret assembly connected to the
frame and including: a drive shaft extending in a vertical
direction along a longitudinal axis from the lower base to the
upper base, a first turret portion extending in the vertical
direction along the drive shaft; a vacuum supply, a turret
starwheel coaxial with the drive shaft, the turret starwheel having
a vacuum port thereon, the vacuum port being fluidly connected to
the vacuum supply, the turret starwheel being configured to hold
the container using suction received from the vacuum supply, a
second turret portion extending in the vertical direction along the
drive shaft and above the first turret portion, the second turret
portion including a cam, and forming ram assemblies extending
around and connected to the second turret portion, wherein each of
the forming ram assemblies includes: cam followers configured to
follow the cam as the forming ram assemblies rotate around the cam;
a forming die operatively connected to the cam followers such that
the forming die moves in the vertical direction while following the
cam; and a knockout tooling device.
19. The rotatable forming apparatus of claim 18, wherein the turret
starwheel further includes a channel portion, the vacuum port being
formed in the channel portion.
20. The rotatable forming apparatus of claim 18, wherein each of
the forming ram assemblies further comprises a drive cylinder that
causes axial movement of the knockout tooling device and is
configured to operate independently of the forming die.
21. The rotatable forming apparatus of claim 20, wherein the drive
cylinder includes an outer surface that connects to the forming die
and an inner surface that connects to the knockout tooling
device.
22. The rotatable forming apparatus of claim 20, wherein the drive
cylinder includes a drive cylinder shaft that extends parallel to
the drive shaft.
23. The rotatable forming apparatus of claim 18, wherein the
knockout tooling device includes a knockout tooling device shaft
that is coaxial to and extends around a guide cylinder shaft.
24. The rotatable forming apparatus of claim 18, wherein each of
the forming ram assemblies further includes at least two slide
blocks, a profiled rail extending through each of the at least two
slide blocks, and a drive cylinder configured to slide each of the
at least two slide blocks along the profiled rail in the vertical
direction.
25. The rotatable forming apparatus of claim 18, wherein the first
turret portion is a fixed turret portion and the second turret
portion is an axially movable turret portion, the axially movable
turret portion including an adjustment mechanism configured to
adjust the second turret portion in the vertical direction along
the drive shaft with respect to the first turret portion so as to
configure the forming turret assembly readily adjustable for
containers of different lengths.
26. The rotatable forming apparatus of claim 18, further comprising
a transfer turret assembly extending from and connected to the
lower base of the frame and including one of an infeed starwheel
that receives the container and transfers the container to the
turret starwheel and a transfer starwheel that receives the
container from the turret starwheel and transfers the container to
another turret starwheel.
27. The rotatable forming apparatus of claim 26, further comprising
a recirculation mechanism configured to receive the container and
return the container to the infeed starwheel.
28. The rotatable forming apparatus of claim 18, wherein the lower
base has a bottom surface and a generally opposing top surface, the
bottom surface contacting a support surface, the drive shaft
extending from the top surface of the lower base to the upper
base.
29. A method for modifying a shape of a container, comprising:
feeding the container into a first forming turret assembly that
includes a first turret portion having push ram assemblies
extending around and connected to the first turret portion, the
first turret portion including a first cam, each of the push ram
assemblies having a push ram cam follower configured to follow the
first cam, each of the push ram assemblies being configured to push
the container, a second turret portion having forming ram
assemblies extending around and connected to the second turret
portion, the second turret portion including a second cam, each of
the forming ram assemblies having a respective forming ram cam
follower configured to follow the second cam, each of the forming
ram assemblies further comprising a forming die operatively
connected to a respective forming ram cam follower; rotating the
first forming turret assembly such that the push ram cam followers
rotate around the first cam and such that the forming ram cam
followers rotate around the second cam, the rotating causing one of
the push ram assemblies and a respective one of the forming ram
assemblies to move toward one another, thereby pushing the
container into the respective forming ram assembly such that a
first forming operation is performed on the container; and
transferring the container from the first forming turret assembly
to a second forming turret assembly; and using the second turret
assembly to perform a second forming operation on the
container.
30. The method of claim 29, wherein each of the forming ram
assemblies including a first drive cylinder, a first forming die
and a first knockout tooling device, the method further comprising:
activating one of the first drive cylinders to cause axial movement
of the first knockout tooling device in a vertical direction; and
activating the first forming die independently of the activated
first drive cylinder to cause axial movement of the first forming
die in the vertical direction and rotational movement of the first
forming die.
31. The method of claim 29, wherein the first forming turret
assembly includes a drive shaft extending from a top surface of a
lower base, the top surface being generally opposite a bottom
surface, the bottom surface contacting a support surface.
32. The method of claim 29, further comprising re-circulating the
container to the first forming turret assembly.
33. A rotatable forming apparatus for modifying a shape of a
container, the apparatus comprising: a frame having a lower base
and an upper base; and a forming turret assembly connected to the
frame and including: a drive shaft extending in a vertical
direction along a longitudinal axis from the lower base to the
upper base, a first turret portion extending in the vertical
direction along the drive shaft, the first turret portion including
a first cam, the first turret portion further including push ram
assemblies extending around and connected to the first turret
portion, each of the push ram assemblies including a push ram cam
follower configured to follow the first cam as the push ram
assemblies rotate around the first cam such that the push ram
assemblies move in the vertical direction while following the first
cam, a turret starwheel coaxial with the drive shaft, and a second
turret portion extending in the vertical direction along the drive
shaft, the second turret portion including a second cam and cam
followers, the second turret portion further including forming ram
assemblies extending around and connected to the second turret
portion, each of the forming ram assemblies including a forming ram
cam follower configured to follow the second cam as the forming ram
assemblies rotate around the second cam, each of the forming ram
assemblies including a forming die operatively connected to the cam
followers such that the forming ram assemblies move in the vertical
direction while following the second cam.
34. The rotatable forming apparatus of claim 33, wherein each of
the forming ram assemblies further includes a knockout tooling
device and a drive cylinder that causes axial movement of the
knockout tooling device and is configured to operate independently
of the forming die.
35. The rotatable forming apparatus of claim 33, wherein the first
turret portion is generally fixed and the second turret portion is
axially movable, the second turret portion including an adjustment
mechanism configured to adjust the second turret portion in the
vertical direction along the drive shaft with respect to the first
turret portion so as to configure the forming turret assembly
readily adjustable for containers of different lengths.
36. The rotatable forming apparatus of claim 33, wherein the
rotatable forming apparatus further includes a vacuum supply, the
turret starwheel further comprising vacuum ports that fluidly
communicate with the vacuum supply, the turret starwheel being
configured to hold the container using suction received from the
vacuum supply.
37. The rotatable forming apparatus of claim 36, wherein the turret
starwheel further includes a channel portion, the vacuum ports
being formed in the channel portion.
38. The rotatable forming apparatus of claim 36, wherein the lower
base has a bottom surface and a generally opposing top surface, the
bottom surface contacting a support surface, the drive shaft
extending from the top surface of the lower base to the upper base.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a Continuation of U.S. application Ser.
No. 14/357,350, filed Oct. 20, 2014, which is a U.S. national stage
of International Patent Application No. PCT/US2011/059866, filed
Nov. 9, 2011, the contents of which are incorporated entirely
herein by reference.
FIELD OF EMBODIMENTS
[0002] The present embodiments relate generally to a rotating
forming apparatus for modifying a shape of a container and to a
method for modifying a shape of a container.
DESCRIPTION OF RELATED ART
[0003] Conventional forming apparatuses have been used to modify
the shape of a container (e.g. a can, food or beverage container,
jar). Limited components, such as the turret assembly, starwheels
and forming die, on conventional forming apparatus move in an
indexing manner such that indexing and forming are not performed
simultaneously. Indexing refers to moving a container to a first
fixed position, storing the container in the first fixed position
until a given process ends, moving the container from the first
fixed position to a second fixed position for the next process to
start and so on. As a result of indexing and forming not being
performed simultaneously, conventional forming apparatuses prevent
continuous high speed rotation of the forming apparatus.
Consequently, conventional forming apparatuses neck only about 200
containers per minute.
[0004] A need exits for a rotatable forming apparatus that modifies
the shape of a container and a method of modifying the shape of a
container that address one or more of the above described
disadvantages. A need also exists for a rotatable forming apparatus
that modifies the shape of a container and a method of modifying
the shape of a container that allows easy access to forming dies,
assembly and maintenance.
SUMMARY
[0005] One embodiment relates to a rotatable forming apparatus for
modifying a shape of a container that comprises a frame and a
forming turret assembly. The frame has a lower base and an upper
base. The forming turret assembly connects to the frame and
includes a drive shaft, a fixed turret portion, a turret starwheel,
an axially moveable turret portion and forming ram assemblies. The
drive shaft extends in a vertical direction along a longitudinal
axis from the lower base to the upper base. The fixed turret
portion extends in the vertical direction along the drive shaft.
The turret starwheel is coaxial with the drive shaft and is
configured to receive the container. The axially movable turret
portion extends in the vertical direction along the drive shaft and
above the fixed turret portion. The axially moveable turret portion
includes a cam and an adjustment mechanism configured to adjust the
axially moveable turret portion in the vertical direction along the
drive shaft with respect to the fixed turret portion so as to
configure the forming turret assembly readily adjustable for
containers of different lengths. The forming ram assemblies extend
around and connect to the axially movable turret portion. Each of
the forming ram assemblies includes cam followers, a forming die, a
knockout tooling device and a drive cylinder. The cam followers are
configured to follow the cam as the cam rotates. The forming die is
operatively connected to the cam followers such that the forming
die moves in the vertical direction while following the cam. The
drive cylinder causes axial movement of the knockout tooling device
and is configured to operate independently of the forming die.
[0006] Another embodiment relates to a method for modifying a shape
of a container. The method comprises feeding the container into a
first forming turret assembly that includes a first axially
moveable turret portion and first forming ram assemblies extending
around and connected to the first axially movable turret portion.
Each of the first forming ram assemblies includes a first drive
cylinder, a first forming die and a first knockout tooling device.
The method also comprises activating the first drive cylinder to
cause axial movement of the first knockout tooling device in a
vertical direction and activating the first forming die
independently of the activated first drive cylinder to cause axial
movement of the first forming die in the vertical direction and
rotational movement of the first forming die. Additionally, the
method comprises transferring the container from the first forming
turret assembly to a second forming turret assembly. The second
forming turret assembly includes a second axially moveable turret
portion and second forming ram assemblies extending around and
connected to the second axially movable turret portion. Each of the
second forming ram assemblies includes a second drive cylinder, a
second forming die that is different from the first forming die and
a second knockout tooling device. The method additionally comprises
activating the second drive cylinder to cause axial movement of the
second knockout tooling device in the vertical direction and
activating the second forming die independently of the activated
second drive cylinder to cause axial movement of the second forming
die in the vertical direction and rotational movement of the second
forming die.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] These and other features, aspects and advantages of the
disclosed embodiments will become apparent from the following
description, appended claims and the accompanying exemplary
embodiments shown in the drawings, which are briefly described
below.
[0008] FIG. 1a is a side view of a container before the container
enters the rotatable forming apparatus.
[0009] FIG. 1b is a front view of the container of FIG. 1a after
the container exits the rotatable forming apparatus.
[0010] FIG. 2 is a front elevated view of a portion of a rotatable
forming apparatus.
[0011] FIG. 3 is a cross-sectional view of FIG. 2 along line
3-3.
[0012] FIG. 4 is a top view of FIG. 2.
[0013] FIG. 5 is a cross-sectional view of a transfer turret
assembly, having a transfer starwheel or infeed starwheel of a
rotatable forming apparatus.
[0014] FIG. 6 is a top view of an infeed starwheel.
[0015] FIG. 7 is a top view of a transfer or discharge
starwheel.
[0016] FIG. 8 is a side view of a forming turret assembly of a
rotatable forming apparatus and a portion of the frame of the
rotatable forming apparatus.
[0017] FIG. 9 is a cross-sectional view of the forming turret
assembly of FIG. 8.
[0018] FIG. 10 is a detailed view of section 10 of FIG. 9.
[0019] FIG. 11 is a detailed view of section 11 of FIG. 8.
[0020] FIG. 12 is a ISO, partially exploded view of a forming ram
assembly, with a forming die and knockout tooling device, of a
rotatable forming apparatus.
[0021] FIG. 13 is a front, assembled view of the forming ram
assembly.
[0022] FIG. 14 is a side, assembled view of the forming ram
assembly of FIG. 13.
[0023] FIG. 15 is a bottom, assembled view of the forming ram
assembly of FIG. 12.
[0024] FIG. 16 is a view of FIG. 15 along line 16-16 where air
lines are not shown.
[0025] FIG. 17 is a cross-sectional view of FIG. 15 along line
17-17.
[0026] FIG. 18 is a ISO, exploded view of a push ram assembly of a
rotatable forming apparatus.
[0027] FIG. 19 is a front, assembled view of the push ram assembly
of FIG. 18.
[0028] FIG. 20 is a cross-sectional view of FIG. 19 along line
20-20.
[0029] FIG. 21 is a ISO, assembled view of the push ram assembly of
FIG. 18.
[0030] FIG. 22 is a top view of a rotatable forming apparatus for
an in-line system.
[0031] FIG. 23 is a schematic view of a machine arrangement with a
recirculation conveyor system according to an embodiment of the
invention.
DETAILED DESCRIPTION
[0032] Embodiments are illustrated in the drawings. The disclosure
relates to a rotatable forming apparatus for modifying a shape of a
container (e.g. a can, food or beverage container, jar) and a
method of modifying a shape of a container (e.g. a can, food or
beverage container, jar). For the purposes of this application, a
container may refer to one or more containers.
[0033] Machines may be used to form, process or otherwise perform
an action on a container 1 (FIGS. 1A and 1B) such that the shape of
the container 1 is modified from a first shape, such as shown in
FIG. 1A, to a second shape, such as shown in FIG. 1B. In a
multi-stage line, a container 1 is first fed into a first stage
(e.g. a rotatable forming apparatus) to enter pockets in a
turret/starwheel. Each starwheel may have any number of pockets to
hold containers for processing and transfer. For example, a
starwheel may have six, eight, ten, twelve, fourteen, sixteen,
eighteen, twenty pockets to hold six, eight, ten, twelve, fourteen,
sixteen, eighteen, twenty containers, respectively. It will be
recognized that the starwheel is capable of having one pocket up to
any suitable number of pockets. After exiting the first stage, the
container 1 may enter a second stage.
[0034] Once fed into the multi-stage line, the container 1 is
processed through any number of stages, e.g. a necking stage, a
curling stage, an expansion stage or any other suitable process or
forming stage. When the container passes through all
process/forming stages, the container is discharged from the
machine. In embodiments, the multi-stage line may be a
recirculating system or an in-line system 1100 (FIG. 22).
[0035] Referring to FIGS. 2-11, a rotatable forming apparatus 100
for modifying a shape of a container 1 may comprise a frame 202
(FIGS. 8-9) and a forming turret assembly 200 connected to the
frame 202. The frame 202 includes a lower base 10 and an upper base
1000 (FIGS. 2 and 8-9). The forming turret assembly 200 may include
a drive shaft 201 (FIG. 8), a fixed turret portion 216, a turret
starwheel 102, an axially moveable (e.g. adjustable) turret portion
215 forming ram assemblies 40. The forming turret assembly 200 may
also include push ram assemblies 20 (FIGS. 2-3, 8-9 and 11). The
fixed turret portion 216 may be referred to as a push ram block and
the axially moveable turret portion 215 may be referred to as a
forming ram block, an adjustable moveable turret portion or an
axially adjustable moveable turret portion.
[0036] In embodiments, the drive shaft 201 may extend in a vertical
direction 500, along a longitudinal axis 1001-1001 of the forming
turret assembly 200, from the lower base 10 to the upper base 1000
of the frame 202. The drive shaft 201 may connect to the lower base
10 and the upper base 1000 via any suitable connectors (e.g.
bearings, couplings, drive gear). The drive shaft 201 may support
the fixed turret portion 216 and the axially moveable turret
portion 215 (FIG. 8). The drive shaft 201 may be driven by a drive
mechanism 101 (FIG. 3). Cams 23, 43 may connect to a base support
located concentric to the drive shaft 201 where rotation of the
drive shaft 201 causes the reciprocating and satellite motion of
ram assemblies while interceding with the cams 23, 43. 270 degrees
of the cam 23 is used for the forming operation in each stage.
[0037] The fixed turret portion 216 extends in the vertical
direction 500 along the drive shaft 201. The fixed turret portion
216 is fixed so that the orientation (e.g. bottom line) of the
container 1 that enters and exits the rotatable forming apparatus
100 relative to the mechanism (e.g. infeed and discharge conveying
system), which helps move the container 1 through all stages of the
rotatable forming apparatus 100, does not change. This allows for
easier setup and control of the rotatable forming operation.
[0038] The turret starwheel 102 (FIG. 3) is coaxial with the drive
shaft 201. The turret starwheel 102 is configured to receive
containers 1 from an infeed starwheel 2 or a transfer starwheel 12
(FIGS. 3 and 6). The transfer starwheels 12 are configured to
receive the container 1 from the first stage process turret (e.g.
forming turret assembly) and feed the container to the next stage
process turret. The turret starwheel 102 may have any suitable
number of components (e.g. six, eight, ten, twelve). The components
may also be referred to as pockets. The turret starwheel 102 may
have any suitable number of components (e.g. six, eight, ten,
twelve) that a push ram assembly holds and may push the container 1
into a forming ram assembly in order to change the form/shape of
the container. The forming ram assembly may also be referred to as
a die ram assembly (FIGS. 12, 15-17) or expander ram assembly
(FIGS. 13-14). The die ram assembly may neck the container while
the expander ram assembly may expand the shape of the
container.
[0039] The axially movable turret 215 (FIG. 8) extends in the
vertical direction 500 along the drive shaft 201 and is above the
fixed turret portion 216. The forming ram assemblies are located on
the axially moveable turret portion 215. The forming ram assemblies
are communicate with a cam 43 that may connect to a base support
located concentric to the drive shaft 201 (FIG. 9) and is oriented
by a key connection with an upper bearing housing. Rotation of the
drive shaft 201 causes the cam 43 to rotate. The axially moveable
turret portion 215 may include an adjustment mechanism 70, 71, 72,
73, 74, 75, 205 (FIGS. 10-11). 270 degrees of the cam 43 is used
for the forming operation in each stage. The adjustment mechanism
70, 71, 72, 73, 74, 75, 205 is configured to adjust the axially
moveable turret portion 215 in the vertical direction 500 along the
drive shaft 201 with respect to the fixed turret portion 216 so as
to configure the forming turret assembly 200 readily adjustable for
containers 1 of different lengths.
[0040] The forming ram assemblies 40, 40a, 40b (FIGS. 12-17) extend
around and connect to the axially movable turret 215. Each of the
forming ram assemblies 40 connects to the outer circumferential
surface of the axially movable turret 215. Each of the forming ram
assemblies 40 includes at least two slide blocks 47, a profiled
rail 48 extending through each of the at least two slide blocks 47
and a drive cylinder 46 configured to slide each of the at least
two slide blocks 47 along the profiled rail 48 in the vertical
direction 500.
[0041] Each of the slide blocks 47 includes ball bearings (not
shown). The slide blocks 47 are configured to slide along the
profiled rail 48 such that the forming ram assembly 40 moves up and
down in the vertical direction 500 with respect to the fixed turret
portion 216 and the axially moveable turret portion 215. A
conventional forming ram assembly includes only one slide block.
The increased number of slide blocks 47 of the disclosed forming
ram assembly 40 allows for the forming assembly 100 to provide for
a longer stroke distance of the forming ram assembly 40 and to
increase the stability and life of the forming ram assembly. Each
of the slide blocks 47 includes ball bearings (not shown).
[0042] The profiled rail 48 connects to the axially moveable turret
portion 215 via connectors (e.g. nuts and bolts). The rail is
"profiled" due to its shape. The rail 48 is cut or formed into the
outline shown in FIGS. 12 and 14 and, therefore, is a profiled
rail. Alternatively, the rail 48 may be cut or formed into any
other suitable shape (profile). For example, the rail 48 may be
formed to have a rectangular shape with grooves or ridges (FIGS. 12
and 14), a single rounded profile or a combination of rounded
curves and angular or flat portions.
[0043] Each of the forming ram assemblies 40 also includes an
adapter 58 (FIG. 14) that mounts to a bracket 68 (FIG. 12) which is
attached to the slide blocks 47. One end 558 of the adapter 58
includes provisions for mounting cam followers 44 that follow the
cam 43 (FIG. 8). The other end 559 of the adapter 58 includes
provisions for mounting to the bracket 68 and to the slide blocks
47. The rotation of the axially moveable turret portion 215 and the
interaction between the cam followers 44 and the cam 43 causes the
slide blocks 47 to slide along the profiled rail 48 with respect to
the drive shaft 201.
[0044] Each of the forming ram assemblies 40, 40a, once assembled
with tooling components, (FIGS. 12 and 15-17) includes a forming
die 51, a knockout tooling device 52 and a drive cylinder 46. The
drive cylinder 46 may comprise a pneumatic cylinder. The drive
cylinder 46 may be referred to as a knockout cylinder. The drive
cylinder 46 may move in a downward vertical direction 500 due to
gravity and air line pressure variation due to air path resistance.
The drive cylinder 46 receives air line pressure variation from an
air manifold assembly that fixes to the drive shaft 201 and rotates
with the drive shaft 201. Once a container 1 contacts the knockout
tooling device 52, the drive cylinder 46 moves in the vertical
direction 500 that results from the forming die following the cam
43, thereby allowing the container 1 to go over the knockout
tooling device 52 while forming of the container 1 occurs. Pressure
is kept inside the container 1 while forming occurs to help with
the forming operation.
[0045] The forming die 51 operatively connects to the cam followers
44 such that the forming die 51 moves in the vertical direction 500
and satellite rotation to follow the cam 43 profile. The forming
die 51 of each of the forming ram assemblies 40a for an axially
moveable turret portion 215 may be the same in an in-line system,
but may differ from the forming ram assemblies 40a of any other
axially moveable turret portion 215 in the rotatable forming
apparatus 100 such that the shape of a container 1 is altered one
way in the one axially movable turret 215 that the container 1
interacts with and is altered a second way in the other axially
moveable turret portion 215 that the container 1 interacts with. In
a recirculating system, the forming dies 51 of the forming ram
assemblies 40 may not be the same. For example, the first, third,
fifth, etc. forming dies 51 may be the same while the second,
fourth, sixth, etc. forming dies 51 may differ from the first,
third, fifth, etc. forming dies. The axially moveable turret
portion 215 proceeding the first axially moveable turret portion
215 that the containers 1 enter includes forming dies 51 that
differ from the forming dies 40 of the preceding axially moveable
turret portion 215. The forming die 51 in both an in-line and
recirculating system may first neck the container 1 and then expand
the container 1 along the system such that the container 1 that
exits the system resembles the container 1 in FIG. 1B.
[0046] The knockout tooling device 52 helps to release the
container 1 from the forming die 51 after the forming die 51 necks
the container 1. The knockout tooling device 52 catches a leading
edge of the container 1 while the container 1 is being necked by
the forming die 51 to prevent the container 1 from having an
irregular shape. The knockout tooling device 52 is coaxial with the
forming die 51.
[0047] The drive cylinder 46 (FIG. 12) causes axial movement of the
knockout tooling device 52 and is configured to operate
independently of the forming die 51. The drive cylinder 46 connects
to the forming ram assembly 40, 40a at an opening of the forming
ram assembly 56. As shown in FIG. 17, the drive cylinder 46
includes a drive cylinder shaft 59 that extends parallel to the
drive shaft 201. The knockout tooling device 52 connects to the
drive cylinder shaft 59 via a bolt 53 that extends into the drive
cylinder shaft 59 when the knockout tooling device 52 connects to
the drive cylinder shaft 59. The knockout tooling device 52
connects to an inner surface of the container 1. The knockout
tooling device 52 includes a knockout tooling device shaft 59 that
is coaxial to and extends around a guide cylinder shaft 67. When
the drive cylinder 46 receives air, the drive cylinder shaft 59
moves downwards due to air flow that causes the differential
pressure, thereby causing the knockout tooling device 52 to move in
the vertical direction 500 along the drive shaft 201.
[0048] The drive cylinder 46 may include a drive cylinder air
passage 65. The drive cylinder air passage 65 extends through the
drive cylinder shaft 59. When the drive cylinder air passage 65
receives air, the air enters a container 1 that interacts with the
forming die 51 so that the container 1 does not collapse upon
itself when the shape of the container 1 is modified by the forming
die 51. An outer surface 64 of the drive cylinder 46 may connect to
the forming die 51.
[0049] As shown in FIGS. 8 and 12-17, each of the forming ram
assemblies 40 may also include an air input conduit 45, 55. The air
input conduit 45 receives air from a pressure manifold. The air
delivery conduit 45, 55 connects to a first conduit 61, a second
conduit 62 and a third conduit 63. The first conduit 61
communicates with the drive cylinder 46, the second conduit 62
communicates with the inside of the container 1 and the third
conduit 63 communicates with the inside and outside of the formed
container 1. Air delivered to the first conduit 61, moves the
piston of the drive cylinder 46. Air delivered to the second
conduit 62 enters the inside of the container 1 so that the
container 1 does not collapse upon itself. Generally, air delivered
to the second conduit 62, helps the shape of the container 1 when
it is modified by the forming die 51. Air delivered to the third
conduit 63 keeps and prevents leaks through the knockout tooling
device 52 and the container 1.
[0050] As shown in FIGS. 2, 8-9, 11 and 18-21, push ram assemblies
20 (lifter ram assemblies) may extend around and connect to the
fixed turret portion 216. Each of the push ram assemblies 20 is
configured to move the container 1, such that it contacts one of
the forming ram assemblies 40. The push ram assemblies 20 may be
referred to as lifter ram assemblies because they move in the
vertical direction 500 to lift or lower the container 1 in the
vertical direction 500.
[0051] As shown in FIGS. 18-21, each of the push ram assemblies 20
may include at least two slide blocks 27 and a profiled rail 28
extending through each of the at least two slide blocks 27. The
slide blocks 27 are configured to slide along the profiled rail 28
such that the push ram assembly 20 moves up and down in the
vertical direction 500 with respect to the fixed turret portion 216
and the axially moveable turret portion 215. A conventional push
ram assembly includes only one slide block. The increased number of
slide blocks 27 of the push ram assembly 20 allows for the forming
assembly 100 to provide for a longer stroke distance of the push
ram assembly 20 and to increase the stability of the push ram
assembly 20 because the increased number of slide blocks 27 covers
a greater distance than a single slide block 27. Each of the slide
blocks 27 includes ball bearings (not shown).
[0052] The profiled rail 28 connects to the fixed turret portion
216 via connectors (e.g. nuts and bolts). The rail is "profiled"
due to its shape. The rail 28 is cut or formed into the outline
shown in FIGS. 18 and 21 and, therefore, is a profiled rail.
Alternatively, the rail 28 may be cut or formed into any other
suitable shape (profile). For example, the rail 28 may be formed to
have a rectangular shape with grooves or ridges (FIGS. 18 and 21),
a single rounded profile or a combination of rounded curves and
angular or flat portions.
[0053] Each of the push ram assemblies 20 also may include an
adapter 221 (FIG. 18) that mounts to the slide blocks 27. One end
222 of the adapter 221 includes provisions for mounting cam
followers 24. The other end 223 of the adapter includes provisions
for mounting a push plate device 21 (e.g. a pad). The push plate
device 21 may mount to the adapter via a bolt 224 and bushings 225.
The push plate device 21 is a vacuum push plate device and the push
plate 21 moves up or down in the vertical direction 500 with
respect to the longitudinal axis 1001-1001. The cam followers 24
follow the cam 23. U.S. Pat. No. 7,530,445, which is herein
incorporated by reference in its entirety, describes a similar push
ram assembly. Unlike the push ram assembly in U.S. Pat. No.
7,530,445, the push ram assembly 20 has at least two slide blocks
27 and is designed to work for a vertical rotatable forming
apparatus.
[0054] As shown in FIG. 10, the forming turret assembly 200 may
also include a jam nut 70 connected to the drive shaft 201 and an
adjuster nut 73 pinned to the jam nut 70 so that the adjuster nut
73 rotates with the jam nut 70. Additionally, the forming turret
assembly 200 may include a slit jam nut 71 and split clamp collar
72 configured to attach to the jam nut 70 and an expanding key such
that the axially movable turret 215 does not move in the vertical
direction 500 along the drive shaft 201 and may be configured to
detach from the jam nut 70 such that the axially movable turret 215
moves in the vertical direction 500 along the drive shaft 201. The
split clamp collar 72 may fix the slit jam nut 71 to the jam nut
70. When the slit jam nut 71 is released from the jam nut 70 and
the expanding key tapered screw is released, the axially moveable
turret portion 215 moves in the vertical direction 500. To the
contrary, when the slit jam nut 71 is pulled down by the jam nut
71, the split clamp collar 72 is clamped and the expanding key's
taper screw is fully tightened so that the axially moveable turret
portion 215 remains stationary. Additionally, the forming turret
assembly 200 may include a turret alignment tool 205 (FIG. 8) which
helps align the forming turret assembly 200 with respect to the
transfer turret assembly.
[0055] As shown in FIG. 11, the forming turret assembly 200 may
also include a spanner nut 74, screws 75, collars 76 and a clamp
collar 72. Before adjusting the height of the axially movable
turret 215, to turn the spanner nut 74, the screw 75 and clamp
collar 77 must be removed. The jam nut 70, adjuster nut 73, slit
jam nut 71, split clamp collar 72, spanner nut 74, screws 75,
collars 76 and clamp collar 77 may form the adjustment mechanism.
The adjustment mechanism may be manually activated.
[0056] The rotatable forming apparatus 100 may also include a
transfer turret assembly 300 (FIGS. 3 and 5) that extends from and
connects to the lower base 10 of the frame 202. The transfer turret
assembly 300 connects to the forming turret assembly through the
lower base 10 of the frame 202 at the lower base 310 of the
transfer turret assembly 300 via bearing and drive gear. An
infeed/discharge starwheel 2 or a transfer starwheel 12 connects to
the transfer turret assembly 300 via connectors (e.g. nuts, bolts)
at the upper base 311 of the transfer turret assembly 300.
[0057] The rotatable forming apparatus 100 may also include a
lubrication mechanism (not shown). The lubrication mechanism
lubricates each container 1 to ensure that the container 1 easily
passes through the rotatable forming apparatus 100. The lubrication
mechanism may include a lubricating track that is connected to or
part of the infeed starwheel 2 of the rotatable forming apparatus
100. An example of a lubrication mechanism can be found in U.S.
Patent Application No. PCT/US2010/024988, which is herein
incorporated by reference in its entirety.
[0058] The rotatable forming apparatus 100 may be part of an
in-line system (not shown) or a recirculating system (not shown).
In an in-line system (FIG. 22), each and every turret assembly 200
extends in a single line such that the containers 1 operated on in
the system only move through the rotatable forming apparatus in a
single pass. In an in-line system, each forming turret assembly 200
includes the same type of forming die where the forming die on each
successive forming turret assembly 200 in the single pass includes
a different forming die from the previous forming turret assembly
200 in the single pass. In this way, the shape of the containers 1
is progressively modified.
[0059] If the rotatable forming apparatus 100 is part of a
recirculating system, the rotatable forming apparatus 100 includes
a recirculation mechanism (not shown) that is configured to receive
the container 1 and return the container 1 to the infeed starwheel
2. The recirculation mechanism may move the containers 1 from a
downstream one of the turret assemblies 200, 300, after a first run
(or pass) through the rotatable forming apparatus 100, and
recirculates the containers 1 to an upstream one of the turret
assemblies 200, 300. The upstream turret assemblies 200, 300 may be
those at or close to the transfer turret assembly 300 connected to
the infeed starwheel 2. The containers 1 recirculated pass through
a second run (or pass) in the rotatable forming apparatus 100 to
subject the containers 1 through the successive forming operations
of the forming turret assemblies 200. When the containers 1 pass
through the second run, the containers 1 do not pass through
forming operations that are identical to the first run. Rather the
containers 1 in the second pass are in different pockets of the
starwheels for different forming operations.
[0060] The rotatable forming apparatus 100 may include any suitable
number of passes (or runs), such as two, three, four, five, etc.
runs. The starwheel of each forming turret assembly 200 and each
transfer turret assembly 300 will include the appropriate number of
varying pockets for the applicable number of passes. For example,
if the rotatable forming apparatus 100 includes three passes, each
turret starwheel 102 will include three different types of pockets.
Examples of recirculation mechanisms can be found at FIG. 23 and in
U.S. Pat. No. 7,886,894, which is herein incorporated by reference
in its entirety.
[0061] For both an in-line system and a recirculating system, the
method for modifying the shape of the container includes feeding a
container 1 into a continuously rotating first forming turret
assembly 200 that includes a first axially moveable turret portion
215 and first forming ram assemblies 20 extending around and
connected to the first axially movable turret 215 where each of the
first forming ram assemblies 20 includes a first drive cylinder 46,
a first forming die 51 and a first knockout tooling device 52. A
continuously rotating first transfer turret assembly 300 feeds the
container 1 to the first forming turret assembly 200.
[0062] Once the container 1 enters the first forming turret
assembly 200, the first drive cylinder 46 is activated to cause
axial movement of the first knockout tooling device 52 in a
vertical direction 500 along a longitudinal axis 1001-1001. The
first drive cylinder 46 is activated when a suitable amount of air
enters the first drive cylinder 46. The air enters the drive
cylinder 46 when air enters the input conduit 45 and flows from the
input conduit 45 to the air delivery conduit 55, from the air
delivery conduit 55 to the third conduit 63 and from the third
conduit 63 to the inside of the drive cylinder 46.
[0063] Once the container 1 enters the first forming turret
assembly 200, the first forming die 51 is activated independently
of the activated first drive cylinder 46 to cause axial movement of
the first forming die 51 in the vertical direction 500 along the
longitudinal axis 1001-1001 and rotational movement of the first
forming die 51. Axial and rotational movement of the first forming
die 51 occurs when the turret rotates around the fixed cams 23, 43,
first drive cylinder 46 activates. The first drive cylinder 46
activates when a suitable amount of air is delivered. The air
enters the first drive cylinder 46 when the air that enters the
input conduit 45 flows from the input conduit 45 to the air
delivery conduit 55, from the air delivery conduit 55 to the first
conduit 61 and from the first conduit 61 to the drive cylinder 46
(FIG. 12). While the first forming turret assembly 200 rotates with
the container 1, the container 1 is inserted into the first forming
die 51 and the shape of the open end or top of the container 1 is
modified by the first forming die 51 and then withdrawn. The first
forming die 51 is able to apply a neck to the container 1, that is
some embodiments may be 200 mm from the top of the container 1.
[0064] After the container 1 is shaped by the first forming die 51,
the container 1 is transferred to a second transfer turret assembly
300 that includes a transfer starwheel 12 and subsequently
transferred to a second forming turret assembly 200 that includes a
second axially moveable turret portion 215 and second forming ram
assemblies 20 extending around and connected to the second axially
movable turret 215. Each of the second forming ram assemblies 20
includes a second drive cylinder 46, a second forming die 51 and a
second knockout tooling device 52. The second forming turret
assembly 200 operates similarly to the first forming turret
assembly 200, but includes different forming dies to modify further
the shape of the container 1.
[0065] For a recirculating system, the container 1 may be fed from
the second forming turret assembly 200 back to the first forming
turret assembly 200 if there are only two second forming turret
assemblies. There can be any number of forming turret assemblies.
For example, the container 1 may be fed from the second forming
turret assembly 200 to one or more forming turret assemblies 200.
Regardless of the number of forming turret assemblies 200, the
container may be recirculated to the first forming turret assembly
200. For an in-line system, the container 1 moves from one forming
turret assembly to another forming turret assembly until the
forming process of the container 1 is complete. In both a
recirculated and in-line system, the containers 1 continue to be
fed from one forming turret assembly to another forming turret
assembly via a transfer turret assembly. To facilitate transferring
the container 1 to and from the forming turret assembly 200 to the
transfer turret assembly 300, the rotatable forming apparatus 100
may include external guide rails (not shown).
[0066] The starwheels 2, 12, 102 may be arranged in embodiments to
hold containers 1 in position using suction received from a vacuum
supply 203 (FIG. 8) that communicates with vacuum transfer tubes
22, 41 (FIG. 8). Each starwheel 2, 12, 102 may have a vacuum port
(not shown), formed in a channel portion, that fluidly communicates
with the vacuum supply 203 (e.g. negative pneumatic pressure) via a
suitable manifold. The vacuum is delivered to the vacuum ports and
the surface area of the containers 1, that are exposed to the
suction, is increased to a degree that the containers 1 are stably
held in position as the shape of each container 1 is modified by
the forming die.
[0067] As a result of the above-described rotatable forming
apparatus 100, in embodiments 1200 containers/minute may be
processed by the forming apparatus 100 in comparison to
conventional forming apparatuses which process only 200
containers/minute. Moreover, as a result of the above-described
rotatable forming apparatus 100, easy access of the forming dies,
assembly and maintenance is possible.
[0068] As utilized herein, the terms "approximately," "about,"
"substantially," and similar terms are intended to have a broad
meaning in harmony with the common and accepted usage by those of
ordinary skill in the art to which the subject matter of this
disclosure pertains. It should be understood by those of skill in
the art who review this disclosure that these terms are intended to
allow a description of certain features described and claimed
without restricting the scope of these features to the precise
numerical ranges provided. Accordingly, these terms should be
interpreted as indicating that insubstantial or inconsequential
modifications or alterations of the subject matter described are
considered to be within the scope of the disclosure.
[0069] It should be noted that the term "exemplary" as used herein
to describe various embodiments is intended to indicate that such
embodiments are possible examples, representations, and/or
illustrations of possible embodiments (and such term is not
intended to connote that such embodiments are necessarily
extraordinary or superlative examples or preferred examples).
[0070] It should be noted that the orientation of various elements
may differ according to other exemplary embodiments, and that such
variations are intended to be encompassed by the present
disclosure. It is recognized that features of the disclosed
embodiments can be incorporated into other disclosed
embodiments.
[0071] It is important to note that the constructions and
arrangements of the rotatable forming apparatus or components
thereof as shown in the various exemplary embodiments are
illustrative only. Although only a few embodiments have been
described in detail in this disclosure, those skilled in the art
who review this disclosure will readily appreciate that many
modifications are possible (e.g., variations in sizes, dimensions,
structures, shapes and proportions of the various elements, values
of parameters, mounting arrangements, use of materials, colors,
orientations, etc.) without materially departing from the novel
teachings and advantages of the subject matter recited in the
claims. For example, elements shown as integrally formed may be
constructed of multiple parts or elements, the position of elements
may be reversed or otherwise varied, and the nature or number of
discrete elements or positions may be altered or varied. The order
or sequence of any process or method steps may be varied or
re-sequenced according to alternative embodiments. Other
substitutions, modifications, changes and omissions may also be
made in the design, operating conditions and arrangement of the
various exemplary embodiments without departing from the scope of
the present disclosure.
* * * * *