CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of United States Provisional Application Serial No 60/01 5,202, filed April 4, 1996 entitled "Die Necking Machinery For Making Beverage Cans"

BACKGROUND OF THE INVENTION

Field of the Invention

This invention generally relates to progressive die forming aparatus and more particularly to a multi-station apparatus for forming metal containers

Description of the Related Art

Progressive die station arrangements for can forming have been utilized for a number of years A can bottom profiler for a rotary turret die set is disclosed in U S patent No 5,467,628 Other progressive die station arrangements are used for forming the neck on the can Most prior art designs for forming thin wall cans have involved gravity feed staggered die stations arranged on a single massive bed plate These systems have an inherent disadvantage in that additional stages cannot be added to accommodate for different can necking designs and can lengths

One solution to this problem is a side by side progressive rotary die turret arrangement in which a series of rotary turret s provides a sequence of progressively advanced necking operations, usually ending with a flanging operation on the reduced diameter can neck One such arrangement is disclosed in PCT publication No 96/33032 by Marπtt et al This publication discloses a modular base can processing apparatus which has a single central driven module and one or more right hand modules and/or one or more left hand modules arranged side by side on a facility floor The center module supports a spindle shaft for the die turret and two drive shafts for transfer star

wheels, one on either side of the die turret The base for this equipment is two pieces, one for suppoiting one end of the die turret and its rotary shaft head end and the star wheels, and a tailstock support poition which supports the other end of the die turret drive shaft The die turret support portion and the tailstock support portion are separate pieces which are bolted together Each of the right hand and left hand modules carries one die turret and one transfer star wheel The modules are not interchangeable and alignment between adjacent modules is complex

Another modular support for a necking station and a transfer station used in a can necking apparatus is disclosed in U S Patent No 5,553,826 to Schultz In this design, the support for the transfer station is a separate box which is bolted to the support plate for the necking turret station One problem with such a design is that the tolerances between modules are large and variable The installation of each transfer station must be individually adjusted to the accurately mate with the necking stations on either side of it

This alignment step is time consuming and prone to errors requiring additional ad|ustment time, which results in prolonged down time or setup time for the necking apparatus as a whole

SUMMARY OF THE INVENTION

The apparatus in accordance with the present invention is a modular apparatus for progressively forming a cylindrical can such as reducing a neck diameter of an open can which comprises a plurality of identical, stand alone forming modules arranged side by side typically on a generally horizontal floor surface Each module is identical except for the shape of the particular die set being used in that module Adjacent modules are mated together bv least three and preferably four spaced datum pads machined into each side of the unitary body of each module in a common vertical plane Each module comprises a hollow unitary frame body, a necker turret shaft assembly carried

in first bores through the frame body and a transfer star wheel assembly aligned parallel to the turret assembly and shaft mounted in second bores through the frame body parallel to the axis of the first bores The module also has a lubricating supply and return manifold mounted on the frame body foi distribution of lubricating fluid to the turret assembly, a vacuum supply coupled to the transfer star wheel assembly, a pressurized air supply header connected to the neckei turret assembly for directing pressurized air through the turret into the cans being processed by the turret and passed to the transfer star wheel assembly, and drive members coupling the turret assembly to the transfer assembly together

Each module is identical to an adjacent module in structure and operation When a series of modules are aligned side by side to form a train of modules forming the can necking apparatus, the transfer star wheel of the module at one end is replaced by a special in-feed star wheel The module at the other end of the train of modules mated with a service module which carries a special discharge star wheel which is a mirror image of the in-feed star wheel This service module carries lubricating oil supply and return pumps, air pressure regulators and a vacuum pump, which supply common headers on each of the modules The single drive motor assembly which drives the entire train of modules may be affixed to any one of the transfer star wheel drive gears of any module and is preferably mounted to the module closest to the center of the train in order to distribute the dπve gear loading most efficiently

The unitary frame body of each module has a first outer side wall and an opposite second outer side wall Each of the side walls has at least three, and preferably four, spaced, outwardly facing datum pads having machined surfaces lying in a common vertical plane These outwardly facing datum surfaces are accurately machined and accurately spaced laterally apart on opposite side walls of the frame bod) In addition, the first and second bores

are accurately located with reference to these sets of datum surfaces This ensures accurate and identical spacing of these features relative to the datum surfaces, module to module, so that when a plurality of the modules, placed side by side with the datum surfaces in mating relation, they are automatical ly accurately aligned together and operationally and mechanically coupled together without the need for additional alignment or adjustment of the main and transfer star wheel positions

Further, another aspect of the modular arrangement in accordance with the present invention is that the modules of the apparatus may be operated interchangeably in either direction with the same components as a result of this modularity without impacting setup or operation efficiency In such situations, only the in-feed and discharge star wheels and guide assemblies would need to be repositioned at opposite ends of the train, the lower guides between main and transfer star wheels reversed, the air manifold dam screws and high pressure air fittings relocated, and the die sets reversed in module sequence positions to maintain the sequence of progressive necking operations from one end of the train of modules to the other Alternatively, instead of swapping die sets, the series of modules may simply be rearranged without changing the tooling beyond repositioning the in-feed and discharge star wheels and guides

In addition, should an additional stage be needed to be added to the necking operation, one mated pair of modules is simply uncoupled, the line translated to provide the necessary space, and a new module slipped into place and mated to the corresponding datum pads on the adjacent modules Alternatively, should fewer stages be needed, one module may be quickly removed in a similar manner Once mated, the adjacent modules will again be in proper alignment with proper critical clearances being maintained between the transfer star wheel and the necker turret star wheel because of the vertical datum planes piovided by the three or four mating datum pads

In another aspect of the present invention, tooling changes or adjustments to accommodate different can lengths, for example 12 ounce (355 milliliters) and 16 ounce (450 milliliters) can lengths are minimized Once the individual can support pads are adjusted for one can height on each turret in the line, different lengths may be adjusted for by changing or adding spacers against the pusher ram turret on the main shaft which adjusts the entire turret assembly for different can lengths This feature minimizes down time for conversion setup

Another feature of the invention is the provision of a discharge star wheel assembly that is virtually identical to the in-feed star wheel assembly in order to smoothly transfer completed cans to a linear can transfer apparatus (not shown) for further production operations The in-feed star wheel assembly, the concept of which was originally developed by Coors Brewing Co , involves the use of hooked teeth on the star wheel that ensure constant velocity and constant pitch during transfer from the linear in-feed line to the rotary necking turret thus maximizing smoothness during transfer and minimizing can chatter and consequent can denting The present invention applies a mirror image star wheel with hooked teeth in the discharge assembly to similarly provide smooth discharge from the necking apparatus into the linear transfer apparatus (not shown)

A still further feature of the invention is the conservation of internally applied air pressure to the cans during forming This is accomplished by provision of an air pressure manifold coupled to the necking die turret which has an overlapping stepped increased air pressure provided into each of the cans in its pocket on the turret star wheel as it rotates into the full die insertion position at top dead center (TDC) of each turret along with recapture or feedback from air released from the inside each can prior to transfer

More specifically, a low pressure air is initially supplied into the can as it is picked up from the tiansfei star wheel and rotated upward This low pressure air seats the can against the pusher pad and in the pocket of the main star wheel As each can begins entry into the die, air pressure fed through the center of the die into the can is increased to a medium pressure Air pressure is increased to a high pressure to prevent buckling as the die begins necking the can as the can is further pressed into the die so that as the can approaches TDC it has ful l internal support As the main star wheel continues to rotate beyond TDC, the particular necking operation is now complete and the pusher pad begins to retract The high pressure air supplied into the can is isolated The high pressure air in the can pushes the can against the retracting pusher pad and away from the die During this period, the internal air pressure in the can is bled back to the medium and low pressure manifolds rather than releasing it to ambient After the can is pushed back out of the die as the main star wheel rotates, low pressure air is again applied to hold the can against the pusher pad until just pπor to the can being picked up by the transfer star wheel with the aid of vacuum for transfer of the can to the next module

This recapture of air pressure from the high pressure applied at TDC of the turret is in essence a pressure feedback system which conserves the use of pressurized air utilized to provide internal can support during the necking operations The exhausting high pressure air from within the can is directed to the medium pressure supply plenum and to the low pressure supply plenum

More particularly, low pressure air is supplied to the interior of a can as it is picked up in the can pocket of the turret star wheel from the transfer star wheel This low pressure blown into the can pushes the can firmly against the push pad, properly locating the can for the operation to come As the turret rotates upward toward TDC, the air pressure is changed to a medium pressure to prime the can as it enters the necker tooling Prior to TDC, high pressure air is supplied into the can to provide lateral internal support to the thin side

wall of the can during the die forming Then as the turret rotates past TDC, the can is no longer being necked Consequently , the high pressure is no longer needed and the high pressure supply is isolated from the can The high pressure then bleeds from the can back to the medium and low pressure plenum This bleed back process recoups about 30% of the air volume which would otherwise be required to operate the system Finally, low pressure an is provided to blow the can back from the die prior to the transfer stai wheel picking up the can to transfer it to the next stage

The modular apparatus in accordance with the present invention furthei includes a service module connected to either the right hand or left hand end of the series of modules The service module comprises a unitary body having a generally rectangular base portion and an upright support portion supporting a single transfer star wheel assembly carrying either an in-feed or out-feed star wheel The unitary service module body has at least three and preferably four datum surfaces in a common vertical plane along one side of the module adapted to mate with the corresponding datum surfaces on an adjacent module The base supports a vacuum pump, an air pressure supply manifold adapted to mate with the air pressure header on each module, and a lubrication pump assembly adapted to connect with a lubrication supply header and return header on an adjacent module

BRIEF DESCRIPTION OF THE DRAWING

Fig 1 is a rear perspective view of a can processing system having five modular apparatuses arranged side by side in accordance with the invention

Fig 2 is a rear perspective view of one modular apparatus of the invention

Fig 3 is a front perspective view of the module apparatus shown in Fig 2

Fig 4 is a plan view of the apparatus in Fig. 2. Fig 5 is a left side view of frame of the apparatus shown in Fig 2 Fig 6 is a right side view of frame of the apparatus shown in Fig 2 Fig 7 is a front view of the frame of the apparatus shown in Fig 2 Fig 8 is a rear view of the frame of the apparatus shown in Fig. 2

Fig. 9 is a vertical sectional view of the apparatus taken along the line

Fig 10 is a horizontal sectional view of the apparatus taken along the line 10-10 in Fi ' z»> 5.

Fig 1 1 is an enlarged fragmentary sectional view of the assembled mated bases of adjacent modules taken along line 1 1-11 in Fig 1

Fig 12A, 12B, and 12C is an exploded view of the main turret and shaft assembly in accordance with the present invention.

Fig 13 is a sectional view of the transfer star wheel shaft assembly in accordance with the present invention

Fig. 14 is a sectional end view of the transfer star wheel assembly taken along the line 14-14 shown in Fig. 13

Fig 15 is a perspective view of the transfer star wheel removed from the transfer star wheel assembly

Fig 16 is a schematic of the air distribution system in the present invention

Fig. 17 is an enlarged partial sectional view of the air manifold assembly portion of the module 12 shown in Fig 9

Fig. 18 is a sectional end view taken along the line 18-18 in Fig 17 which shows the manifold surface porting

Fig 19 is a schematic representation of the air manifold in relation to the port holes on the face of the rotor during module operation

Fig 20 is a simplified view of the main and transfer star wheels in a system of modules arranged in a train in accordance with the invention

Fig 21 is a diagram of can position through the main star wheel turret assembly in accordance with the invention

Fig 22 is a knockout cam profile diagram in accordance with the present invention

Fig 23 is a pusher cam profile diagram in accordance with the pi esent invention

DETAILED DESCRIPTION OF THE INVENTION

Overall System Description

Referring now to the drawing, a perspective view of a system assembly 10 of five modular apparatuses 12 in accordance with the present invention along with a service module 14 is shown in Fig 1 This complete system 10 includes a drive motor apparatus 16 attached preferably to the center module 12 and a pneumatic brake assembly 390 attached at one or both ends of the assembly 10 The drive motor apparatus 16 may be interchangeably connected to any transfer star wheel gear 18 in the system 10 Similarly, the brake assembly 390 may be interchangably mounted to any transfer star wheel gear 18 in the system 10 The transfer star wheel gear 18 of each module 12 meshes with and drives the main turret dπve gear 20 of the same module 12 In Fig 1, the dπve motor apparatus 16 is connected in a preferred central module 12 of the system 10 in order to equalize loading on the gears Thus the transfer star wheel gear 18 of the central module 12 drives all of the gears 18 and 20 of the system 10 shown in Fig 1 The brake assembly 390 is

connected to the transfer star wheel gear 18 on the module 12 farthest from the service module 14 Alternatively, and preferably for a longer train of modules 12, a brake apparatus 390 would also be installed on the service module 14 at the other end of the train

The service module 14 supports system components such as lubricating oil pumps, air pressure supply headers and regulators, a vacuum pump, and other system shared components such as operational sensor controls, etc The oil and air manifolds on each module 12 are connected to this service module 14 via conventional piping The vacuum pump is connected to each transfer assembly, as will be further described below, through large openings in a box shaped cavity beneath the transfer starwheel shaft bore through the unitary base of each module 12

Thus the only connections which must be broken or made when adding a module 12 to the system 10 or subtracting a module 12 from the system are the lubrication, air pressure and vacuum manifold connections to the adjacent modules These connections are not tolerance sensitive The critical alignment between components and the functional mechanical connection between adjacent modules 12 are ensured by mating connection between machined pads which are located in a common vertical plane on both sides of each module 12

The system 10 typically is used to perform progressive necking operations of two piece beer and beverage cans, and typically terminates in a flanging step Therefore, in the exemplary system as shown in Fig 1 , a stream of cans (not shown) enter at one end of the train of modules 12 The necks of the cans are progressively shaped in each of the first four modules 12 The last module 12 forms a flange on the formed neck of each can so that a lid may be placed on and secured to the open end of the can after the can has been filled, in a separate operation, not shown The last module 12, or the transfer

star wheel of the service module 14, depending on the direction of can throughput, transfers the stream of formed cans from the system to subsequent processing equipment (not shown)

General Module Description

Each module 12 includes a hollow unitary frame body 22 which supports a main star wheel shaft and turret assembly 24, a star wheel transfer assembly 26, air supply headers connected to an air supply manifold assembly 28 also on the service module 14, portions of a multi-module vacuum supply header or chamber 30, and portions of a lubrication supply header and return sump connected to a lubrication manifold assembly 32 also on the service module 14 Optionally, a module may also include a drive motor apparatus 16 to supply motive power to the module 12 and any modules connected thereto or a brake assembly 390

The main star wheel shaft and die turret assembly 24 carries a dπve gear 20 affixed at one end of a main shaft 34, a die turret 36 which preferably has twelve movable die modules 38 mounted thereon and a reduced diametei portion forming a main star wheel 40 with twelve can pockets 42 fastened thereto, and a pusher pad dπve turret assembly 44 adjustably spaced from the star wheel 40 on the main shaft 34 The pusher pad drive turret assembly 44 supports the cans for movement into and out of the die modules 38 as the assembly 24 is rotated

The transfer star wheel assembly 26 includes a drive gear 18 attached to one end of a transfer shaft 46, a star wheel 48 having twelve vacuum assisted transfer can pockets 50 attached to the opposite end of the transfer shaft 46, and a guide assembly 52 sandwiching the transfer star wheel 48 and providing guides for cans 128 as the cans are being picked up or discharged from the transfer star wheel 48

The gears 20 and 18 are meshed together such that as one shaft rotates clockwise, the other rotates counterclockwise Foi example, as viewed in Fig 2, if the main gear 20 rotates clockwise, cans would be received, from the left, by the transfei star wheel 48, carried down, under and then up, counterclockwise, by the transfer star wheel 48 as it rotates The cans then would move upward toward the main star wheel 40 in the pockets 50 of the transfer star wheel 48, and then be released and grabbed into the can pockets 42 of the main star wheel 40 and carried up and over in a clockwise direction by the main star wheel 40 As the main star wheel 40 reaches top dead center (TDC) each of the cans is pushed fully into the die module 38 for the particular forming operation that the particular module 12 is set up to perform

Each of the twelve die modules 38 carried on the die turret 36 on the main shaft 34 has a knockout ram 54 which follows a stationary cam 56 This cam 56 essentially causes the ram 54 in each of the die modules 38 to each move with its opposing push pad as the module 38 goes past a top or Top Dead Center (TDC) position Each pusher pad drive turret assembly 44 includes a pusher module 58 which carries a push ram 60 which is driven by a stationary pusher cam sleeve 62 encircling the main shaft 34 The push ram 60 causes each pusher pad 64 to move axially toward its die module 38 as the pusher pad module approaches TDC As the main can pocket 42 passes through TDC, the can 128 carried in the can pocket 42 is squeezed into the necking die module 38 and is partially necked As the can 128 and the main star wheel turret assembly 24 rotate further past TDC, the push pad 64 retracts, and the can 128 is pushed back out of the die module 38 by internally provided air pressure in conjunction with the knock out ram 54 in preparation for transfer to the next station

Unitary Frame Body

The frame body for the can necking apparatus module 12 is a weldment that forms a single, unitary body 22 that comprises a generally rectangular box shaped base member 68 adapted to rest on a horizontal surface such as a facility floor via cushioning and leveling foot pads 72 Left, right, front, and rear views of the body 22 ai e separately shown in Figs 5, 6, 7, and 8 The top 74 of the base 68 is a rectangular steel plate The bottom of the base member 68 is typically open and the top 74 and sides may be reinforced by angle shaped cross members (not shown)

The base 68 supports a generally hollow first housing portion 76 extending upward from the rear end portion o the top 74 of the box shaped base member 68 This first housing portion 76 has a rectangular bottom section 78 and a generally octagonal sided tubular top section 80 The horizontal top of the top section 80 is open for access to pusher module tooling This top is preferably closed by a bolted transparent panel 66 which allows operator access to the pusher modules and permits observation of the internal components during module operation As is best shown in Figs 5 and 7, the top section 80 is generally symmetrical about a central axis 82 of a first generally horizontal through bore 84 though the front and back walls of the top section 80

The frame body 22 also has a generally hollow second housing portion

86 axially spaced from the first housing portion 76 The second housing portion 86 extends upward from the front end portion of the top 74 of the box shaped base member 68 The second housing portion 86 has a generally rectangular bottom section 88 which spans the top 74 of the base member 68 and a rectangular box shaped top section 90 which has a second through bore 92 coaxial with the first through bore 84 The top of top section 90 is open to permit die/knockout ram module replacements without disassembly of the entire module 12 The top is preferably closed by a bolted transparent panel 70 to permit observation of ram operation while the module is in operation

The bottom section 88 also has trapezoidal outer side walls 96 which extend rearward past the bottom of the top section 90

As is best shown in Figs 5 through 9, the top of bottom sections 88 and 78 and the bottoms of the top sections 80 and 90 are formed by a flat, two inch thick plate 122 The bottom sections 78 and 88 also have horizontal wire ways formed by channels shown in dotted lines beneath the plate 122 These wire ways support various control and sensor wiring (not shown)

The frame body 22 also has a hollow transfer shaft support housing portion 94 extending upward from the top of the base section 88 adjacent the top section 90 along the right side of the housing portion 86 The bottom of the shaft support housing portion 94 opens into the bottom section 88 through a vacuum passage 1 18 through the plate 122 The shaft support housing 94 has a generally tubular top portion 98 having a third through bore 100 having a central axis 102 parallel to the axis 82 of the first and second through bores 84 and 92

As shown in Fig 5, the base member 68 has a pair of integral datum pads 104 adjacent the front and rear ends on the right side of the base 68 The shaft support housing portion 94 and the bottom section 96 each has another datum pad 104 on their outer right sides. Each of these datum pads 104 has a machined surface During fabrication of the frame body 22, the surfaces of these datum pads 104 are machined to accurately lie in a common vertical plane along the right side of the base member 68

The base member 68 has another pair of integral datum pads 106 along the left side adjacent the front and rear ends of the base 68 as shown in Fig 6 Each of the first and second housing portions has another datum pad 106 on their outer, left sides These datum pads 106 are also machined during fabrication of the unitary frame body 22 so that their datum surfaces

accurately lie in a common vertical plane along the left side of the base member 68

The datum surfaces of pads 104 and 106 are also accurately machined to be exactly 27 000 inches apart between laterally corresponding pads 104 and 106 The first and second main through bores 84 and 92 in the first and second housing portions 76 and 86 and the transfer through bore 100 in the transfer shaft support housing 94 are then accurately located and machined using the location of the machined surfaces of pads 104 and 106 as datum references

The provision of accurate datum pads 104 and 106 with surfaces in common vertical planes ensures accurate alignment between mating modules 12 When adjacent modules are mated, each pad 104 mates with a corresponding pad 106 as is shown in Fig 1 1 and the vertical planes become one common vertical plane Since the width of each module is constrained to 27 000 inches and the through bores are accurately machined with reference to these vertical planes, the accurate alignment between the transfer star wheel assembly 26 and gear 18 of one module 12 and the adjacent main star wheel assembly 24 and gear 20 of the adjacent module 12 is guaranteed without any adjustment beyond joining the mating pads 104 and 106 as in Fig 11

Each of the pads 104 has either two or three parallel through holes 108

The upper pad 104 on the tubular top section 98 of the transfer shaft housing 94 and the pad 106 on the left outer side of the upper section 90 of the second housing portion 86 each have only two holes 108 The outer two holes on the pads with three holes receive bolts 1 10 The center hole 108 receives an aligning pin 112 which is press fit into the hole 108 in pad 106 and slip fit into the hole 108 in pad 104 The pads 104 and 106 which have two holes receive a pin 112 in one hole 108 and a bolt 110 through the other Again, the pin 112 is press fit into the hole in pad 106 and slip fits into the hole 108

in the mating pad 104 on the adjacent module 12 This arrangement simplifies alignment as the four pads 104 and 106 on each side triangulate and stabilize the connection between mated modules to ensure accurate alignment

Each of the frame bodies 22 is welded together and then stress relieved prior to machining the surfaces of datum pads 104 and 106 and prior to final machining of the through bores 84, 92, and 100 so that the final frame body 22 is accurately dimensioned with respect to the center to center distances between the bores and the datum surfaces of pads 104 and 106

Referring now back to the side views of Figs 5 and 6, each side wall 96 of the bottom section 88 has an aperture 1 14 therethrough This aperture 114 mates with another identical aperture 114 in the opposite side wall 96 of the bottom section 88 of an adjacent module 12 A flexible tubular boot (not shown) preferably made of neoprene foam is placed around the aligned apertures 1 14 and sandwiched between adjacent modules 12 so that the cavities within the bottom sections 88 are connected together The last module 12 in the train or system 10 has a cover 1 16 which closes the last aperture 1 14 The service module 14 also has an aperture 1 14 These connected bottom sections 88 which are also connected to the upper transfer shaft support portions 94 form the multi-module vacuum chamber 30

A vacuum pump preferably mounted on the service module 14 is connected to and takes suction on the vacuum chamber 30, i e , through this aperture 1 14 into the series of connected bottom sections 88 and upper sections 94 Thus during system operation, a vacuum is drawn in all of the bottom sections 88 and upper transfer sections 94. The passage 118, shown in dotted lines in Fig 5, between each transfer shaft support housing 94 through the top of the bottom section 88 connects the transfer shaft support housing 94 to the vacuum in the bottom sections 88 Thus the connected bottom sections

88 form a vacuum header for the system 10, the function of which is described in more detail below

As is best shown in Fig 9, an oil collection trough 120 is formed by an inverted steel channel on the plate 122 between the bottom of the upper section 90 and the bottom of the top section 80 A discharge channel 124 through the plate 122 leads into the open space behind the bottom section 88 and between the side walls 96 This discharge channel 124 connects to a lubrication return header 126 which is in turn connected to the lubrication manifold assembly 32 on the service module 14 The upper surface of the plate 122 forming the bottom of upper section 90, the bottom of top section 80, the trough 120 and the discharge channel 124 together provide an oil collection sump for turret lubrication

Returning now to Fig 1, each module 12 is lubricated from a lubrication supply manifold assembly 32 Lubricating fluid is pumped through a header 384 on each base 68 and from there to each main shaft 34 via a tube 386 to a swivel hydraulic connection 388 on the rear end of the main shaft 34 into the axial bore 130 Lubricating fluid is then distributed through the main shaft components Specifically, oil is fed to the radial bores in the turrets 36 and 160 from the axial bore 130, through the radial bores 132 and the annular grooves 162 The used oil drips onto the plate 122 and returns through the return header 126 behind the supply header 384 from which an oil pump draws to supply the header 384

Main Star Wheel Shaft and Turret Assembly

The main star wheel shaft and turret assembly 24 fits within the first and second through bores 84 and 92 in the first and second housing portions 76 and 86 respectively The assembly 24 is shown installed in the frame body 22 in Figs 9 and 10 and in an exploded view in Figs 12A, 12B, and 12C Referring first to Fig 12B, the main star wheel shaft and turret

assembly 24 includes a main shaft 34 which carries the integral die turret block 36 and main star wheel 40, and, as shown in Fig 12A, includes the pusher pad drive turret assembly 44

The main shaft 34 is a cylindrical member which has an axial through bore 130 and a pair of spaced radial through bores 132 The main shaft 34 has a drive end 134 of reduced diameter which receives the drive gear 20 The drive end 134 is supported in a bearing 136 which is mounted to a main shaft support plate 138 bolted and doweled to a transfer plate 150 which is in turn bolted and doweled to the transfer shaft support housing 94

A retention ring 140 which has six axial threaded bores 142 spaced therearound is adhesively bonded to the shaft 34 at an axial location between the through bores 132 This retention ring forms a fixed flange on the shaft 34 to which all rotating components are fastened via three long bolts 144 extending in one direction through the die turret block 36 and three long bolts 146 extending in the opposite direction through the pusher pad dπve turret assembly 44 components

On the right hand side of the retention ring 140 is first assembled the die turret 36 and an air distributor sleeve 148 Then a die/knockout cam sleeve 56 is slipped over the distributor sleeve 148 An air manifold assembly 154 is then loosely assembled on to the shaft 34 First, a manifold plate 262 is slipped over the distributor sleeve 148 and butted against and the cam sleeve 56 Then an air distribution rotor 156 is slipped onto the shaft 34 The air distribution rotor 156 is pinned to the air distributor sleeve 148 which is in turn also pinned to the die turret 36 These three components are then bolted to the retention ring 140 via long bolts 144 These three components have a close slidin *σg fit on the main shaft 34

The manifold plate 262 and the cam sleeve 56 are pinned and bolted together This manifold plate 262 eventually will be bolted to the upper

housing 90 and the remainder of the air manifold assembly 154 fastened to the plate 262 Thus the manifold plate 262, the air manifold 248, the air manifold support 282 and the die/knockout ram cam sleeve 56 are not mounted to the shaft 34 but remain stationary during module operation

As is best shown in Fig 9, an oil seal 158 is provided between the die turret 36, the distributor sleeve 148, and the main shaft 34 and another seal 1 58 between the main shaft 34, the retention flange ring 140 and the turret 36 Two more oil seals 158 are space axially apart on the main shaft 34 beneath the pusher turret 160 In addition, a shallow annular groove 162 is provided around the shaft 34 at each of the through bores 132 under the die turret 36 and under the pusher turret 160 These grooves 162, several radial bores 164 through the pusher turret 160, several radial bores 166 through the die turret 36 and the axial through bore 130 through the main shaft 34 provide paths by which lubricating oil is distributed to the moving components, including the pusher modules 58 and the knockout ram die modules 38

The die turret 36 is a single, machined metal, generally cylindrical element having a larger diameter portion 168 and a smaller diameter portion 170 The larger diameter portion 168 has twelve symmetrically arranged axially extending outer surfaces or sides 172 to which the die and knockout ram modules 38 are bolted In addition, two dowel holes are provided on each flat to accurately locate each module 38 on its flat surface 172 During the machining of these surfaces 172, twelve additional can pocket surfaces 174 are also machined on the smaller diameter portion 170 coaxially aligned with the ram module surfaces 172 An axially extending keyway 176 is also machined in each of these can pocket surfaces 174 using the same machining setup Twelve can pockets 42 are then bolted to the can pocket surfaces 174 to form the main star wheel 40 Therefore exact alignment between the can pockets 42 of the main star wheel 40 and the die/knockout ram modules 38 is guaranteed

The shaft mounted die turret assembly 36 components, I e , the die turret 36 (and the can pockets 42, die/knockout ram modules 38, and a ram seal retainer plate 184 mounted to the die turret 36), the air distribution sleeve 148, and the air distribution rotor 156 are fixed to the shaft 34 via the three long bolts 144 which thread into three of the six bores 142 in the retention ring 140 The can pocket end of the die turret 36 has an axial recess 180 which fits over a portion of the retention ring 140 and a portion of a flanged adjusting ring 182 threaded onto the retention ring 140 on main shaft 34

The adjusting ring 182 is used to change the overall axial distance between the pusher pad drive turret assembly 44 and the die turret assembly 36 in order to relatively quickly change the module 12 to accommodate different neck lengths as will be described more fully below The die turret assembly 36 position on the shaft 34 is fixed by the three long bolts 144 into the retention ring 140 Only the position of the components to the left of the retention ring 140 may be axially adjusted to accommodate various can lengths in the module 12

Prior to assembly of the can pockets 42 onto the die turret 36 and assembly of components to the left of the retention ring 140, the annular shaped knockout ram seal retainer plate 184 which has twelve spaced apertures 186 for receiving the free ends of the die modules 38 is slipped over the shaft 34 and the smaller diameter portion 170 of the die turret 36 up against the shoulder of the larger diameter portion 168 Each of the die modules 38 extend through the apertures 186 in this plate 184

The left or front end of the main shaft 34 carries the pusher turret assembly 44 shown in Fig 12A This assembly 44 includes the micro- adjusting ring 182, one or more spacer rings 188, an annular pusher ram seal retainer plate 190 which has twelve apertures 192 therethrough mounted on

the cylindrical pusher turret 160, the pusher turret 160, a spacer sleeve 194, a pusher cam sleeve 62, and a bearing 198 The pusher cam sleeve 62 slips over the spacer sleeve 194 and is bolted to the unitary frame 22 and therefoi e remains stationary The outer race of the bearing 198 is supported by the cam sleeve 62 A ring shaped retainer plate 200 bolted to the frame 22 retains the outer race of the bearing 198 and is bolted to the pusher cam sleeve 62

The inner race of the bearing 198 is pressed against the spacer sleeve 194 on the shaft 34 by an annular pusher turret retainer plate 178 The retainer plate 178 and spacer sleeve 194 are in turn bolted to the pusher turret 160 via three bolts 152 The retainer plate 178, spacer sleeve 194, pusher turret 160, and spacer rings 188 are also all drawn against the micro-adjusting ring 182 and the retention ring 140 by three equally spaced long bolts 146

The pusher turret block 160 is a cylindrical machined metal body with a central bore for receiving the main shaft 34 The turret 160 has twelve flat outer, axially parallel, peripheral side surfaces 196 for mounting the twelve pusher modules 58 The turret block 160 also has three equally spaced axial holes through the body around the central bore to receive the bolts 146 therethrough There are also three blind holes in the front face for bolts 152 There are also three other holes in the rear face of the turret block 160 to receive aligning pins or dowels (not shown) which project axially outward from the retention ring 140 toward the pusher turret 160 three inches from the left face of the retention ring 140 Three cylindrical aligning sleeves, coaxial with the bolts 144, project from the recess 180 and engage in counter bores in the right hand face of the retention ring 140, the remaining thickness of the retention ring 140 being threaded to accept the bolts 144 These aligning pins or dowels ensure that the flat surfaces 196 on the pusher turret 160 align very closely with the surfaces 174 and 172 of the die turret 36 when the main shaft components are assembled

The assembly sequence of components on the main shaft 34 shown in Figs 12A, 12B, and 12C into the unitary body 22 is as follows The entire assembly shown in Fig 12A,B,C is installed into the frame body 22 as a unit with the exception of the air manifold assembly 154 This component is installed after the main shaft is installed Assembly commences with tehe installation of dowels and hollow sleeves (not shown) into opposite faces of the retention ring 140, the retention ring 140 having been previously bonded to the main shaft 34 to create an integral unit An oil seal 158, the die/knockout ram turret 36, a second oil seal 158, and the air distribution sleeve 148 are first installed on the rear end of the shaft 34 The knockout cam sleeve 56 and the air manifold plate 262 are then loosely slid onto the rear end of the shaft 34 and over the cam sleeve 148 The air manifold i otoi 156 is then slipped onto the end of the shaft 34 and long bolts 144 inserted through the rotor 156, the air distribution sleeve 148, the turret 36, and threaded into the retention ring 140 and tightened

Seal retainer ring plates 184 and 190 are slipped over the front end of the shaft 34 and fed onto the smaller diameter portion 170 of the turret 36 The mιcro-ad|ustment ring 182 is then threaded onto the retention ring 140 Spacers 188 are then installed next to the ring 182 followed by an oil seal 158, the pusher turret 160, another oil seal 158, and the spacei sleeve 194 Pusher cam sleeve 62 is then slid over the spacer sleeve 194 The front bearing 198 is then installed and retained with the bearing retainer 178 Bolts 152 are then installed through the retainer 178 and through the spacer sleeve 194 and threaded into the turret 160 Bolts 146 are then installed through the bearing retainer 178, the spacer sleeve 194, the turret 160, the spacers 188, and threaded into the retention ring 140 Bolts 152 and 146 are then tightened Pusher modules 58 and die/knockout ram modules 38 are then installed, located by dowels on their undersides which fit into machined dowel holes in the machined surfaces of the turrets 160 and 36 respectively Seal rings 190 and 184 are then slid into place over the noses of the die/knockout ra and

pusher ram assemblies and onto the cylindrical portions of the turrets 36 and 160 This entire assembly is then inserted axially through housing portions 90 and 80 until the outside diameter of cam sleeve 62 slides therough the end of the bore 84 The front bearing retainer plate 200 is bolted through spacer ring 189 to the front end face of the upper housing portion 80 of the housing portion 76 to retain the front end of the assembly in place Then the air manifold plate 262 is bolted to the rear face of the upper housing portion 90

Alternatively, the ram modules may be separately installed aftei installation of the mam shaft 34 in the housings 80 and 90 In this case, the pusher modules 58 are each installed on one of the twelve surfaces 196 of the pusher turret 160 Each of the modules 58 is positioned such that the pusher ram 60 and the pusher pad 64 fits through the aperture 192 in the pusher seal retainer plate 190 The opposite end of the pusher ram 60 has a pair of spaced rollers 202 which then fit down on either side of a cam nb 204 on the pusher cam sleeve 62 The module 58 is then bolted in place on the pusher turret 160

Similarly, the knockout ram/die modules 38 are installed by tilting them such that the knockout ram and die end fits within the apertures 186 of the seal plate 184 and then the rear end of the module 38 lowered such that a pair of spaced rollers 206 on the rear end of the knockout ram 54 fit on either side of the cam rib on the cam sleeve 56 The modules 38 are then each bolted in place to each of the twelve flat surfaces 172 of the large diameter portion 168 of the die turret 36

The pusher cam sleeve 62 is not permanently fixed to the housing 76 Its position may be adjusted axially within the bore 84 through the front face of the housing 76 through application of different sizes of spacer rings 189 This is necessary so that overall adjustments may be made to permit cans 128 of different lengths to be processed in the module 12 with minimal down time

for adjustments This adjustment for different can sizes is made as follows The bearing retainer plate 200 is loosened or removed, the bolts 146 loosened, and the spacers 1 88 either added or removed. An appropriately sized spacer ring 189 is installed and the bolts 146 retightened and the retainer plate 200 reinstalled Assuming that each of the pusher pads 64 has been properly adjusted previously for one can length, no further adjustment is necessary for cans of different lengths

Thus, by changing spacers 188 and the cooperating spacer ring 189 between the retainer plate 200 and the front face of the upper housing 80 , changes for can height can be quickly made without any time consuming adjustment of pusher pads or the micro-adjustment ring 182 Adjustment of the micro-adjusting ring 182 is required only to uniformly adjust the can penetration into the die 346, therefore determining the neck position on the can 128 This simplified procedure enables changes between can size to be performed quickly and efficiently with minimal readjustments being required

Transfer Shaft Assembly

Referring now to Figs 13 and 14, a vertical axial sectional view and a front end view respectively are shown of the transfer star wheel shaft assembly 26 The assembly 26 includes a transfer shaft 46 bearing supported in the tubular bore 100 through the tubular top section 98 of the transfer shaft support housing 94 The rear end of the transfer shaft 46 carries the transfer drive gear 18 which meshes with the main gear 20

A transfer support plate 150 is doweled and bolted to the rear face of the transfer housing top section 98 This vertically mounted transfer support plate 150 extends laterally across the rear of the module 12 and is bolted and doweled to the main shaft bearing support plate 138 The main shaft 34 extends through an aperture 210 through the plate 138 A rear main shaft bearing 136 is bolted to the plate 138 which rotatably supports the rear or

drive end 134 of the main shaft 34 from the transfer support housing 94. When two modules 12 are connected together, the plate 138 is supported by two adjacent transfer support housings 94 through the plates 150 bolted to either side of the plate 138

At the front end of the transfer shaft 46 is a vacuum transfer star wheel assembly 26 which utilizes a vacuum applied during the lower half rotation of a transfer star wheel 48 in order to grab and hold cans 128 as they are rotated downward and released from the main star wheel can pockets The vacuum is applied through a rectangular tubular vacuum plenum 212 which is connected via a tube 214 to the vacuum chamber 30 created in the transfer support housing 94 and the bottom section 88 of the second housing portion 86 as described above The vacuum plenum 212 is also connected through a master adapter plate 216 via tubing connected to five apertures 218 into a space between the plate 216 and a disk shaped manifold blade 219 This space is isolated from the space vertically above the shaft 46 by a pair of reversible, wedge shaped manifold dams 220, as shown in Fig 14, fastened between the master adapter plate 216 and the manifold blade 219

The free end of the transfer shaft 46 has a transfer star wheel 48 bolted thereto. The star wheel 48 has a solid central disk portion 222 and a tubular sleeve shaped peripheral can pocket rim portion 224 around the periphery of the disk portion 222 The can pocket rim portion 224 has twelve radially outwardly extending teeth forming axially extending ridges forming twelve U shaped can pockets 50 around its periphery Each can pocket 50 has a radial through bore 226 joining an axial channel 310 and three transverse channels 312 in the curved surface of the pockets 50 intersecting the axial channel 310 These channels 310 and 312 distribute the vacuum pressure around the can 128 when a can is captured in the pocket 50 during the lower half rotation of the star wheel 48

The master adapter plate 216 has a flat disk portion 228, a central tubular hub portion 230, and an outer sleeve 232 concentrically about the hub portion 230 The outer sleeve 232 and the hub poition 230 are spaced so as to sandwich the front end of the tubular top section 98 of the transfer shaft support housing 94 therebetween The master adapter plate 216 is pinned and bolted to the tubular top section 98 The master adapter plate hub portion 230 acts as a bearing retainer for the front end bearing on the transfer shaft 46 The outside diameter of the outer sleeve acts as a location diameter for various can guide plates making up the can guide assembly 52

The disk portion 228 provides a mounting surface for the upper and lower guide assemblies 52 and supplies the mounting location for the reversible dams 220 which control the application of vacuum between the master adapter plate 216b and the manifold blade 219 The disk portion 228 also provides location for the manifold spacer 314 and supports the vacuum tubes 208 which transfer the vacuum from the vacuum plenum 212 to the internal star wheel area bounded by the lower half of the manifold blade 219, the master adapter plate 216, the dams 220, the transfer shaft 46, and the nm portion 224 of the star wheel 48

The size and design of the channels in the can pockets 50 are such as to optimize vacuum flow, give maximum can support, and minimize vacuum leakage The slots 234 in the disk portion 228 , which accommodate bolts to bolt the star wheel 48 to the transfer shaft 46, are provided to permit the star wheel 48 to be adjusted for timing between the transfer shaft 46 and the main turret star wheel 40 Finally, the outside diameter of the master adapter plate 216 is so machined as to provide minimal clearance with the star wheel 48 and acts as the rear sealing surface of the vacuum area within the star wheel 48

In operation, as the star wheel 48 rotates, the can pockets 50 sequentially pass by one of the dams 220 into the vacuum area below This

causes a vacuum to be pulled in the channels 310 and 312 in the can pockets 50 Thus, as a can 128 on the main star wheel assembly 24 passes downward after TDC and reaches about a horizontal position, air pressure applied through the lower half of the die/knockout ram module 38 is removed At the same time, one of the transfer pockets 50 is aligned with this can 128 and vacuum is applied through the channels 310 and 312 to cause the can 128 to be sucked against the transfer pocket 50 As the main star wheel 40 and the transfer star wheel 48 continue rotation, the can 128 is carried away from the main star wheel 40, toward the next main star wheel 40 in the next module 12 Similarly, when the pocket 50 carrying the can 128 on the star wheel 48 again approaches a horizontal position on the opposite side, adjacent the next main star wheel 40, the star wheel 48 passes the other dam 220, cutting off the vacuum applied through the channels 310 and 312 At this point, low air pressure applied through a die/knockout ram module 38 on the next main turret star wheel assembly 24 pushes the can 128 firmly against the corresponding pusher pad 64 aligned with the mating main can pocket 42 The net effect is a smooth transfer of cans 128 between the main star wheel 40 and the transfer star wheel 48 and to another main star wheel 40 Fine adjustment of the timing between the star wheels 48 and the main star wheels 40 may be made by loosening and rotating the star wheel 48 via the slots 234

Drive and Brake Assemblies

The system 10 of modules 12 has been designed to allow the drive motor apparatus 16 and the brake assembly 390 to be fitted to any transfer assembly 26 along the length of the train 10 This provides optimum flexibility for a train of modules 12 It is always ideal to ensure that the drive apparatus 16 is mounted centrally to a train By having a moveable drive assembly 16. it allows this unit to be moved easily from one module 12 to another

The gearbox and drive motor are mounted on a support plate which, depending on motor size, spans one or two bases and which is held in position in three places at the top by the gearbox support spacer which is doweled to the gearbox adapter plate, by three spacer bars which tie the drive support plate to the base 68, and at the bottom by an angle plate which is mounted to a machined face on the base 68 of the frame 22

On the end of the transfer housing (base) 68 the rear adapter plate is replaced by a gearbox adapter plate which is doweled and bolted in the same way, but which is taller to provide location for the gearbox support spacer

Drive is transmitted to the gear train for the full machine module 12 through a modified gear 18 which replaces the standard gear 18 on the end of the transfer shaft 46 This modified gear has a series of holes on a large pitch circle Attached to the gear is a drive quill This fits through the gearbox and is driven by the gearbox through a shπnk-disk with the gearbox output The benefit of this arrangement is that it is the gear that is driven and not the shaft The torque applied to the drive gear is transmitted directly to the other gears The transfer shaft is then driven from the gear 18 This minimizes the torque in the transfer shaft Location faces on the drive quill ensure that the transfer shaft 46 and the quill are coaxial, I e no adverse loading is placed on the transfer shaft 46

The motor is hung on the support plate Belt tension between the gearbox and the motor is achieved by the use of fixed centers The motor is accurately positioned relative to the gear box input shaft Alternatively, a sliding motor base may be used Note that it is essential that the input shaft of the gearbox and the motor shaft are parallel The motor and gearbox are sized to suit the number of modules 12 in the system 10 Typically, a 40 horsepower motor can supply up to 10 modules 12 The belt and sheaves are sized for machine speed

The brake assembly 390 may be placed on any transfer shaft 46 to ensure optimum flexibility of the module and train configurations, however, an end location remote from the drive apparatus 16 is preferred The brake quill and brake support plate are mounted and supported in the same way as the drive assembly 16 The brake is a fail-safe air actuated brake which requires its own low volume, high pressure air supply to keep the brake open Typically brakes are mounted on each end of a train of modules 12

Air Manifold and Distribution

Fig 16 is a schematic of the air distribution system utilized in the present invention An air compressoi 238 provides the main air supply pressure of nominally 60 psig The incoming supply is filtered in a filter 240 before being split to the three different pressure regulators a high pressure regulator 242, a medium pressure regulator 244 and a low pressure regulatoi 246 The air pressures are then fed to a horseshoe shaped manifold 248 in the air manifold assembly 154 via high, medium and low pressure headers 250, 252, and 254 Typically the high pressure header is maintained at 40 psig, the medium pressure is at 20 psig and the low pressure header is maintained 10 psig Each supply is regulated and a dial gives the actual pressures

Typically each of the die necking modules 12 of the invention requires volumes of between 90 and 100 SCFM air flow from the medium pressure compressor 238 This is a much reduced volumetric flow rate compared to conventional machines This is made possible by the unique air manifold arrangement of the present invention which permits the use of medium pressure compressors to supply the volumes of air necessary for the die necking process As a result, the power requirements to generate the necessary air supply are greatly reduced compared to conventional machines

Air is transferred from the incoming supply headers 250, 252, and 254 to each module 12 through modified AB S tubing Header 250 divides into

three polyflow (reinforced polyethylene) hoses 256 connected to the air manifold 248 Header 252 divides into two medium pressure supply polyflow hoses 258 connected to the air manifold Header 254 divides into two low pressure supply polyflow hoses 260 also connected to the air manifold 248 This air distribution arrangement is repeated identically for each module 12 in the system 10

A partial sectional view of a module 12 showing the manifold assembly 154 and air distribution rotor 156 arrangement is shown in Fig 17 The air manifold assembly 154 comprises an annular manifold plate 262, the horseshoe shaped flat manifold 248, a horseshoe shaped manifold support which is in turn clamped to the manifold plate 262, and the air distribution rotor 1 56 fastened to the air distribution sleeve 148 on the main shaft 34

The air distribution rotor 156 is a truncated cone shaped member which is bolted to the air distribution sleeve 148 via the three through bolts 144 The rotor 156 has a central bore receiving main shaft 34 and has nine small axial blind bores 264 and three stepped large axial through bores 265 symmetrically spaced about the central bore The large bores 265 loosely receive the bolts 144 there through thus forming annular passages therethrough The rotor 156 also has twelve angled bores 266 which intersect with the bottoms of the blind bores 264 and the large bores 265 and which exit through the flat annular front face 268 of the rotor 156 at locations radially spaced from the axial bores 264 and 265 Each of these angled port bores 266 lies in the same radial plane through the rotor 156 as its intersecting axial bore 264

The openings of the nine axial bores 264 and the three larger through bores 265 in the front face 268 of the rotor 156 mate with openings of nine blind axial bores 270 and three larger through bores 271 in the air distribution sleeve 148 The front end portion of the distribution sleeve 148 has a radial

flange 272 which has twelve threaded ports 274 which connect with the bottom ends of the axial bores 270 and 271 A flexible polyflow (reinforced polyethylene) hose 276 connects each port 274 to one of the die/knockout ram modules 38 The ram modules 38 are discussed in more detail below

The openings in the front face of the rotor 156 of the twelve angled port bores 266 are radially positioned to mate with openings in the horseshoe shaped flat manifold 248 This manifold 248 is supported by seven pistons 278 which ride in seven appropriately shaped cylindrical blind bores forming chambers 280 in a horseshoe shaped manifold support 282 The manifold support 282 is clamped to the manifold plate 262 via three clamp plates 284 which engage a groove 286 around the outer edge of the manifold plate 262

The manifold 248 has seven tubes 288 projecting from the manifold's front face and which are press fit into seven circumferentially spaced axial bores 290 These tubes 288 are also press fit into axial bores through each piston 278 Thus the manifold 248 is free to move axially back and forth via the pistons 278 riding in the chambers 280 in the manifold support 282 and constrained from rotation by three dowl pins (not shown).

The rear face 292 of the air manifold 248 has a low friction pad 294 of Turcite bonded thereto to minimize friction and wear between the manifold and the front face 268 of the rotor 156 during module operation The manifold 248 has nine threaded radial bores 296 spaced about the periphery of the manifold Seven of these bores intersect with the axial bores 290 The third and seventh bores do not intersect with axial bores 290 through the body of the manifold The third and seventh bores do intersect with blind bores through the rear face 292 of the manifold

Fig 18 is a face view of the manifold 248 Showing the seven air supplie hoses 256, 258, and 260 connected to their appropriate bores 296 via fittings 298 Each of the bores 290 connect with an elongated timing slot 300

in the face 292 of the manifold 248 These arcuate slots 300 mate with the ports of the angled bores 266 in the front face 268 of the rotor 156 as the rotor rotates The top slot 300, for the third high pressure connection, has a socket head cap screw 304 installed in the right of a pair of threaded holes 306 on either side of the axial through bore 290 This socket head cap screw 304 acts as an air dam to form a removable end to this particular slot 300

As the main shaft 34 rotates, each bore 266 intersects with the one of the slots 300 to distribute either low pressure, medium pressure, high pressure, then medium pressure, then low pressure, and finally no pressure through the rotor 154, the bore 270, port 274, hose 276 into the module 38 and ultimately into the can 128 in the can pocket on the main star wheel 40 Thus the manifold 248 provides air pressure application timing during the necking process of each can 128 while it is on the main turret The rotational position of the manifold 248 may be adjusted to fine tune this timing by loosening the clamp plates 284 and rotating the manifold 248 and manifold support 282 clockwise or counterclockwise

In operation, as a can 128 is fed into the main star wheel 40, low air pressure is fed through the knockout ram 54 of the die/knockout ram module 38 into the can 128 This stabilizes the can against the push pad 64 as the can is transferred from the pocket 50 of the transfer star wheel 48 into the can pocket 42 on the main star wheel 40 of the main turret 36 Medium pressure is then applied as the can 128 is entering the throat of the die The medium pressure primes the can 128 with air pressure prior to the forming By using the medium pressure there is onlv a limited waste of compressed air A further benefit of this medium supply is that it centralizes the can 128 in the throat of the die as air is forced out between the outside diameter of the can and the throat of the die

High pressure is then used once the can 128 is located in the die It supports the can during the die necking operation The can 128 against the die face acts as a seal for this high air pressure At the top of the cycle there is no additional high pressure feed As the can leaves the die, medium pressure is again applied to strip the can (although the residual air in the can will fulfill this operation) At the end of the cycle the low pressure feed stabilizes the can against the push pad prior to discharge of the can into the transfer star wheel

Fig 19 shows diagramatically how the air system is configured and how it functions The high, medium and low pressure headers 250, 252, and 254, respectively, feed seven air hoses to the air manifold assembly 2 low pressure lines 260, 2 medium pressure lines 258 and three high pressure lines 256 These in turn feed into the circumferential slots 300 which are on the same pitch circle as the twelve bore openings 266 in the mating face 268 of the rotoi 156 Each of these bores ultimately feed through a central bore 308 through the knockout ram 54

The diagram in Fig 19 shows how the rotor ports move through the different air supplies Each circle represents a can on the turret and its port or opening on the front face 268 of the rotor 156 Each horizontal row represents different angular positions of the rotor 156 as can 128 passes from into the first slot 300 through the last slot 300 The first slot 300 is sized so that only one rotor port is in the initial low pressure feed at any one time However, as can one is entering the initial low pressure slot (signified by the hashed vertical strip beneath its corresponding slot 300) another can (can No 7 in Fig 19) is just leaving the final low pressure supply slot 300 on the far right This allows for air to be stabilized between the two ports, reducing waste

A can 128, I e, its port 266, will enter the medium supply slot 300 as the port trailing it will enter the low pressure slot 300 Again, the medium

supply on the discharge (right side in Fig. 18 and 19) is also feeding at the same time as the medium supply on the in-feed side. The key feature to the air supply manifold 248 is that the configuration of the slots 300 in the manifold 248 allows air to be re-used. Note that when the port on the rotor 156 passes out of the third high pressure slot 300, the path is blocked. The can, at this time, is firmly sealed in the die/knockout ram module. When this port reaches the medium pressure slot, high pressure still resides within the can and passages. Consequently, air is actually fed from the can and passages back into the medium pressure supply header rather than to atmosphere This residual air in the can will also bleed back into the medium pressure supply channel on the in-feed side (left in Fig. 19).

As the turret and rotor 156 further rotates to position this particular port in line with the last low pressure slot, the residual medium pressure in the can and passages feeds back into the low pressure supply. This regenerative pressure feature allows the system 10 and each individual module 12 in accordance with the invention to be largely self sufficient of medium and low air pressure supplies once the system 10 has been turned on and cans 128 start to feed through the machine. This feature provides a substantial savings in air volume required for system operation, on the order of at least 30% less air volume than in comparable conventional machines .

The manifold 248 is completely symmetrical with respect to the top center position of the manifold, which is at 105° in Fig. 18. The manifold assembly is symmetrical with the exception of the two plugged threaded bores 296 which contain plugs 302. With only minor changes, the module 12 may be operated in the reverse direction The setup shown in Fig. 18 is for clockwise rotation. In order to operate the module 12 in a counterclockwise direction, the plugs 302 in the plugged bores 290 are swapped with fittings 298 of the other two high pressure hoses 256, and the socket head cap screw 304 is moved to the other threaded hole 306 on the other, or left side of the

axial hole 290 in the top elongated slot 300. The system drive motor apparatus 16 is then operated in reverse, after changing appropriate can guide assemblies

The manifold plate 262 is doweled and bolted to the rear face of the upper section 90 of the unitary frame body 22 The manifold plate 262 also acts as a mounting face for the knockout cam sleeve 56 and cam spacer 152, if any, and houses a rear oil seal 310 The rear oil seal prevents lubricating oil from entering the air manifold assembly area The manifold 248 and manifold support 282 are horseshoe shaped, which allows the assembly to be removed from the main shaft without a major disassembly operation The manifold 248 is made of steel with a "Turcite" face plate 294 bonded to its rear face 292 Turcite is the trade name for a low friction, high wear resistance surface material. The rotor 156 rotates against this surface

Seven piston tubes 288, with pistons 278 fixed to the ends, are press fitted in the axial bores 290 The positioning of the piston tubes 288 thus correlate with the positions of the slots 300 through the pad 294 on the working face 292 These pistons fit in the piston chambers 280 in the manifold support 282 As low, medium and high pressure air are fed into the manifold 248, the majority of the air is fed into the slots 300, into the ports 266 on the rotor 156 and then into the knockout rams 54 Air is also fed back through each of the piston tubes 288 into the piston chamber 280 This then forces the piston faces, and thus the manifold 248, onto the working face 268 of the rotor 156 to create an air tight seal There are also springs (not shown) in four of the chambers 280 to press the manifold against the rotor 156 during initial startup of the module 12 Note also that there are different pressures exerted between the manifold and the rotor 156 via the pistons around the manifold depending on the incoming supply air pressure This has the effect of applying the most pressure to the areas of the rotor 156 where the greatest

sealing forces are required, 1 e in the areas of high pressure Once air flow starts, the air pressure under each piston seals the manifold face

The piston bores 280 are deep enough to allow for a 0 400" adjustment of neck depth There will always be a seal between the manifold 248 and the rotor 156, irrespective of the position of the rotor relative to the manifold plate 262 The use of three high pressure ports in the manifold 248 rather than one is designed to optimize air consumption for different neck depths For example, at the deepest neck the can will hit the knockout at the 45 degree point For shallower necks, the point of contact will be later in the cycle, thus it is possible to blank off the ports feeding the first and/or second high air pressure slots 300 The spacing between the slots between the high and medium slots is 0 040" smaller than the diameter of the opening of the port 270 in the rotor 156 This is to prevent can collapse due to no internal air pressure being present at machine start-up, 1 e it is not possible for any rotor port 270 to be starved of air

ln-feed and Discharge Assemblies

A simplified representation of a system 10 of modules 12 including an in-feed assembly 314 on a service module 14 and a discharge assembly 316 on the last module 12 is shown in Fig 20A and Fig 20B The in-feed assembly 314 is identical to a standard transfer star wheel assembly 26 as shown in Figs 13, 14, and 15 except that the teeth 320 on the star wheel 318 forming the can pockets 50 are particularly canted or angled toward the direction of rotation

The in-feed guide assembly 322 configuration depends on the particular installation, but typically, this assembly is a modified transfer guide assembly 52, shown in Fig 13, which includes a downwardly slanted chute for dispensing the cans 128 into the in-feed star wheel 318 The assembly 322 comprises two parallel plates onto which guides 324 and 326 are spaced and

mounted The rear plate is mounted, through a spacer, onto the master adapter plate 216 The front plate is supported off of the rear plate by a series of spacer bars A change in can height requires these spacer bars to be changed

The in-feed guide assembly 322 is totally symmetrical, allowing it to be assembled on either the left hand or the right hand end of the train, as is shown in Fig 20A The canted tooth profile of the in-feed star wheel 318 provides a momentary acceleration to each can 128 as it is picked out of the stack of cans in the in-feed chute so as to properly space the cans apart in the in-feed starwheel can pockets 50 The can spacing then remains constant throughout the modules 12 in the system 10 The profile of the in-feed stai wheel teeth 320 also allows the last can in the stack to be positively picked up and fed into the machine, thus eliminating a need for a constant pressure of waiting cans in the chute

The profile on each tooth 320 of the in-feed star wheel 318 is made up of a series of distinct radii which are blended together to form the star wheel profile There is an abrupt transition between the can pocket radius and the profile of the starwheel tooth which acts as a brake to the system to prevent the back pressure of cans stacked in the chute from forcing two cans into the same pocket on the star wheel 318 Each starwheel tooth 320 is generated by an iterative process of visualizing overlaying cans on each other back up into the in-feed chute. From this the radii of best fit are developed •

The discharge assembly 328 is identical to a transfer assembly 26 previously described with the exception of the star wheel shape and the assembly may include a guide assembly 322 that is identical to that of the in- feed assembly as is shown in Fig 20A or the discharge guide assembly may have another configuration such as the horizontal discharge guide assembly 330 as shown in Fig. 20B. The only difference between the discharge assembly 328 and the in-feed assembly 314 shown in Fig 20A is that the

discharge star wheel 332 is an exact mirror image of the in-feed star wheel 318, with teeth 334 canted in the opposite rotational direction It is this unique feature which prevents or minimizes can damage as the processed cans 128 are transferred out of the system 10 In the case of the system 10 shown in Fig 20A, the flow of cans 128 may be in either left to right or right to left as is shown The reversal of direction only requires air manifold reconfiguration as above described, and relocation of the lower guides 392 as shown in Figs 20A and 20B, and, if a flanger die set is used, replacement of the flanger cam sleeve (not shown),

The svstem 10 shown in Fig 20B is set up for can flow from left to right The star wheel 332 is in the in-feed assembly 314 in this configuration The star wheel 318 is in the discharge assembly 340, mounted on a transfer shaft support housing 94 of the end module 12 of the system 10 The discharge guide assembly 330 shown in Fig 20B is made up of two plates with guide rails 336 and 338 mounted to the inside faces of both plates The discharge guide plates are separated by spacer bars which are changed for different can heights as in the in-feed guide assembly 322

In Fig 20B, cans 128 are decelerated as they are fed out of the discharge transfer star wheel 318, then move along a horizontal guide portion before being discharged out of the machine into the line track work (not shown) This configuration of assembly allows differing output angles to be achieved on the same basic configuration A swing gate 342 on the top of the discharge guide assembly 330 can be rotated upward and serves as an access point for the removal of cans Further, this swing gate 342 acts as a pressure release, I e if there is a discharge jam, the gate will be forced open, allowing cans to escape This prevents can jams within the system 10

The use of a mirror image in-feed star wheel compared to the in-feed star wheel 318 as the discharge star wheel 332 to discharge the cans 128 is a

unique feature of the present invention The mirror image discharge star wheel 332 decelerates the cans 128 smoothly and gently and feeds them into the discharge stack at a speed commensurate with passage of the cans through the system This minimizes the potential for can damage due to adjacent cans decelerating rapidly by banging them into each other as they enter the discharge stack and subsequent track work Accordingly, fewer can rejects are experienced with the system 10 in accordance with the invention compared to conventional processing systems

Die/Knockout Ram Module

Referring now to Fig 17, each of the die/knockout ram modules 38 has a stationary housing 344 which is bolted to the outer surface 176 of the die turret block 36 The knockout ram 54 slides within the hollow housing 344 and carries a necking die 346 threaded onto its distal end which projects through one of the apertures 186 in the knockout seal retainer plate 184 This housing 344 and the die 346 remain stationary on the turret 36 during module operation

The knockout ram 54 has a cylindrical portion 348 and a rectangular cam follower support portion 350 extending axially rearward from the cylindrical portion 348 The module housing 344 has an axial bore 352 which slidingly receives the cylindrical portion 348 of the knockout ram 54 The housing 344 also has a pair of axially parallel rails 354 which extend rearwardly on either side of the rectangular cam follower support portion 350

The rectangular cam follower support portion 350 has two cam follower rollers 356 on its underside which extend downward toward the knockout ram cam sleeve 56 and sandwich both sides of the cam rib 206 Since the cam sleeve 56 is stationary and the knockout ram module 38 is fastened to the rotating turret block 36, the cam rollers 356 follow the cam nb 206 as the block 36 and main shaft 34 are rotated This in turn causes the knockout ram

40

to move back and forth through the housing 344 and into and out of the open end of the can 128

As the ram 54 moves back and forth, it is prevented from rotational movement by a guide roller 358 which projects upward between the two parallel rails 354 of the housing 344

Each module 12, except the last, preferably carries twelve die/knockout ram modules 38 having identical dies 346 screwed in place on each of the die module housings 344 Each module 12 has a progressively different set of dies 346 than the module 12 next to it Thus, as a can 128 enters and passes through the system 10, the can neck is partially formed in each module 12 The final module 12 in the system 10 preferably carries twelve flanging modules (not shown) which have internally rotating flanging wheels on a central rotating shaft which produce a flat radial flange around open end of the can 128 This flange is then mated and crimped together with a can lid in subsequent processing equipment (not shown)

The die/knockout ram modules 38 may be easily removed from the module 12 without removing the main shaft 34 and main star wheel turret assembly 24 The access plate 70 is raised and the air hose 276 disconnected from the module 38 The knockout ram seal retainer plate 1 84 is moved forward, the module hold down bolts are removed and the rear end of the module 38 is lifted upward so that the rear end clears the housing 90 The front end of the module 38 carrying the dies 346 may then be slipped back through the opening 186 in the seal retainer plate 184 and the module 38 removed from the housing 90

Pusher Ram Modules

Each of the pusher modules 58 is bolted to the pusher turret 160 in a manner similar to that of the die/knockout modules 38. The pusher module 58 is positioned such that it is in line with one of the die/knockout ram modules 38. Referring now to Figs. 10 and 12A, the pusher module 58 comprises a pusher module housing 360 having a central bore 362 and a pair of forwardly extending parallel rails 364 The pusher ram 60 slides within the housing 360. The pusher ram 60 has a cylindrical portion 366 and a rectangular portion 368 extending from the cylindrical portion 366. The cylindrical portion 366 slides within the bore 362 with the rectangular portion 368 sliding between the rails 364 of the housing 360. The pusher ram 60 has a pair of spaced cam rollers 202 which extend down from the rectangular portion 368. These cam rollers 202 sandwich and ride on the cam rib 204 on the pusher cam sleeve 62. The pusher ram 60 is prevented from side to side movement by a roller 372 which projects upward from the rectangular portion 368 and rides between the parallel rails 364 of the housing 360.

The pusher ram 60 moves back and forth in the housing 360 as the turret 160 rotates with the main shaft 34 since the pusher cam sleeve 62 is stationary. This forward and back movement is caused by the cam rollers 202 following the cam rib 204 on the cam sleeve 62.

The cylindrical portion 366 of the pusher ram 60 has a central threaded end bore 374 which receives a threaded push pad support 376. The push pad support 376 in turn has the pusher pad 64 on its rear end. The pusher pad 64 is secured to the support 376 and the ram 60 via a through bolt 378 which is threaded into the cylindrical portion 366.

The individual axial position of each pusher pad 64 is adjusted by loosening the bolt 378 and turning the support 376. When the proper position is reached, the bolt 378 is again tightened to lock the pusher pad 64 in place Once each pusher pad 64 position is set for a given can length, the adjustment

for different neck depths may usually be made by loosening the long bolts 146 and adjusting the micro-adjustment ring 182 as elsewhere described

The pusher modules 58 may be easily removed from the module 12 The bolted transparent access plate 66 is raised or removed and the six bolts securing the top module 58 to the turret block 160 are removed The front end of the module 58 is then lifted upward so that the rollers 202 disengage the nb 204 on the cam sleeve 62 The seal retainer plate 190 is moved rearward away from the housing portion 76 The pusher pad 64 and the front of the pusher ram 60 is then pulled through the aperture 192 in the seal retainer plate 190 and the top module 58 removed from the housing portion 76 Replacement of the module 58 is simply the reverse

Cam Arrangement

The cam sleeves 56 and 62 provide the timing of the neck forming operation in each module 12 by moving the pusher ram 60 and the knockout ram in a predetermined manner The cam sleeve pairs 56 and 62 are preferably identical and thus interchangeable between necker modules Fig 21 provides a plan schematic view of can motion as a series of cans 128 travel through a main star wheel assembly 24 in a typical module 12 Figs 22 and 23 show the cam profiles to generate the motion shown in Fig. 21 It is to be understood, however, that the motion provided by the cam sleeves represented in Figs 21 through 23 are exemplary only Each progressive die set in the sequential modules 12 of the system 10 perform slightly different operations on the cans 128. The strokes of the rams are preferably constant However, this could differ, depending on the particular application Thus the fol lowing description is representative only

When the can 128 is first picked up in pocket 42 at a horizontal 0° position, the knockout ram 54 is not fully retracted. The period of the cam is 216 degrees Thus the knockout ram is still inside the die 346 but moving

outward at the can transfer point The knockout cam commences ram movement 1 8 degrees before the can transfer point Dashed line 380 represents the path of the knockout cam rib 206 through its period as the can rotates upward through top dead center and back through a horizontal position ( 1 80°) Note that the knockout cam 206 pushes the knockout i am 54 first into the can 128 and then the knockout ram 54 follows the can 128 as it approaches and leaves the TDC position This minimizes internal can wall distortions as the can enters and leaves the die 346 on the ram housing 344 During turret rotation from 198° through 342°, the knockout cam rib 206 retains the knockout ram 54 in a fully retracted position

The dashed line 382 represents the path of the pusher cam rib 204 as the main star wheel turret assembly 24 rotates through 1 80° from a horizontal position to a horizontal position The pusher cam rib 204 begins to push the can 128 toward the die/knockout ram module 38 at about -22° and reaches full stroke at 90° or top dead center The pusher ram 60 retracts symmetrically back to a fully retracted position at about 192° and remains there through the remainder of rotation of the pocket 42 until pocket 42 again reaches a position of about -22°

Referring now to Fig 22, a preferred profile of the knockout cam track is shown with reference to top dead center The center low point 384 of the profile corresponds to the top dead center position of the module 38 The position of the knockout ram 54 is advanced from - 108° left of TDC through - 63° left of TDC and then retracted through TDC The ram 54 is again advanced from TDC through +63° and then retracted through + 108° in a retracted position Beyond these positions, the cam retains the ram 54 in a fully retracted position

Referring now to Fig 23, a preferred profile of the pusher cam track is shown with reference to top dead center The cam 204 starts to push the pad

64 at - 1 12° before TDC and continues on a straight ramp to TDC and then retracts the pad 64 on a straight ramp to +1 12° after TDC, after which the pad remains retracted until the pusher module 58 again reaches - 1 12°

The cam sleeves 56 and 62 are identical for all necking dies 346 used m the modules 12 In other words, the cam sleeves 56 and 62 are universal for necker modules Consequently, if the direction of can flow through a system 10 is to be changed, say from right to left in Fig 1 to left to right, the port connections on the air manifold assembly 154 need to be changed as described above The cam sleeves do not have to be changed The sequence of depth settings of the pusher pads 64 must be reversed This is accomplished by changing the neck depths on each module 12 by simply adjusting the micro- adjusting ring 182

The design of the cam sleeves 56 and 62 addressees two problems present in the conventional necking apparatuses The primary one is the challenge of having the fewest number of different or variable parts, especially those parts which are expensive and/or those with a long manufacturing cycle The cam sleeves 56 and 62 fulfill both of these criteria

Also, the fewest numbers of parts being replaced or changed when modules are separated and then recombined in different order or combinations achieves optimum modularity The cam sleeves 56 and 62 in accordance with the present invention achieve these goals The pair of cam sleeves 56 and 62 are universal The pusher cam sleeve provides the pusher ram with approximately 0 08 inches of excess motion

Conventional necking machines are set up with the can path moving progressivelv away from the dies If the can is transferred from one necking turret to the next in these conventional machines, the face of the push plates must be behind the bottom of the can To achieve this the can path is staggered If the direction of processing in such a conventional machine is

reversed, this stagger has to be reset in the opposite direction In conventional machines, this stagger is at least 0.03 inches or more The greater this stagger, the larger this problem becomes as train lengths get longer than six stages or turrets on one single base

The apparatus in accordance with the present invention solves this problem By taking the can 128 out of the transfer star wheel 48 before the pusher pad 64 is fully retracted the effect of staggering is achieved without additional expense and sacrifice of true modularity At 0° in the present invention, the vacuum transfer star wheel 48 will capture the can 128 when about 0 10 inches retraction of the pusher plate 64 is remaining Thus a 2 00 inch diameter can base is just covered by a 2 25 inch diameter pusher plate 64 at - 1 1 °, at which point the pusher plate 64 has moved axially less than 0 02 inches from the position at 0° Therefore, in the apparatus of the present invention, we have about 0 08 inches of "insurance"

The total pusher cam stroke is preferably 1 750 inches Because of the disproportionate angle taken up by the initial accelerations and decelerations, of this total stroke only a small portion, 0 08 inches, occurs during the initial 1 8° of rotation By extending the cam stroke by 36°, i e , by 20%, the speed capability of the apparatus 12 and system 10 in accordance with the present invention is increased correspondingly by 20%, thus vastly improving the potential throughput of cans

The modular can forming apparatus 12 and the system 10 in accordance with the invention has been described with reference to a particular embodiment thereof There are many alternatives, variations and equivalents to each of the modules and components thereof that are believed to be within the broad scope and fair meaning of the present invention For example, the motor assembly 16 is shown preferably installed on a central module 12 A different size of motor configuration could be mounted to any one module 12

or between two modules Alternatively, two coordinated motor assemblies could be utilized, one at each end of the train of modules 12 Similarly, the brake assembly 390 may be located other than as shown

The particular shape of individual housing components of the unitary frame 22 may be other than as particularly shown and described For example, the upper housing 90 could be other than a box shape The octagonal housing portion 80 could be other than octagonal The transfer assembly 26 could be arranged on the opposite side of the main star wheel turret assembly 24, so long as the modules are identically configured The service module 14 may be placed at either end of the train of modules 12 Other modifications and changes will also become readily apparent to those skilled in the art to which this invention pertains It is therefore to be understood that all such modifications, changes, alternatives and variations are within the scope of the present invention as defined by the following claims