System and Method for Orienting the Rolling Direction of an End Shell in a Metal Container Manufacturing Process

Abstract

A system and method of orienting the rolling direction of metallic objects is provided. More specifically, the present invention relates to systems and methods used to align the rolling direction of metallic objects in a predetermined orientation in a high-speed manufacturing system. The rolling direction is determined by sensing grinding marks on the metallic objects. The metallic objects may subsequently be formed by tools that have been adapted to work with, or transverse to, the rolling direction. Optionally, the tools may form the metallic objects into container end closures adapted to seal a container of a predetermined size and type.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority under 35 U.S.C. §119(e) to U.S. Provisional Patent Application Ser. No. 62/278,049 filed Jan. 13, 2016, which is incorporated herein in its entirety by reference.

FIELD OF THE INVENTION

The present invention relates generally to the manufacture of container end closures. More specifically, the present invention relates to methods and apparatus for orienting and registering the rolling direction of a plurality of metallic end shells at high speed before the end shells are converted into end closures by a conversion press.

BACKGROUND

Metallic containers offer distributors and consumers many benefits. The metallic body of a container provides optimal protection properties for products. For example, the metallic body prevents CO₂ migration and UV radiation which may damage personal care, pharmaceutical, beverages, and food products and other UV-sensitive formulations, negatively influencing the effectiveness of ingredients, as well as the fragrance, flavor, appearance, or color of the product. Metallic containers also offer an impermeable barrier to light, water vapor, oils and fats, oxygen, and micro-organisms and keep the contents of the container fresh and protected from external influences, thereby guaranteeing a long shelf-life. The surfaces of metallic containers are also ideal for decorating with brand names, logos, designs, product information, and/or other preferred indicia for identifying, marketing, and distinguishing the metallic container and its contents from other products and competitors. Thus, metallic containers offer bottlers, distributors, and retailers an ability to stand out at the point of sale.

Additionally, many consumers prefer metallic containers compared to containers made of glass or plastic. Metallic containers are particularly attractive to consumers because of the convenience they offer. The light-weight of metallic containers makes them easier to carry than glass containers. Metallic containers are particularly suitable for use in public places and outdoors because they are more durable than glass containers. Further, some consumers avoid plastic containers due to concerns that the plastic may leach chemicals into consumable products.

As a result of these and other benefits, sales of metal containers were valued at approximately $53 billion globally in 2014. A large percentage of the metallic container market is driven by beverage containers. According to one report, approximately 290 billion metallic beverage containers were shipped globally in 2012. One U.S. trade group reported that 126 billion metal containers were shipped in the U.S. alone in 2014.

Metallic containers come in a variety of shapes and sizes. Typically, at least one end of a metallic container is sealed by an end closure. End closures are formed from end shells in a process separate from the container body. An end closure is interconnected, or “double seamed,” to the neck of a container after the container is filled with a beverage or other product. The manufacture of end closures requires a number of processing steps collectively referred to as a conversion process. Examples of known conversion processes are generally illustrated and described in “How Ball Makes Beverage Ends,” available at http://www.ball.com/Ball/media/Ball/Global/Downloads/How_Ball_Makes_Beverage_Ends.pdf (last visited Nov. 11, 2016) and U.S. Pat. No. 6,533,518, which are each incorporated herein by reference in their entirety.

To meet this demand, metallic container manufacturing facilities operate some of the fastest, if not the fastest, production lines in the container industry. Because of the high speeds required to produce end closures for metallic containers, techniques or processes that may work in other industries or with end closures formed of other materials do not necessarily work at the high speeds required for metallic end closure production lines. Accordingly, specialized equipment is required for many of the operations performed to form the end closures. The production equipment must also be durable and easy to service to avoid down-time on the high-speed production lines used to form metallic end closures.

Referring now to FIG. 1, a prior art conversion process 2 is generally illustrated for the conversion of coiled aluminum to a finished end closure 14. The process generally starts with a coil 3 of stock metal. As one of skill in the art will appreciate, the stock metal includes grains formed as the metal sheet is produced. The grains have a crystallographic orientation that develops during the hot rolling and cold rolling processes used to produce the metal sheet. As the metal material is rolled repeatedly in the same direction, the metal becomes striated, forming the grain with a crystallographic orientation. The crystallographic orientation cannot be detected by visible light; X-rays are normally required to determine the crystallographic orientation of the grain. However, the crystallographic orientation generally correlates with the rolling direction. The cold rolling used to produce the metal sheet also transfers roll grinding marks 4 to the metal sheet, frequently with the last rolling operation. The grinding marks 4 may be detected by visible light (and without X-rays) and have an orientation 5 and the appearance of straight, generally parallel markings in the metal. The grinding marks are also generally parallel to the rolling direction and thus may be used to determine the rolling direction. Although the grinding marks 4 are visible to the human eye, the real impact on the performance of containers and end closures formed from the metal occurs at the microscopic level. The metal sheet is stronger and has better metallurgical properties such as one or more of strength in resistance to deflection and resistance to strain deformation when oriented perpendicular to the rolling direction (or perpendicular to the crystallographic orientation of the grain). Similarly, the metal sheet has less preferable metallurgical properties when oriented parallel to the rolling direction (or parallel to the crystallographic orientation of the grain).

After receiving the metal coil 3, the coil is loaded onto an uncoiler 6 that unwinds the stock metal. The stock metal is then received by a shell press 7. The shell press includes precision tooling to punch out blanks from the metal material and form the blanks into end shells 8. The blanks may be generally circular. The rolling direction 5 of the end shells 8 is randomly oriented as the end shells 8 leave the shell press 7 and as the end shells 8 are transported through subsequent stations 9-13 of the conversion process 2.

A curler 9 receives the end shells and forms a lip around a circumferential edge of the end shells 8. Liners 10 apply sealing compounds to the end shells. The sealing compounds may optionally be cured by a liner oven 11. The end shells may then be accumulated in a balancer 12. The balancer ensures an uninterrupted flow of end shells are available for processing by a conversion press 13.

The balancer 12 supplies the end shells to the conversion press 13. The rolling direction 5 orientation of the end shells 8 entering the conversion press 13 is random because there is no reliable method for orienting the end shells in the current conversion process 2.

The conversion press 13 converts the end shells into end closures 14. Examples of prior art conversion presses are provided in U.S. Pat. No. 9,321,097 and U.S. Pat. No. 9,393,610 which are each incorporated herein in their entirety. The end closures 14 may be adapted to seal any variety or size of metallic container. The conversion press 13 may coin, cut, incise, bend, and form the metal of the end shell 8 depending on the type of end closure 14 formed. For example, when end closures 14 for beverage containers are manufactured, the conversion press 13 uses multiple progressive die sets which raise a rivet that is generally centered on a closed end-wall of the end shell. Severable scores 15 are formed to define a tear panel 16 that can be opened to form a pour opening. Finally, the conversion press 13 connects a pull tab 17 to the rivet. Other operations 18, such as decorating, may be performed on the end closures 14. The end closures 14 are then bagged, palletized, and stored until needed to seal a filled container body.

An important consideration in designing and fabricating metallic end closures 14 involves providing a desirable balance between minimizing material requirements (such as providing relatively thin-gauge metal) while achieving an end closure 14 that will maintain its integrity and/or form, despite shipping and handling impacts or forces and impacts arising from dropped beverage containers and shipping mishaps. Moreover, it is critical to provide a metallic end closure 14 which maintains integrity and/or form even when the content of a metallic container sealed by the end closure 14 is under pressure due to carbonated or other gas-pressured contents and/or arising from high internal temperatures, including, in some cases, pasteurization temperatures.

Unfortunately, as shown in FIG. 1, in the prior art conversion process 2, the rolling direction 5 orientation of the end closures 14 is random with respect to the scores 15 and other features formed during the conversion process. As the rolling direction orientation is unknown when the end shells 8 enter the conversion press 13, the metal must be assumed to be in the worst possible orientation of strength. Stated otherwise, the conversion press 13 must be designed assuming that the crystallographic orientation of the grain of the end shells 8 is in the weakest possible orientation with respect to the tooling of the conversion press 13. Any coining, cutting, embossing, incising, bending, forming, or other operations performed by the conversion press 13 may land in or on the rolling direction 5 of the metal, or be oriented unfavorably with respect to the rolling direction 5. Accordingly, the tooling of the conversion press 13 must be designed to prevent weakening (or failure) of end shells 8 that are in the worst possible orientation when converted into end closures 14. Thus, the tooling design of the conversion press 13 may not be optimized since the engineering and design parameters are based on the worst possible metal grain orientation. Similarly, certain features, such as scores that are stronger or that have increased resistance to failure that could be formed on the end closures 14 when formed with a favorable rolling direction orientation, cannot be formed due to the random orientation of the rolling direction 5 because of the risk of end closure failure. Alternatively, the assumption that the end shells 8 are in the worst possible orientation with respect to the metal grain requires the use of thicker gauge materials, which inherently increases the material costs associated with the metallic end closure 14.

Accordingly, there is an unmet need for systems and methods to align and register the rolling direction orientation of a plurality of metallic end shells at high speed before the end shells are converted into end closures by a conversion press in a container end closure production line without decreasing the efficiency, or increasing the costs, of current container end closure manufacturing processes.

SUMMARY OF THE INVENTION

The present invention provides methods and apparatus for aligning the metal rolling direction of end shells relative to a reference axis in a cost-effective, fast, and reliable manner. After the rolling direction of the end shells are aligned, the end shells may be converted into end closures by a conversion press.

One aspect of the present invention is to provide an orienting apparatus that can quickly detect and efficiently align the rolling direction of metallic end shells in a high-speed production process. In one embodiment of the present invention, the orienting apparatus is operable to identify the metal rolling direction and rotate an end shell. Optionally, the orienting apparatus rotates the end shell by mechanical contact with a portion of the end shell or by rotation of a support holding the end shell. In one embodiment, to rotate the end shell the orienting apparatus contacts an exterior surface portion of the end shell.

In one embodiment, the orienting apparatus includes an optical or other type of sensor to sense roll grinding marks present on the end shells. In another embodiment, the orienting apparatus is operable to align a plurality of the end shells at a cycle speed of at least 750 cycles per minute. In another embodiment of the present invention, the orienting apparatus can operate at up to approximately 800 cycles per minute.

Another aspect of the present invention is an orientation system to align the rolling direction of metallic work pieces before further metal forming operations are performed on the metallic work pieces. In this manner, the tooling used to perform the metal forming operations may be optimized increasing the strength and resistance to strain deformation of a product produced from the metallic work pieces by the further metal forming operations. In one embodiment, by aligning the rolling direction of the metallic work pieces before performing the further metal forming operations, the metallic work pieces may be formed from a thinner metal stock material. In another embodiment, the metallic work pieces comprise metallic end shells. In still another embodiment, the further metal forming operations are performed by a conversion press that forms the metallic work pieces into metallic end closures.

In accordance with another aspect of the present invention, a system for sensing and subsequently aligning the rolling direction of a metallic end shell to a preferred position is disclosed. The system is operable to simultaneously align multiple metallic end shells. The system generally comprises, but is not limited to: (1) a balancer operable to receive the metallic end shells and place the metallic end shells in a transport system; (2) the transport system operable to move the metallic end shells through the system and selectively prevent rotation of the metallic end shells; (3) an orientation system operable to receive the metallic end shells and rotate the metallic end shells such that the rolling direction of the metallic end shells is within a predetermined angle with respect to a reference axis of the system; and (4) a conversion press operable to form the metallic end shells into metallic end closures adapted to seal a container of a predetermined size and shape. In one embodiment, the metallic end shells generally comprise an open end, a closed end-wall portion, and a sidewall portion extending therebetween. Optionally, a curl may be formed on a sidewall portion proximate to the open end.

In one embodiment, the orientation system comprises sensors and actuators interconnected to servo units. The transport system moves the metallic end shells to a first index position of the orientation system. Sensors of a first sensor group at the first index position determine the orientation of roll grinding marks of each of the metallic end shells. The roll grinding marks are generally parallel to the rolling direction and used to determine the orientation of the rolling direction of each metallic end shell. After a predetermined dwell time, the transport system moves the metallic end shells to a second index position. At the second index position, servo units activate actuators which rotate the metallic end shells axially to align the roll grinding marks, and the rolling direction, with the reference axis. In one embodiment, the actuators of the second index position can rotate to align the rolling direction of the metallic end shells to within about plus or minus 12° of the reference axis, and more preferably to within about plus or minus 10°. In another embodiment, a light is associated with the sensors. In one embodiment, each sensor may be associated with a light.

Optionally, the transport system may move the metallic end shells to a third index position associated with sensors of a second sensor group. The second sensors may determine the second orientation of the roll grinding marks of each of the metallic end shells. Optionally, a light may be associated with the second sensors. The transport system may then move the metallic end shells to a fourth index position. A second actuator group may optionally be positioned proximate to the fourth index position to rotate the metallic end shells axially to further align the metallic end shells with the reference axis. In one embodiment, the actuators of the second actuator group can rotate to align the rolling direction of the metallic end shells to within about plus or minus 3° of the reference axis, and more preferably to within about plus or minus 1°. In another embodiment, the actuators of the first and second actuator groups can rotate metallic end shells up to about 45° during a dwell period of the transport system. In one embodiment, the dwell period is less than about 60 ms.

The orientation system may further include sensors of a third sensor group associated with a final index position. The third sensors may determine the final orientation of the roll grinding marks of each of the metallic end shells. A light may be associated with the third sensors. Metallic end shells with final rolling direction orientations that are not within the predetermined angle may then be removed from the system before reaching the conversion press.

In one embodiment, the system includes an ejector. The ejector removes metallic end shells for which the rolling direction orientation is not within a predetermined angle with respect to the reference axis from the transport system. In one embodiment, the ejector uses a gust of compressed gas, such as air, to remove the metallic end shells from the transport system. In another embodiment, the ejector contacts and applies a mechanical force to metallic end shells that are not properly aligned. The force removes the metallic end shells from the transport system.

In one embodiment, the sensors of the first, second, and third sensor groups comprise cameras. The cameras are operable to image metallic end shells to locate and determine the orientation of roll grinding marks on each of the metallic end shells. Said another way, the cameras are operable to capture an image of the metallic end shells with sufficient resolution to identify roll marks on the metallic end shells. The cameras may then provide data regarding the orientation of the roll grinding marks of each of the metallic end shells to a control system. Alternatively, the cameras may provide an image of each metallic end shell to the control system. The control system may then analyze the images to determine the orientation of the roll grinding marks on each of the metallic end shells. The control system may then determine an amount of axial rotation required to align the rolling direction of each metallic end shell with the reference axis. After determining the amount of axial rotation for each metallic end shell, the control system sends a command to the actuators to rotate the end shells such that the rolling direction is substantially aligned with the reference axis.

In one embodiment, the control system identifies the roll grinding marks (including rolling striations) by comparing each image received from the sensors to pictures (or other data) of a known reference, for example, in a database. The known reference may include roll grinding marks that are aligned with the reference axis. Continuing this example, the control system can identify rolling striations in the metallic end shells and determine if the rolling striations are in the desired orientation by comparing them to the rolling striations of the known reference.

In one embodiment, the actuators contact a predetermined portion of the metallic end shell and rotate axially to rotate the rolling direction of the metallic end shell to the predetermined angle. The actuators may rotate either clockwise or counterclockwise. In one embodiment, the actuators contact at least a portion of the closed end-wall of the metallic end shell. In another embodiment, the actuators contact the sidewall portion of the metallic end shell or, alternatively, a closed end-wall portion of the metallic end shell. In another embodiment, the actuators are operable to rotate a support element upon which the metallic end shell is positioned.

In yet another embodiment, the system is operable to identify the orientation of roll grinding marks and subsequently orient from 1 to 8 metallic end shells substantially simultaneously. In a more preferred embodiment, the system is operable to orient 4 metallic end shells substantially simultaneously.

In one embodiment, the predetermined angle of the rolling direction with respect to the reference axis is between about 0° and about 7°. In a more preferred embodiment, the predetermined angle is less than about 5°. In a still more preferred embodiment, the predetermined angle is less than about 2°.

In one embodiment, after the metallic end shells are rotated by the orientation system, the metallic end shells are formed into metallic end closures comprising a peripheral curl and a central panel. In another embodiment, the metallic end shells are formed into metallic end closures for a beverage container. Accordingly, the metallic end closures generally include a peripheral curl, a chuck wall extending downwardly from the peripheral curl, a countersink interconnected to a lower end of the chuck wall, a central panel interconnected to the countersink, a tear panel in the central panel, and a pull tab operably interconnected to an exterior surface the central panel.

In another embodiment, the orientation system is removably integrated in an end closure production process associated with the system. Accordingly, the orientation system may be removably positioned upstream of the conversion press.

In one embodiment, the transport system includes a system adapted to prevent unintended or inadvertent movement of each metallic end shell. In one embodiment, the system comprises a clamp that applies pressure to the metallic end shell to hold the metallic end shell in a predetermined orientation. In another embodiment, the system comprises a vacuum clamp that applies a suction to a predetermined portion of the metallic end shell.

Optionally, the system may further include a control system. The control system receives information related to the roll grinding marks of the metallic end shells from the sensors of the orientation system. The control system then uses the roll grinding mark information to determine if the rolling direction of the metallic end shells is within the predetermined angle compared to the reference axis. If the rolling direction is not within the predetermined angle, the control system determines an axial amount of rotation required to move the rolling direction to within the predetermined angle. The control system then sends a signal to a servo unit associated with actuator to rotate the metallic end shell. The control system may also be interconnected to the ejector and the conversion press. The control system may send a signal to the ejector to remove improperly aligned metallic end shells from the transport system.

Another aspect of the present invention is to provide an orientation system operable to determine and align a rolling direction of a metallic work-piece that can quickly and efficiently be removably integrated into a metal forming process. The orientation system generally includes, but is not limited to: (1) a first sensor at a first index position operable to sense roll grinding marks, the roll grinding marks used to determine an initial orientation of a rolling direction of the metallic work-piece; and (2) a first actuator at a second index position operable to rotate the work-piece axially to substantially align the rolling direction with a reference axis. In one embodiment, the orientation system is operable at up to about 800 cycles per minute. In one embodiment, the metal forming process is a container end closure manufacturing process and the work-piece is a metallic end shell. In another embodiment, the orientation system can align the rolling direction of from 1 to 8 metallic work-pieces substantially simultaneously.

In one embodiment, the first actuator can rotate axially at least one of clockwise and counterclockwise. In another embodiment, the first actuator is adapted to contact and apply a frictional force to a predetermined portion of the work-piece. In another embodiment, the first actuator is interconnected to a servo unit. The servo unit is interconnected to a system controller that determines an axial amount of rotation required to substantially align the rolling direction with the reference axis. In one embodiment, the first actuator can align the rolling direction of the end shells to within about plus or minus 12° of the reference axis, and more preferably to within about plus or minus 10°. In another embodiment, the first actuator can rotate an work piece such that the rolling direction of the work piece is within about 3° of the reference axis. Optionally, the first actuator can rotate the work piece such that the rolling direction is substantially aligned with the reference axis within less than about 60 milliseconds. In another embodiment, the first actuator can rotate the work piece at least about 45° within less than about 60 milliseconds.

Optionally, the orientation system may include a second sensor at a third index position. The second sensor is operable to sense roll grinding marks used to determine a second orientation of the rolling direction of the metallic work-piece.

In one embodiment, the orientation system includes an ejector. The ejector is operable to divert the work-piece from the metal forming process if the second sensor determines the second orientation of the rolling direction of the work-piece is not within a predetermined angle with respect to the reference axis. In one embodiment, the ejector is operable to divert the work-piece without contacting the work-piece. For example, the ejector may use suction or a blast of air to divert the work-piece without contacting the work-piece. Additionally, or alternatively, the ejector may include a magnet to attract or repel the work piece without contact. In another embodiment, the ejector is operable to contact and apply a mechanical force to the work-piece to divert the work-piece from the metal forming process.

In another embodiment, the orientation system may include a second actuator at a fourth index position. The second actuator is operable to rotate the work-piece axially if the second sensor indicates the second orientation of the rolling direction of the work-piece is not within a predetermined angle with respect to the reference axis. In one embodiment, the second actuator can align the rolling direction of the end shells to within about plus or minus 3° of the reference axis, and more preferably to within about plus or minus 1°. Optionally, the second actuator has the same, or similar, performance characteristics and capabilities as the first actuator.

Optionally, the orientation system may include a control system. The control system is interconnected to the sensors, servo units associated with the first and second actuators, and the ejector. When the roll grinding marks of the work-piece captured by the sensors indicate the rolling direction is not within the predetermined angle with respect to the reference axis, the control system can send a signal to one of the servo units. The signal may include an amount and a direction of rotation required to align the rolling direction with the predetermined angle. Optionally, the control unit may send a signal to the ejector to remove the improperly aligned work piece from the metal forming process. The control system may also be interconnected to downstream equipment. For example, in one embodiment the control system is interconnected to, and may receive information from and send information to, a conversion press.

Still another aspect of the present invention is a novel method of orienting end shells in a high-speed production process based on the metal rolling direction. The method generally includes, but is not limited to: (1) receiving, by an orientation system, a plurality of unoriented end shells; (2) determining an orientation of a metal rolling direction of each of the end shells; (3) if the orientation of the rolling direction of an end shell is not in a predetermined orientation, determining an amount of axial rotation required to properly orient the end shell; and (4) rotating the end shell by the determined amount of axial rotation such that the metal rolling direction is oriented in a predetermined position. In one embodiment, the end shells are subsequently received by a conversion press and formed into end closures adapted for interconnection to a neck of a container. In another embodiment, the end closures include one or more of a peripheral curl, a chuck wall extending downwardly therefrom, a countersink interconnected to the chuck wall, a central panel interconnected to the countersink, and a tab operably interconnected to the central panel.

In one embodiment, the orientation system includes sensors and actuators interconnected to servo units. The sensors can sense roll grinding marks in the end shells to determine the rolling direction of each end shell. In one embodiment, the sensors comprise cameras to image each end shell. The images taken by the cameras have sufficient resolution and clarity to identify grinding marks present on each end shell, the grinding marks indicating the rolling direction of a metal sheet from which each of the end shells is formed.

The servo units activate the actuators to rotate end shells that are not in the predetermined orientation. More specifically, the actuators rotate axially to substantially align the rolling direction with the predetermined orientation. The actuators may rotate either clockwise or counterclockwise. In one embodiment, the actuators contact at least a portion of a closed end-wall of the end shells. In another embodiment, the actuators contact a sidewall portion of the end shells or, alternatively, a closed end-wall portion of the end shells. In still another embodiment, the actuators are operable to rotate improperly oriented end shells without contact the end shells. For example, the actuators may rotate a support element associated with an end shell. In one embodiment, the actuators rotate improperly oriented end shells by the determined amount in less than approximately 60 milliseconds. In another embodiment, the actuators may rotate the improperly oriented end shells by up about 45° in less than approximately 60 milliseconds.

Optionally, the method may further comprise removing improperly oriented end shells from the process. Accordingly, the method may include determining a second orientation of the grinding marks of the end shells after rotating improperly oriented end shells by the determined amount. In one embodiment, an ejector applies a contact force to the improperly oriented end shells to remove them from the process. Optionally, the improperly oriented end shells may be removed without contact. Thus, in another embodiment, the ejector uses a gust of air or suction to remove improperly oriented end shells from the process.

Yet another aspect of the present invention is a system for aligning a rolling direction of a metallic end shell to a preferred position. The system includes, but is not limited to: (1) a transport system to move the metallic end shell through the system; (2) a sensor to sense an orientation of a grinding mark on the metallic end shell, wherein the grinding mark is associated with the rolling direction of a metallic sheet from which the metallic end shell is formed; and (3) an actuator to rotate the metallic end shell such that the rolling direction of the metallic end shell is within a predetermined angle with respect to a reference axis of the system. Optionally, the system may further comprise a servo unit associated with the actuator to rotate the metallic end shell by a predetermined amount in less than approximately 60 milliseconds.

In one embodiment, the system includes a second sensor to sense a second orientation of the grinding mark after the actuator has rotated the metallic end shell by the predetermined amount. Additionally, the system may optionally include a second actuator to rotate the metallic end shell by a predetermined amount. In another embodiment, the system includes an ejector to remove the metallic end shell from the system if the second orientation is not within the predetermined angle with respect to the reference axis.

In one embodiment, the actuator is operable to rotate the metallic end shell such that the rolling direction is within about 12° of the reference axis. In another embodiment, the second actuator is operable to rotate the metallic end shell such that the rolling direction is within about 3° of the reference axis. In one embodiment, the first and second actuators contact a predetermined portion of the metallic end shell to rotate the metallic end shell. In another embodiment, the first and second actuators rotate improperly oriented metallic end shells by the predetermined amount in less than approximately 60 milliseconds. In another embodiment, the first and second actuators may rotate the improperly oriented metallic end shells by up about 45° in less than approximately 60 milliseconds.

Optionally, the system may include a control system. The control system receives information related to the orientation of the grinding mark from the sensor. Using the sensor information, the control system determines an axial amount for the actuator to rotate the metallic end shell to orient the rolling direction of the metallic end shell within the predetermined angle.

The above-described embodiments, objectives, and configurations are neither complete nor exhaustive. As will be appreciated, other embodiments of the invention are possible using, alone or in combination, one or more of the features set forth above or described in detail below.

As will be appreciated by one of skill in the art, the method and apparatus of the current invention may be used to determine and orient the rolling direction of any metal, including aluminum, tin, steel, and combinations thereof. Further, the method and apparatus of the current invention may be used in any metal manufacturing process to align the rolling direction of any metallic workpiece with tooling of a downstream apparatus of the manufacturing process without impairing the operating rate of the downstream apparatus.

As used herein, an “end shell” describes a metallic work piece prior to entry of the end shell into a conversion press. After entering the conversion press, the end shell is converted by the conversion press into an “end closure.”

References made herein to “end shells,” “end closures,” or “container end closures” should not necessarily be construed as limiting the present invention to a particular size, shape, or type of end shell or end closure. It will be recognized by one skilled in the art that the present invention may be used to orient the rolling direction of end shells of any variety, size, or type, including end shells that will be converted into end closures for beverage containers, aerosol containers, and food containers, including any type of two-piece or three-piece container. Similarly, the method and apparatus of the present invention may be used to orient the rolling direction of end shells of any type of metal. Further, the present invention is not limited to orienting end shells in a beverage container end closure manufacturing process. Accordingly, the present invention may be used to orient the rolling direction of any type of metallic work piece in a manufacturing process.

One of skill in the art will appreciate that an end closure formed from an end shell may comprise one or more of, but are not limited to: a peripheral curl, a chuck wall extending downwardly from the peripheral curl, a countersink interconnected to a lower end of the chuck wall, a central panel interconnected to the countersink, a tear panel in the central panel, and a tab operably interconnected to an exterior surface of the central panel. In one embodiment of the present invention, the end closure comprises a peripheral curl and a central panel. In another embodiment, the end closure includes a tab interconnected to an exterior surface portion of the central panel.

The phrases “at least one,” “one or more,” and “and/or,” as used herein, are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions “at least one of A, B and C,” “at least one of A, B, or C,” “one or more of A, B, and C,” “one or more of A, B, or C,” and “A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.

Unless otherwise indicated, all numbers expressing quantities, dimensions, conditions, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.”

The term “a” or “an” entity, as used herein, refers to one or more of that entity. As such, the terms “a” (or “an”), “one or more” and “at least one” can be used interchangeably herein.

The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Accordingly, the terms “including,” “comprising,” or “having” and variations thereof can be used interchangeably herein.

It shall be understood that the term “means” as used herein shall be given its broadest possible interpretation in accordance with 35 U.S.C., Section 112(f). Accordingly, a claim incorporating the term “means” shall cover all structures, materials, or acts set forth herein, and all of the equivalents thereof. Further, the structures, materials, or acts and the equivalents thereof shall include all those described in the Summary of the Invention, Brief Description of the Drawings, Detailed Description, Abstract, and Claims themselves.

The Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements or components. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

BRIEF DESCRIPTION OF DRAWINGS

The accompanying drawings, which are incorporated herein and constitute a part of the specification, illustrate embodiments of the invention and together with the Summary of the Invention given above and the Detailed Description of the drawings given below serve to explain the principles of these embodiments. In certain instances, details that are not necessary for an understanding of the disclosure or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein. Additionally, it should be understood that the drawings are not necessarily to scale.

FIG. 1 is a schematic flow diagram of a prior art end closure conversion process;

FIG. 2 is a schematic flow diagram of an end closure conversion system including a system for orienting the rolling direction of metallic end shells according to one embodiment of the present invention and illustrating an end closure formed from a metallic end shell by a conversion press;

FIG. 3 is a side elevation view of an orientation system according to one embodiment of the present invention;

FIG. 4 is a top plan view of the orientation system of FIG. 3; and

FIG. 5 is a process flow diagram of a method of aligning the rolling direction of a metallic object in a high-speed production process according to one embodiment of the present invention.

Similar components and/or features may have the same reference number. Components of the same type may be distinguished by a letter following the reference number. If only the reference number is used, the description is applicable to any one of the similar components having the same reference number.

To assist in the understanding of one embodiment of the present invention the following list of components and associated numbering found in the drawings is provided herein:

Number Component
2      Prior art conversion process
3      Coil of stock metal
4      Roll grinding marks
5      Rolling direction
6      Uncoiler
7      Shell press
8      End shells
9      Curler
10     Liners
11     Liner oven
12     Balancer
13     Conversion press
14     End closures
15     Score
16     Tear panel
17     Pull tab
18     Other operations
20     End closure conversion system
22     Reference axis
24     End shells
25     Rolling direction
26     Upstream equipment
27     Closed end-wall of an end shell
28     End shell sidewall
30     Balancer
32     Transport system
33     Die cap
34     Stabilizer
35     Axis of die cap
36     Orientation system
38     First position
40     First sensor group
41     Light
42     Second position
44     First actuator group
48     Third position
50     Second sensor group
51     Light
52     Fourth position
54     Second actuator group
58     Fifth position
60     Third sensor group
61     Light
62     Sixth position
66     Ejector
70     Control system
76     Conversion press
80     End closure
81     Peripheral curl
82     Central panel
83     Score
84     Tear panel
85     Tab
86     Rivet
88     Downstream equipment
90     Method of orienting rolling direction
92     Start operation
94     Receive timing and position information
96     Receive unoriented end shells
98     Determine first rolling direction orientation
100    Determine if rolling direction orientation is properly aligned
102    Determine an amount to rotate improperly oriented end shells
104    Rotate end shell
106    Determine second rolling direction orientation
108    Determine if rolling direction orientation is properly aligned
112    End shells proceed to conversion press
114    End operation

DETAILED DESCRIPTION

The present invention has significant benefits across a broad spectrum of endeavors. It is the Applicant's intent that this specification and the claims appended hereto be accorded a breadth in keeping with the scope and spirit of the invention being disclosed despite what might appear to be limiting language imposed by the requirements of referring to the specific examples disclosed. To acquaint persons skilled in the pertinent arts most closely related to the present invention, a preferred embodiment that illustrates the best mode now contemplated for putting the invention into practice is described herein by, and with reference to, the annexed drawings that form a part of the specification. The exemplary embodiment is described in detail without attempting to describe all of the various forms and modifications in which the invention might be embodied. As such, the embodiments described herein are illustrative, and as will become apparent to those skilled in the arts, may be modified in numerous ways within the scope and spirit of the invention.

Although the following text sets forth a detailed description of numerous different embodiments, it should be understood that the detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such claim term by limited, by implication or otherwise, to that single meaning.

Referring now to FIG. 2, an end closure conversion system 20 of one embodiment of the present invention is illustrated. The system generally includes a balancer 30, a transport system 32, an orientation system 36, and a conversion press 76.

The balancer 30, in one embodiment, receives end shells 24 from up-stream equipment 26 associated with the system 20. In one embodiment, the balancer 30 is a mechanical sponge that controls the flow of the end shells 24 between the up-stream equipment 26 (such as an uncoiler, shell press, curler, liner, or liner over) and the orientation system 36. The balancer 30 maintains the proper speed and flow of the end shells 24 to ensure a consistent, non-interrupted flow of end shells 24 into the orientation system 36. The balancer 30 accumulates end shells 24 from the up-stream equipment 26 to ensure the orientation system 36 and the conversion press 76 are supplied with end shells if the upstream equipment goes offline, for example, for maintenance, during unscheduled stops, or when new coils of stock metal are loaded in an uncoiler.

In one embodiment, the balancer 30 loads the end shells 24 into the transport system 32. The transport system 32 moves the end shells 24 through the orientation system 36 and to the conversion press 76. In one embodiment, when loaded into the transport system 32, a curl of the end shell sidewall 28 (illustrated in FIG. 3) faces toward the transport system 32. Similarly, an exterior surface of a closed end-wall 27 of the end shell 24 faces away from the transport system 32. The transport system 32 is operable to allow the end shells 24 to rotate axially around an axis 35 substantially perpendicular to the closed end-wall 27 when contacted by an actuator 44 of the orientation system 36.

In one embodiment, the transport system 32 optionally includes die caps 33 adapted to receive each end shell 24. Each die cap 33 has a generally cylindrical body with a diameter approximately equal to an inside diameter of the end shell 24. One or more ridges, bumps, or protrusions may be formed on an exterior surface portion of the die cap 33 to frictionally engage the inside surfaces of the end shell 24. Optionally, the bumps may be biased and can be extended or retracted from the die cap 33 to increase or decrease friction between the die cap 33 and the end shell 24.

In one embodiment, a first aperture is formed in a portion of each die cap 33. The first aperture is interconnected to a vacuum pump to apply a suction force to an interior surface of an end shell 24 positioned on the die cap 33. The suction force is to prevent unintended movement of the end shell 24. A second aperture of the die cap 33 may be interconnected to a source of a gas, such as air. To release the end shell 24 from the die cap 33, a flow of the gas is released through the second aperture to blow the end shell 24 off of the die cap 33.

In another embodiment, the die cap 33 can selectively rotate axially around its axis 35. Accordingly, the die cap 33 may rotate axially during orientation of an end shell 24. After the end shell 24 is oriented, the die cap 33 can lock its position with respect to the transport system 32 to prevent unintended or inadvertent rotation of the die cap 33. In this manner, the die cap 33 keeps the end shell 24 in a predetermined orientation with respect to the reference axis 22.

The transport system 32 may also include a stabilizer 34 to prevent unintended or inadvertent movement of the end shells 24 as they move through the system 20. In one embodiment, the stabilizers 34 prevent rotation of the end shells 24 by contact with an outside surface of a predetermined portion of the end shell. For example, the stabilizer 34 may comprise any type of clamp including, but not limited to, a matching contour friction clamp or a multipoint circumferential contact clamp. In another embodiment, the stabilizers 34 comprise a suction system adapted to prevent inadvertent or unintended movement of the end shells 24. After the rolling direction 25 is aligned by the orientation system 36 at a predetermined angle with respect to reference axis 22, the stabilizer 34 maintains the alignment of the end shells 24 as they move to the conversion press 76.

Any suitable transport system 32 may be used with the system 20 of the present invention. Optionally, the transport system 32 may comprise pockets adapted to receive the end shells. In one embodiment, the transport system 32 comprises a belt. In another embodiment, the transport system 32 comprises chains. In one embodiment, the transport system 32 includes holders comprising two longitudinal rails connected by shorter lateral rungs. The rails and rungs form pockets that are adapted to receive the end shells 24.

The dimensions of the transport system 32 can be altered to hold end shells 24 of any size. In one embodiment, the transport system 32 has a width sufficient to hold two columns of end shells 24 side-by-side. However, it will be appreciated that the width of the transport system 32 may be adapted to hold any number of columns of end shells 24. In one embodiment, the transport system 32 holds a single column of end shells 24. In another embodiment, the transport system 32 has a width adapted to hold from two to six columns of end shells 24. In one embodiment, illustrated in FIG. 2, the system 20 includes two transport systems 32 that each hold two columns of end shells 24. The transport system 32 moves the end shells 24 through the system 20 with a line drawn through a center of each row of end shells generally perpendicular to the reference axis 22 of the system 20.

The transport system 32 is adapted to rotate through the system 20 from point A proximate to the balancer 30 to point C proximate to the conversion press 76. In one embodiment, the transport system 32 forms a continuous loop that rotates through the system 20 from point A to point C. The end shells 24 are generally spaced at regular intervals along the transport system 32. The transport system 32 moves in indexed steps at a predetermined rate. Each cycle of the transport system 32 generally comprises a deceleration, a dwell period of a predetermined amount of time during which the transport system 32 does not move, and an acceleration and movement of the transport system 32. In one embodiment, each cycle of the transport system 32 is less than about 95 microseconds. In a more preferred embodiment, each cycle is less than about 83 microseconds.

When loaded into the transport system 32 proximate to point A, the rolling direction 25 orientation of each end shell 24 is randomly oriented with respect to the reference axis 22 of the system 20, as shown in FIG. 2. Further, the rolling direction 25 orientation of an end shell 24 may not be parallel to the rolling direction orientation 25 of another end shell.

Referring now to FIGS. 3-4, one embodiment of the orientation system 36 of the present invention is illustrated. The orientation system 36 generally includes sensors 40, 50, 60, actuators 44, 54, and an ejector 66 interconnected to a control system 70.

The transport system 32 moves the end shells 24 to a first position 38 proximate to a first sensor group 40. The sensors of the first sensor group 40 are operable to sense the roll grinding marks 4 in the end shells 24 that indicate the rolling direction 25 of each end shell 24. In one embodiment of the present invention, the sensors of the first group 40 are positioned to sense an exterior surface portion of a closed end-wall 27 of the end shells 24. The sensors of the first group 40 obtain data related to the rolling direction 25 of each end shell 24 when the end shells 24 are at least one of stationary and moving. The sensors send data related to the roll grinding mark orientation of the end shells 24 to the control system 70.

In one embodiment of the present invention, the sensors 40 comprise high speed cameras or another visual inspection device. However, any suitable sensor that can detect the roll grinding marks 4 of the metallic end shells 24 may be used with the systems of the present invention. The cameras have a suitable magnification and resolution to detect the roll grinding marks 4 which are associated with the rolling direction 25 of each end shell 24. In one embodiment, the cameras of the first sensors 40 capture gray-scale images. In another embodiment, the cameras of the first sensors 40 include optics that provide multiple magnifications. In yet another embodiment, the cameras of the first sensors 40 have an adjustable resolution. In one embodiment, the optics, resolution, and shutters of the cameras are controlled by the control system 70.

Optionally, a light 41 is associated with the sensors of the first sensors 40. In one embodiment, the light 41 is operable to provide a strobe illumination such that the first sensors 40 may obtain data from moving end shells 24. Suitable lights are known to those of skill in the art. In one embodiment, the light 41 comprises at least one of an incandescent lamp, an LED, a high intensity light, a laser, a fluorescent light, and an arc discharge lamp. Optionally, one or more angles of illumination may be provided by the light 41. In another embodiment, the light 41 includes two or more lights arranged at different angles with respect to the metallic end shell 24. For example, in one embodiment, a first light 41 may be positioned at an angle of about 90° above the metallic end shells 24. In another embodiment, a second light 41 is positioned at an angle of between about 10° and about 90° or between about 1° and about 10° with respect to the metallic end shells 24. Accordingly, the angle of the light 41 with respect to the metallic end shells 24 may be selected such that the rolling grinding marks 4, which may include scratches in the surface of the metallic end shell 24, reflect light differently than other portions of the exterior surface of the close end-wall 27 that do not include rolling grinding marks 4.

The control system 70 is operable to receive the data from the first sensor group 40. Using the roll grinding mark orientation data, the control system 70 can determine if the rolling direction orientation of each end shell 24 is aligned within a predetermined angle with respect to the reference axis 22. If the control system 70 determines the rolling direction orientation of one or more of the end shells 24 is not within the predetermined angle, the control system 70 is operable determine an axial amount to rotate the end shell 24 to align the rolling direction orientation within the predetermined angle.

In one embodiment, the control system 70 compares the sensor data received from the first sensor group 40 to a known reference stored in memory. For example, the control system 70 may compare the sensor data to a picture of an end shell which is aligned at the predetermined angle with respect to the reference axis 22. The picture of the end shell may be stored in a memory of the control system. In another embodiment, the control system 70 compares the sensor data to a digital model of an end shell with grinding marks 4 and/or rolling striations associated with the rolling direction 25. In this manner, the control system 70 can determine an orientation of the roll grinding marks 4 of a sensed metallic end shell 24 with respect to the reference axis by comparison of the sensor data with the characteristics of the known reference that is properly aligned with the reference axis 22.

Suitable control systems 70 are known to those of skill in the art. The control system 70 may be any programmable logic controller (PLC). One example of a suitable PLC is a Controllogix PLC produced by Rockwell Automation, Inc, although other PLCs are contemplated for use with embodiments of the present invention.

In one embodiment, the predetermined angle between the orientation of the rolling direction 25 and the reference axis is less than about 5°. In a more preferred embodiment, the predetermined angle between the rolling direction 25 orientation and the reference axis is less than about 2°. In a still more preferred embodiment, the predetermined angle between the rolling direction 25 orientation and the reference axis is less than about 1°. Accordingly, the end shells will exit the orientation system 36 with the rolling direction 25 oriented substantially parallel to the direction of movement of the transport system and substantially parallel to the reference axis 22.

Although the reference axis 22 is generally horizontal as seen in FIGS. 2-4, it will be appreciated that the reference axis can be aligned at any desired angle. In another embodiment, the reference axis is rotated 90° and all the end shells 24 exit the orientation system 36 with the rolling direction 25 oriented substantially perpendicular to the direction of movement of the transport system 32. The orientation of the reference axis 22 may be selected by an operator and may be adjusted to any desired angle. For example, an operator may adjust the orientation of the reference axis 22 to ensure the rolling direction 25 is at a preferred orientation with respect to an operation performed by the conversion press 76 or another down-stream apparatus.

The control system 70 can also receive a variety of signals from one or more of the balancer 30, the transport system 32, the conversion press 76, or other equipment of the end closure production line. The signals from the conversion press 76 can indicate that the conversion press 76 is operating, is ready, and/or is not operational. The signals may also include the cycle rate (or operating speed) of the conversion press 76 and a desired alignment of the rolling direction 25 of the end shells 24 with respect to the reference axis 22. The control system 70 can use the signals received from the conversion press 76 to change the amount of time available for each actuator 44, 54 to rotate the end shells 24 during each cycle of the transport system 32.

The control system 70 can also use the signals from the conversion press 76 to change the predetermined angle between the reference axis 22 and orientation of the rolling direction 25. For example, the control system 70 may receive a signal from the conversion press 76 or an operator indicating that rolling direction 25 should be aligned perpendicular with the reference axis 22. One of skill in the art will appreciate that the orientation system 36 may rotate the end shells 24 such that the orientation of the rolling direction 25 forms any angle between approximately 0° and approximately 90° with respect to the reference axis 22.

After a predetermined dwell time, the transport system 32 indexes one position forward toward the conversion press 76. The control system 70 sends signals to first actuators 44 proximate to a second position 42. The signals include instructions to rotate each end shell 24 that is not aligned within the predetermined angle by an amount required to align the orientation of the rolling direction 25 within the predetermined angle.

In one embodiment, the first actuators 44 are adapted to contact a predetermined portion of the end shells 24. In one embodiment, the predetermined portion comprises an exterior surface portion of a closed end-wall 27 of the end shells 24. In another embodiment, the predetermined portion comprises an exterior surface portion of a side-wall 28 of the end shells 24. Optionally, the actuators may engage more than one portion of each end shell 24 substantially simultaneously to rotate the end shell 24. The actuators may rotate either clockwise or counter-clockwise based on the signal received from the control system. Further, servo units associated with each actuator 44 are operable to rotate each actuator a different direction and a different axial amount. In one embodiment, the first actuators 44 can rotate the end shells 24 to align the rolling direction 25 to within about plus or minus 12° of the reference axis 22, and more preferably to within about plus or minus 10°.

In one embodiment, the actuator 44 has a diameter substantially equal to a diameter of a closed end-wall 27 of the end shell 14. In another embodiment, the actuator 44 has a diameter less than the diameter of the closed end-wall 27. In still another embodiment of the present invention, the actuator 44 has a diameter greater than the diameter of the closed end-wall.

Alternatively, in another embodiment, the first actuators 44 rotate the improperly oriented end shells 24 without contacting the end shells 24. In one embodiment, the first actuators 44 contact a portion of a die cap 33 associated with each improperly oriented end shell 24. In this manner, the first actuators 44 can apply a force to a die cap 33 to axially rotate an improperly oriented end shell 24 by a predetermined amount in either a clockwise or counter-clockwise direction.

In one embodiment, servo units associated with the actuators 44, 54 are operable to rotate the end shells 24 in less than approximately 60 milliseconds, and more preferably, in less than about 50 milliseconds. In another embodiment, the servo units associated with the actuators 44, 54 can rotate the actuators up to about 45° during a dwell-period of the transport system 32. Accordingly, in one embodiment, the servo units may rotate the actuators up to about 45° in less than about 60 ms. In a more preferred embodiment, the servo units may rotate the actuators up to about 90° in less than about 60 ms. In yet another embodiment, the servo units can rotate the actuators by about 180° in less than 60 ms. Any suitable servo unit may be used with the orientation system 36 of the present invention. Suitable servo units are known to those of skill in the art.

After the predetermined dwell time, the transport system 32 indexes another position forward toward the conversion press 76. In one embodiment, the control system 70 receives a signal from the transport system 32 before the transport system moves the end shells 24. The control system 70 may use the signals from the transport system to direct the actuators 44, 54 to cease contact with the end shells 24.

Optionally, a second sensor group 50 is positioned proximate to the third position 48. The sensors of the second sensor group 50 may be the same as, or similar to, the sensors of the first sensor group 40. The sensors of the third group 50 are operable to provide data regarding the second orientation of the roll grinding marks 4 of each end shell 24 to the control system 70. Optionally, a light 51 (the same as or similar to light 41) is associated with the sensors of the second sensor group 50.

The control system 70 may use the data received from the sensors of the second sensor group 50 to determine if the orientation of the rolling direction 25 of any of the end shells 24 are not aligned within the predetermined angle with respect to the reference axis 22. If any of the end shells 24 are not aligned with the predetermined angle, the control system 70 may determine a second amount to rotate the end shells 24.

Optionally, the orientation system 36 may include a second actuator group 54 proximate to a fourth position 52. The second actuator group 54 may include actuators and servo units that are the same as, or similar to, the actuators and servo units of the first actuator group 44. Thus, the actuators of the second actuator group 54 may rotate improperly oriented end shells 24 by applying an axially force to at least one of the improperly oriented end shells 24 or to die caps 33 associated with each of the improperly oriented end shells. The actuators 54 can rotate one or more end shells 24 by a second amount determined by the control system 70. For example, as illustrated in FIG. 4, end shells 24B, 24D are rotated by the second actuators 54. Further, end shell 24B is rotated in an opposite direction compared to end shell 24D. In contrast, the rolling directions of end shells 24A, 24C are substantially aligned with the reference axis 22 and are not rotated by the second actuators 54. In one embodiment, the second actuators 54 can rotate the end shells 24 to align the rolling direction 25 to less than about plus or minus 3° of the reference axis 22, and more preferably to less than about plus or minus 1°.

The orientation system 36 may further include a third sensor group 60 proximate to the fifth position 58. The third sensor group 60 includes sensors operable to determine a final orientation of the roll grinding marks 4 of the end shells 24. The sensors of the third sensor group 60 may be the same as, or similar to, the sensors of the first and second sensor groups 40, 50. Additionally, a light 61 may optionally be associated with the sensors of the third sensor group 60.

The control system 70 may use information received from the third sensor group 60 to determine if the rolling direction 25 of the end shells 24 at the fifth position 58 are oriented within the predetermined angle compared to the reference axis 22. If the orientation of the grinding marks 4 corresponding to the rolling direction 25 one or more of the end shells 24 is not within the predetermined angle, the control system 70 is operable to send a signal to activate an ejector 66 positioned proximate to a sixth position 62. The ejector 66 is operable to remove improperly aligned end shells 24 from the transport system 32, as illustrated by the ejection of end shell 24E in FIG. 4.

In one embodiment, the ejector 66 includes a system adapted to contact the improperly aligned end shells 24 to move them from the transport system 32. In another embodiment, the ejector 66 is operable to remove the improperly aligned end shells 24 from the orientation system 36 without contact. For example, in one embodiment, the ejector 66 uses a blast of compressed gas, such as air, or a suction force to remove the improperly aligned end shells 24 from the system.

Although the orientation system 36 is illustrated in FIGS. 3-4 with three sensor groups 40, 50, 60, and two actuator groups 44, 54, one of skill in the art will appreciate that the orientation system 36 of the present invention may include any combination of sensor groups and actuator groups. For example, in one embodiment, the orientation system 36 includes one sensor group 40 and one actuator group 44.

In one embodiment of the present invention, the orientation system 36 can orient approximately 2,000 end shells 24 per minute, and more preferably approximately 2,100 end shells per minute. In another embodiment, the orientation system 36 can orient approximately 1,000,000 end shells in an 8-hour period. In still another embodiment, the orientation system 36 can operate at up to approximately 800 cycles per minute.

It should be understood that although rows of only four end shells 24 are illustrated being processed by the orientation system 36 in FIGS. 2, 4, any number of end shells 24 may be oriented substantially simultaneously in parallel by the orientation system 36 of the present invention. For example, in one embodiment, the orientation system 36 is operable to orient six end shells 24 substantially simultaneously. In another embodiment, the orientation system 36 may orient from one to eight end shells 24 substantially simultaneously.

Referring again to FIG. 2, the orientation of the rolling direction 25 of all the end shells 24 are substantially parallel to each other when the end shells 24 exit the orientation system 36 proximate to point B. Optionally, after the end shells 24 are rotated to a predetermined orientation, the stabilizers 34 of the transport system 32 are operable to prevent unintended or inadvertent rotation of the end shells 24.

In one embodiment, the orientation system 36 rotates each of the end shells 24 until the rolling direction 25 is oriented substantially parallel to the reference axis 22 of the system 20, as viewed in FIG. 2. Although the reference axis 22 is generally horizontal as seen in FIG. 2, it will be appreciated that the reference axis 22 can be aligned at any desired angle. For example, in one embodiment of the present invention, the reference axis may be rotated 90° such that all of the end shells 24 exit the orientation system 36 with the rolling direction 25 and the roll grinding marks 4 oriented substantially perpendicular to the direction of movement of the transport system 32.

Optionally, the orientation system 36 may be removably integrated with the end closure conversion system 20. Accordingly, the orientation system 36 may include an alignment system or stops (not illustrated) that interconnect to connectors located at predetermined positions in the conversion system 20. Alternatively, the connectors may be positioned on the conversion press 76. The alignment system enables the orientation system 36 to be integrated with the conversion press 76 efficiently with a minimum of down time. When a batch of end closures 80 does not require orientation of the rolling direction 25, the orientation system 36 can be removed. Optionally, when a batch of end closures 80 does not require rolling direction orientation, the orientation system 36 can be left in position upstream from the conversion press 76 with the sensors 40, 50, 60 and the actuators 44, 54 turned off. The unoriented end shells 24 can then freely pass through the orientation system 36 without the need to orient or eject unoriented end shells.

An example of an end closure 80 formed by the conversion press 76 from an end shell 24 processed by the orientation system 36 is also illustrated in FIG. 2. The end closure 80 generally includes features such as, but not limited to, a peripheral curl 81, a central panel 82, a score 83 forming a tear panel 84, and a tab 85 operably interconnected to an exterior surface of the end closure 80 by a rivet 86. Optionally, other features may be formed on the end closure, such a secondary vent and the end closure 80 may have any size and geometry. Examples of end closures that may be produced by the end closure conversion system of the present invention are described in U.S. Pat. Nos. 7,100,789, 7,743,635, 8,567,158, 8,727,169, 8,950,619, and 9,248,936, which are each incorporated herein by reference in their entireties.

Because the rolling direction 25 of the end shell 24 used to form the end closure 80 was aligned with the reference axis 22 by the orientation system 36, the features 81-86 of the end closure 80 are formed with an optimal orientation with respect to the rolling direction 25. Additionally, or alternatively, the metal stock metal 3 from which end shells 24 are produced may be thinner compared to stock metal used to form end shells which are not oriented before conversion into end closures by the conversion press 76. Accordingly, the weight and material cost of each end closure 80 may be reduced by orienting the end shells 24 as described herein prior to conversion into end closures 80. The features 81-86 of the end closure 80 may also have improved performance characteristics compared to similar features formed on an end closure in which the rolling direction is not aligned with respect to tooling of the conversion press 76. For example, the features 81-86 of the end closure may have one or more of an improved strength in resistance to deflection, an improved resistance to strain deformation, and have an increased resistance to failure compared to an end closure that is formed with an unfavorable rolling direction orientation.

It will be appreciated that features 81-86 of the end closure 80 may be formed at any angle with respect to the rolling direction 25. For example, the rolling direction 25 may be oriented generally parallel to a line drawn through the tab 85, rivet 86, and tear panel 84 as illustrated in FIG. 2. Alternatively, the rolling direction 25 may be perpendicular or transverse to the line drawn through the tab, rivet, and tear panel.

The end closures 80 may subsequently be processed by downstream equipment 88. In one embodiment, the downstream equipment 88 includes a bagging system and a palletizer. Optionally, the downstream equipment may include an end closure orientation system and/or an end closure decoration system. Examples of end closure orientation systems and decorating systems are described in U.S. Pat. Nos. 9,259,913 and 9,340,368 which are each incorporated herein by reference in their entireties.

Referring now to FIG. 5, an embodiment of a method 90 for orienting the rolling direction 25 of end shells 24 is illustrated. While a general order of operations of the method 90 is shown in FIG. 5, the method 90 can include more or fewer operations, or can arrange the order of the operations differently than those shown in FIG. 5. Further, although the operations of the method 90 may be described sequentially, many of the operations may in fact be performed in parallel or concurrently. Generally, the method 90 starts with a start operation 92 and ends with an end operation 114. Hereinafter, the method 90 shall be explained with reference to systems and apparatus described in conjunction with FIGS. 1-4.

Optionally, a control system 70 of an orientation system 36 may receive timing and position information 94 from a conversion press 76. The timing information may comprise a cycle rate of the conversion press 76. The position information may comprise a position of a transport system 32 that moves the end shells 24 to the conversion press 76.

The control system 70 may use the timing information to determine a maximum radial amount an improperly aligned end shell 24 may be rotated during a dwell period of the transport system 32. More specifically, the control system 70 may use the timing information to determine a dwell period between movements of the transport system 32. A longer dwell time provides more time to axially rotate the end shells 24. Thus, the end shells 24 may be rotated a greater amount during a long dwell than during a shorter dwell time.

The orientation system 36 receives 96 the individual end shells 24 that are unoriented from upstream equipment 26. In one embodiment, the end shells 24 are received from a balancer 30. Sensors 40 of a first sensor group of the orientation system 36 image the end shells 24 to sense the first orientation of the roll grinding marks 4 of each of the end shells 24. The sensors 40 provide information about the orientation of the roll grinding marks 4 to the control system 70. The control system 70 uses information from the sensors 40 to determine 98 the orientation of the rolling direction 25 which is generally parallel to the roll grinding marks 4. In one embodiment, the sensors 40 comprise cameras with sufficient resolution and magnification to identify roll grinding marks 4 in each end shell 24.

The control system 70 uses the information received from the sensors 40 to determine 100 if the rolling direction 25 of the end shells 24 is oriented within a predetermined angle compared to a reference axis 22. In one embodiment, the control system 70 compares the information received from the sensors 40 to reference data stored in memory. The reference data relates to an end shell with roll grinding marks 4 in a preferred alignment with the reference axis 22. In one embodiment, the reference data comprises an image of an end shell that is aligned with the reference axis 22. In another embodiment, the reference data comprises a model of an end shell that is aligned with the reference axis 22. If the rolling direction 25 of the end shells 24 is within the predetermined angle, method 90 proceeds YES and the end shells continue 112 to the conversion press 76 without rotation by the orientation system 36.

Alternatively, if the rolling direction 25 of any of the end shells 24 is not aligned within a predetermined angle compared to the reference axis 22, method 90 proceeds NO and the control system 70 determines 102 an amount to rotate the improperly aligned end shells 24 at operation 102. The control system 70 then sends a signal to servo units associated with actuators 44, 54. In response to receiving the signal, the servo unit rotates an actuator 44, 54 associated with the improperly aligned end shell 24 the determined amount at operation 104. The actuator 44, 54 may rotate axially either clockwise or counterclockwise as determined by the control system 70. In one embodiment, the actuator 44, 54 contacts a predetermined portion of the end shell 24 and applies a frictional force to the end shell causing the end shell to rotate. Additionally, or alternatively, the actuator 44, 54 may rotate the end shell 24 by applying a frictional force to a die cap 33 associated with the end shell 24.

In one embodiment, the control system 70 may determine in operation 102 that the dwell time is not sufficient to complete the axial rotation the end shell 24 such that the rolling direction 25 is within a preferred alignment with the reference axis 22. Accordingly, the control system 70 may send a signal to rotate the end shell 24 a first amount by a first actuator 44 and a second amount by a second actuator 54 in series.

After the actuator 44, 54 rotates the end shell 24, a second sensor 50 senses a second orientation of roll grinding marks 4 of the end shell 24. The control system 70 receives information about the second orientation of the rolling grinding marks 4 from the second sensor 50 and determines 106 the second direction of the rolling direction 25. The control system 70 then determines 108 if the rolling direction 25 of the end shell 24 is in the proper orientation. If the end shell rolling direction 25 is in the proper orientation, method 90 proceeds YES to operation 112. If the rolling direction 25 is not properly oriented, method 90 may return NO to operation 102. Accordingly, the end shell 24 may be rotated by a second actuator 54 by an amount determined by control system 70.

Optionally, in one embodiment, if the end shell rolling direction 25 is not properly oriented when sensed by a third sensor 60, method 90 proceeds NO to remove 110 the improperly oriented end shell 24 from the system 36. The control system 70 sends a signal to an ejector 66 that ejects 110 the improperly oriented end shell 24 from the orientation system 36. Method 90 then ends 114.

When the control system 70 determines 100, 108 that the end shells 24 have a rolling direction 25 that is properly oriented with the reference axis 22, the end shells 24 are transported, in operation 112, by the transport system 32 to the conversion press 76 or other downstream equipment 88. Method 90 then ends 114. One of skill will appreciate that the method 90 may use any number of sensors and actuators to ensure the rolling direction 25 is aligned within a predetermined angle with respect to a reference axis 22 of the orientation system 36.

The description of the present invention has been presented for purposes of illustration and description, but is not intended to be exhaustive or limiting of the invention to the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. The embodiments described and shown in the figures were chosen and described in order to best explain the principles of the invention, the practical application, and to enable those of ordinary skill in the art to understand the invention.

While various embodiments of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. Moreover, references made herein to “the present invention” or aspects thereof should be understood to mean certain embodiments of the present invention and should not necessarily be construed as limiting all embodiments to a particular description. It is to be expressly understood that such modifications and alterations are within the scope and spirit of the present invention, as set forth in the following claims.

Claims

1. A system for aligning a rolling direction of a metallic end shell to a preferred position, comprising:

a transport system to move the metallic end shell through the system;

a sensor to sense an orientation of a grinding mark on the metallic end shell, wherein the grinding mark is associated with the rolling direction of the metallic end shell; and

an actuator to rotate the metallic end shell such that the rolling direction of the metallic end shell is within a predetermined angle with respect to a reference axis of the system.

2. The system of claim 1, further comprising a servo unit associated with the actuator to rotate the metallic end shell by a predetermined amount in less than approximately 60 milliseconds.

3. The system of claim 1, wherein the actuator is operable to rotate the metallic end shell such that the rolling direction is within about 12° of the reference axis.

4. The system of claim 1, wherein the actuator contacts a predetermined portion of the metallic end shell to rotate the metallic end shell.

5. The system of claim 1, further comprising a second sensor to sense a second orientation of the grinding mark after the actuator has rotated the metallic end shell by the predetermined amount.

6. The system of claim 5, further comprising a second actuator to rotate the metallic end shell by a predetermined amount.

7. The system of claim 6, wherein the second actuator is operable to rotate the metallic end shell such that the rolling direction is within about 3° of the reference axis.

8. The system of claim 5, further comprising an ejector to remove the metallic end shell from the system if the second orientation is not within the predetermined angle with respect to the reference axis.

9. The system of claim 1, further comprising a control system that receives information related to the orientation of the grinding mark from the sensor and determines an axial amount for the actuator to rotate the metallic end shell to orient the rolling direction of the metallic end shell within the predetermined angle.

10. A method of orienting an end shell in a high-speed production process based on the metal rolling direction, comprising:

receiving an unoriented end shell;

determining an orientation of a grinding mark present on the end shell, wherein the grinding mark is associated with the metal rolling direction of the end shell;

if the orientation of the grinding mark is not in a predetermined orientation, determining an amount of axial rotation required to properly orient the end shell; and

rotating the end shell by the determined amount of axial rotation such that the metal rolling direction is oriented in a predetermined position.

11. The method of claim 10, wherein rotating the end shell comprises engaging a predetermined portion of the end shell by an actuator.

12. The method of claim 11, wherein the actuator is operable to rotate the end shell by the determined amount in less than approximately 60 milliseconds.

13. The method of claim 10, further comprising a sensor operable to sense the orientation of the grinding mark on the end shell.

14. The method of claim 13, wherein a system controller determines the amount of axial rotation required to rotate the end shell such that the grinding mark is in the predetermined orientation.

15. The method of claim 10, wherein the end shell is subsequently converted into a container end closure by a conversion press, the end closure adapted for interconnection to a neck of a container.

16. The method of claim 10, further comprising determining a second orientation of the grinding mark of the end shell after rotating the end shell by the determined amount.

17. The method of claim 16, further comprising ejecting the end shell if the second orientation of the grinding mark is not in the predetermined orientation.

18. An orientation system operable to determine and align a rolling direction of a metallic work-piece in a metal forming process, comprising:

a first sensor at a first index position to sense roll grinding marks in a metallic work-piece, the roll grinding marks used to determine a first orientation of the rolling direction of the metallic work-piece; and

a first actuator at a second index position to rotate the work-piece axially to substantially align the rolling direction with a reference axis of the orientation system.

19. The orientation system of claim 18, wherein the metal forming process is a container end closure manufacturing process and the work-piece is a metallic end shell.

20. The orientation system of claim 18, further comprising a control system that receives data from the first sensor and determines an amount and a direction of rotation for the first actuator to rotate the work-piece.

21. The orientation system of claim 18, wherein the first actuator can rotate the rolling direction of the work-piece to within about 3° of the reference axis within less than approximately 60 milliseconds.