LUBRICATOR WITH QUICK RELEASE MODULAR MOUNTING

Abstract

Systems and methods are provided for mounting a fluid applicator to or proximate a press, stamping machine or assembly line. The fluid applicators are releasable and replaceable without cleaning or contacting the fluid application surfaces.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Patent Application Ser. No. 62/105,831, filed in the United States Patent and Trademark Office on Jan. 21, 2015, which is incorporated herein by reference in its entirety.

BACKGROUND OF THE DISCLOSURE

Modern manufacturing concepts such as “just in time” (JIT) and “lean manufacturing” have changed the stamping industry. For instance, large inventories of sheet stock are no longer stored on site. Smaller inventories require shorter stamping runs and more frequent setups to accommodate customer orders as they are received.

It is not uncommon for each production run to have individual lubrication needs such as a specific concentration or a different lubricant from a previous run. However, some lubricants may react with others and cause adverse effects (e.g., shearing or coagulation) so clean-up between short runs becomes problematic. Additionally, residual lubricant (“carry out”) in a system may not be compatible with finishing processes. Contamination with the wrong lubricant can adversely affect cleaning, painting or plating of the stock.

Although atomized or spray lubricants can be relatively quickly changed to accommodate different runs, due to undesirable health effects caused by inhalation as well the housekeeping problems created by overspray of such lubricants, the industry is moving away from atomized lubricants. Slippery floors and oily work environments also are undesirable side effects of spray lubricants.

Roller applicators are increasingly used instead of spray applicators. However, roller applicators with wicking contact surfaces cannot be easily or thoroughly cleaned when changing to different lubricants. Moreover, few manufacturers offer roller applicator mounting accessories. Typically, the end user must fabricate brackets or, more often, use whatever is readily available in the work area to position and secure the applicator equipment.

What is needed in the industry is an applicator system that can be changed quickly, reduces contamination, and does not require cleaning rollers or changeover between lubricants. Further, the desired system should be adjustable to accommodate different heights and lateral positions in various working environments.

BRIEF SUMMARY OF THE DISCLOSURE

The present disclosure is directed in general to provide a roller applicator with quick change capability having a complement of mounting options. The roller applicator system is modular in design. Beginning with the roller head, in one embodiment, a cassette can be mounted directly or fit into a quick release mounting base. The base can be permanently mounted and the roller head can be snapped out and replaced by another. A user might designate a specific roller head for a specific lubricant and designate other roller heads for other lubricants, thus eliminating contamination or the need for cleaning. Changeover between lubricants would complement the quick die change technologies employed in the various embodiments of the disclosure.

In one aspect, the device is an applicator whereby lubricant is applied to the top and bottom surfaces of metal strips, typically from coil form, as it enters a stamping press or similar. Opposing rollers having a wicking surface, fibrous or otherwise, contact the named surfaces of the strip and roll on their axles by a motion created by the advancement of the strip being powered by its feeding system(s). The rollers are continuously replenished with lubricant, in this case internally, in graduated amounts to control the thickness of the coating.

According to another embodiment of the present disclosure, a roller assembly is configured for modular mounting and includes quick change features. The roller assembly may have a base affixable to a process line such as stamping equipment. A roller applicator may be rapidly removed and replaced with another roller applicator without cleaning or contacting fluid application surfaces.

In another embodiment, a fluid applicator system may include a fluid applicator; a quick release base for carrying the fluid applicator, the quick release base being configured to hold and release the fluid applicator; a height adjustment assembly configured for positioning the fluid applicator; and means for mounting the fluid applicator proximate a processing line.

The fluid applicator in this embodiment may be a roller configured to apply a lubricant to a stock material. The roller may be two or more rollers that form a nip therebetween through which the stock material travels. One of the rollers may include elastomer rings disposed along the roller to help catch and guide the stock material. Also in this embodiment, the quick release base may include a catch having a spring constant. The catch in a first state may hold the fluid applicator at or near the processing line. The catch in a second state may release the fluid applicator for cleaning, replacement or other maintenance.

The height adjustment assembly may include a slot and may further include a mounting assembly connecting the quick release base to the quick release base. The mounting assembly may be adjustable along the slot. The fluid applicator may be mounted using a bracket or the like to mechanically connect the system to the processing line. Alternatively or additionally, the fluid applicator may be mounted using a magnet for communication with the processing line.

Additional objects and advantages of the present subject matter are set forth in, or will be apparent to, those of ordinary skill in the art from the description herein. Also, it should be further appreciated that modifications and variations to the specifically illustrated, referenced, and discussed features, processes, and elements hereof may be practiced in various embodiments and uses of the disclosure without departing from the spirit and scope of the subject matter. Variations may include, but are not limited to, substitution of equivalent means, features, or steps for those illustrated, referenced, or discussed, and the functional, operational, or positional reversal of various parts, features, steps, or the like. Those of ordinary skill in the art will better appreciate the features and aspects of the various embodiments, and others, upon review of the remainder of the specification.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present subject matter, including the best mode thereof, directed to one of ordinary skill in the art, is set forth in the specification, which makes reference to the appended figures, in which:

FIG. 1 are schematic front and side elevational views of a roller lubricator system in an intended use environment according to an aspect of the present disclosure;

FIG. 2 is a perspective view of a roller applicator cassette as used in FIG. 1;

FIG. 3 is an exploded view of the roller applicator cassette as in FIG. 2;

FIG. 4 are perspective, plan and elevational views of a quick release assembly used with the roller applicator cassette as in FIG. 1;

FIG. 5 is an exploded view of the roller applicator cassette and the quick release assembly as in FIGS. 1-4;

FIG. 6 is a perspective view of a height adjustment assembly used with the roller applicator cassette as in FIG. 1;

FIG. 7 are perspective and elevational views of another embodiment of a height adjustment assembly that may be used with a roller applicator cassette according to another aspect of the disclosure;

FIG. 8 are side elevational and exploded, perspective views of a roller lubricator system according to another aspect of the disclosure and;

FIG. 9 an elevational view of a portion of the roller lubricator system as in FIG. 8;

FIG. 10 a perspective view of a roller lubricator system according to another aspect of the disclosure;

FIG. 11 are perspective views of various components of the roller lubricator system as in FIG. 10; and

FIG. 12 is a perspective view of a roller lubricator system according to another aspect of the disclosure.

DETAILED DESCRIPTION OF THE DISCLOSURE

In general, the present disclosure provides systems and methods for improving operations and functionality of applicator devices during treatment of stock metal strips before the stock enters a stamping press or similar production line. The systems disclosed herein and their equivalents are economical to make and use.

Detailed reference will now be made to the drawings in which examples embodying the present subject matter are shown. The detailed description uses numerical and letter designations to refer to features of the drawings. The drawings and detailed description provide a full and written description of the present subject matter, and of the manner and process of making and using various exemplary embodiments, so as to enable one skilled in the pertinent art to make and use them, as well as the best mode of carrying out the exemplary embodiments. However, the examples set forth in the drawings and detailed descriptions are provided by way of explanation only and are not meant as limitations of the disclosure. The present subject matter thus includes any modifications and variations of the following examples as come within the scope of the appended claims and their equivalents.

Turning now to the figures, FIG. 1 shows a roller lubricator system, designated in general by the numeral 10, arranged next to or connected or attached to a press or stamping machine 1. The exemplary roller lubricator system 10 broadly includes a roller applicator head or cassette 12, a quick release base or assembly 14, a height adjustment assembly 16, a window mounting bracket 18, and a magnetic mounting kit or assembly 20. As shown, by way of brief introduction, a sheet of material such as stock metal 3 in coil form may be unrolled into the roller lubricator system 10. After the roller applicator head 12 applies a lubrication fluid to a surface of the metal 3, the metal 3 proceeds downstream in a production line supported by a bolster 5 where the lubricated metal 3 is stamped, cut or the like.

FIGS. 2 and 3 show the roller applicator head 12 in greater detail. Here, the exemplary roller applicator head 12 may include a cover 22 having a plurality of apertures, notches and cut-outs to accommodate various features of the roller lubricator system 10. For instance, the cover 22 may include a stock entry window or opening 24 and a stock exit window or opening 26 for respectively receiving and dispatching the metal 3 introduced above in FIG. 1. As shown in FIG. 3, one or more hoses or conduits 7 may be connected to a fluid source containing, for instance, a lubrication fluid 9 that may be fed into the roller applicator head 12 and applied to the metal 3. Once the metal 3 is lubricated or otherwise treated with the fluid 9, the metal 3 exits the roller applicator head 12 through stock exit window 26 for stamping or the like.

FIGS. 2 and 3 further show that roller applicator cassette or head 12 may include one or more roller adjustment apertures or holes 28 through which roller pressure adjustment thumbscrews or knobs 54 project, the operation of which are described below. Also shown, a hose quick connector notch 30 and an easy lift roller notch 32 are provided in the cover 22 to accommodate an exemplary roller assembly 34. A manual roller lift handle 57 is provided to ease loading of the roller assembly 34.

As shown most clearly in FIG. 3, the roller assembly 34 may include a frame 36 having opposing connection arms, fingers or hooks 38. In this example, at or near an area where the hooks 38 begin to project from the frame 36, an indentation or trough 40 is formed to assist in connecting or mating the frame 36 of the roller applicator cassette 12 to the quick release assembly 14 as described in greater detail below.

With continued reference to both FIGS. 2 and 3, the roller assembly 34 may include a dual rollers or axles. For instance, a top, upper or first roller 42, which may be needle-bearing mounted, may have a removable plurality of felt washers or rings 44, a cloth tube or the like. The surface 44 may be a wicking, fibrous or similar surface and is continuously replenished with lubricant, in this case internally, in graduated amounts to control coating thickness. More specifically, a quick connector 46 may be in communication with an interior of the top roller 42 such that the fluid 9 may pass through the tube 7, which connects the fluid tank 9 to the connector 46, into the roller 46. Similarly, a bottom, lower or second roller 48 may have removable felt washers or rings 50, a cloth tube or the like. A quick connector 52 may be in communication with an interior of the bottom roller 48 such that the fluid 9 may pass through the tube 7 into the roller 48 via the connector 52. Thus, the fluid 9 is injected into, soaked up by, or permeates the felt rings 44, 50, which in turn contact the metal 3 as it passes into a gap or nip 51 formed between the rollers 42, 48. Once the material 3 is treated or coated, any excess fluid is returned to the tank 9 by an oil return valve or nozzle 58.

FIG. 2 particularly shows that the felt rings 44, 50 may include traction washers 35. The washers 35 may be the same diameter as the felt rings 44, 50. In this example, the felt ring 50 is about one-eighth inch (⅛″) to about one-half inch (½″), particularly about one-quarter inch (¼″) in thickness. The washers 35 disposed about a surface of the ring 50 may be an elastomer (e.g., rubber, urethane, polyurethane and polyurea elastomer) and may be approximately one-thirty-second inch ( 1/32″) to about one-eighth inch (⅛″), particularly about one-sixteenth inch ( 1/16″) in thickness. The compression of the rings 44, 50 allows the elastomer washers 35 to grip without their size being larger. The exemplary thicknesses of the washers 35 and the rings 44, 50 may be altered to accommodate different fluids and/or strip materials. For example, if mineral spirits (with water-like viscosity) was being applied to prepainted stock material having low surface viscosity (low friction), the felt washers 44, 50 and the rubber washers 35 might each be approximately ⅛″ thick to regulate the amount of fluid applied and to improve traction.

FIG. 3 most clearly shows that the height or size of the nip 51 may be adjusted by the roller pressure adjustment knobs 54, briefly introduced above. Here, the roller pressure adjustment knobs 54 are connected to respective spring assemblies 55 that, when tightened by the knobs 54, urge the rollers 42, 48 closer together to make a tighter nip 51. Of course, when the knobs 54 are turned in the opposite direction, as indicated by a double-headed arrow 56, the pressure between the rollers 42, 48 is reduced to accommodate, for instance, a thicker sheet of metal 3, plastic, or other stock material or to apply less fluid 9. Those skilled in the art will appreciate that the knobs 54 are by way of example only. Other forms of controlling nip pressure or size may be realized by practicing the present embodiment, which equivalents are within the scope of the disclosure.

Shown most clearly shown in FIG. 4 is the quick release assembly 14, which receives the cassette 12 described above. In this example, the assembly 14 includes a floor or base 60 that has at least one lateral ledge or projection 62, a rear wall or machine face 64, and a front wall or stock entry face 66. As shown, the front wall 66 includes a notch or opening 68 to seat and partially shield the fluid return nozzle 58 introduced above in FIGS. 2 and 3. Also, the walls 64, 66 may have rotation projections or cylinders 70 for operation with a latch or clip as explained below.

FIG. 4 further shows that the quick release assembly 14 may include latch or clip assemblies 72 disposed in this example at either end of the quick release assembly 14. Here, each assembly 72 may be made of stainless steel or another durable material capable of being formed to provide a spring constant. The latch assembly 72 may have side frames or arms 74 rotatably connected to the rotation cylinders 70. As shown, the latch assembly 72 may be rotated away from the quick release assembly 14 by pressing on a tab 76, which in turn lifts and releases one or more fingers or catches 78 from the cassette 12. Lastly, FIG. 4 shows a plurality of projections or roller head receivers 80 that also interact with features of the cassette 12. These components are described in greater detail below by way of an exemplary operation.

FIG. 5 is an exploded view of the roller applicator cassette 12 and the quick release assembly 14. As shown, the latch assemblies 72 of the quick release assembly 14 are retracted to release the frame 36. The knobs 54, which could be detent mechanisms, ratchets, or other means of controlling nip pressure, project through the cover 22 to control the nip pressure in the roller assembly 34 as introduced above. Also shown, serviceable needle bearings, seals and roller units are shown at 37.

Turning to FIG. 6, the height adjustment assembly 16 briefly introduced in FIG. 1 is shown with a horizontal mounting surface, base, or ledge 82 in this example. The base 82 is used to mount the assembly 16 to or near the stamping machine 1 (see FIG. 1). A vertical wall or machine face 84 is normal to the base 82 and may include one or more vertical slots, slits or windows 86. Each slot 86 receives an adjustable or movable vertical mounting assembly 88. The adjustable mounting assembly 88 may include a vertical wall or face 90 and a horizontal floor or projection 94. As shown, the vertical wall 90 is mated against a portion of the machine face 84. A projection arm 91 depends from a quick release clamp handle 92 through the slot 86. As will be explained in more detail below, if the cassette 12 needs to be lowered or raised relative to the stamping machine 1, the quick release clamp handle 92 may be loosened and the adjustable mounting assembly 88 raised or lowered as required to adjust the vertical position of the cassette 12.

FIG. 7 shows an alternative height adjustment assembly 116 according to another aspect of the disclosure. Here, a magnetic mounting assembly 120 is attached to a wall or face 184 of the adjustment assembly 116. The magnets 120 may be screwed or bolted to the assembly 116 in addition to their magnetic pull, which may be 200 pounds of pull or more. In this example, the vertical wall 184 includes at least four 200 pound pull magnets 120 and may include one or more vertical slots, slits or windows 186. Each slot 186 receives an adjustable or movable vertical mounting assembly 188. The adjustable mounting assembly 188 may include a vertical wall or face 190 and a horizontal floor or projection 194. As shown, the vertical wall 190 is mated against a portion of the machine face 184. A quick release clamp handle 192 permits the assembly 188 to move up and down in the slot 186 as the handle 192 is rotated and released then tightened in a preferred position.

With reference now to FIG. 8, a roller lubricator or applicator system, designated in general by the numeral 210, is shown in an exemplary operation arranged next to or connected or attached to a stock processing line 21. The roller lubricator system 210 broadly includes a roller applicator head or cassette 212, a quick release base, carrier, or assembly 214, a height adjustment assembly 216, and a magnetic mounting kit or assembly 220. In this exploded view, the cassette 212 has been released from the quick release carrier 214 by virtue of clips 272 being retracted. Also shown, a stock support guide or tray 296 having a chamfered edge 298 may be attached to the assembly 214 by screws, welding or the like. The stock support 296 is shown in this example attached to the infeed side of the applicator 212. The stock support 296 could also be attached to the outfeed side or one each to both infeed and outfeed sides of the applicator 212 to help control and feed stock material into and out of the applicator 212. As shown, by manipulating a quick release clamp handle 292 the adjustable mounting assembly 288 may be raised or lowered to adjust the vertical position of the cassette 212 to align it with the processing line 21.

FIG. 9 most clearly shows the roller lubricator system 210 in which the roller applicator cassette 212 is seated in the quick release base 214 at a chosen height set by the height adjustment assembly 216 via the slots 286. As shown, the exemplary roller lubricator system 210 will be attached to a production line or stamping machine using the magnetic mounting kit 220 described above. In this view, the cassette 212 is locked in the quick release carrier 214 by virtue of the clips 272 being rotated inward or in a direction of the cassette 212. Also shown, the fluid return valve 258 is seated in the notch 268.

Turning to FIG. 10, a roller lubricator system for use with a press or stamping machine is designated in general by the numeral 310. The roller lubricator system 310 broadly includes a roller applicator head or cassette 312, a quick release base or assembly 314, a height adjustment assembly 316, a window mounting bracket 318, and a magnetic mounting kit or assembly 320. Here, the window mounting bracket 318 has a machine or vertical face 319 with magnet assembly attachment or vertical slots 323 therein, and a horizontal face 325 with horizontal slots 327 therein. The magnetic mounting assembly 320 includes a plurality of magnets 321 that may be screwed or bolted to a plate 329 in addition to their magnetic pull, which may be 200 pounds of pull or more.

In the example of FIG. 10, the magnets 321 and their plate 329 may be oriented in a longitudinal or up-down direction in which one magnet 321 is positioned substantially above the other, as opposed to being substantially side-by-side. Here, the plate 329 is adjusted along slot 323 as needed to attach between columns or to accommodate a width of a particular stamping machine. Likewise, the kit 316 may be adjusted side-to-side along slots 327 to laterally align the assembly 310 with the stamping machine. Also shown, a stock support 396 may be attached to the assembly 310 to help guide stock material into the applicator head 312.

FIG. 11 shows opposing views of the lubricator system 310 shown in FIG. 10. The roller applicator cassette 312 is shown resting in the quick release base 314 with the height adjustment assembly 316 attached to the window mounting bracket 318. The magnetic mounting assembly 320 will attach the system 310 to the processing line as described above. Again, slots 327, 386 permit a position of the applicator 312 to be adjusted in height and laterally. Similarly, slot 323 permits the plate 329 and therefore, the magnet 321 to be adjusted laterally to accommodate various machine widths.

With reference to FIG. 12, a lubricator or applicator system shown in use with a press or stamping machine 41 is designated in general by the numeral 410. The roller lubricator system 410 broadly includes a roller applicator head or cassette 412, a quick release base or assembly 414, a height adjustment assembly 416, and a magnetic mounting kit or assembly 420. The cassette 412 is locked into the base assembly 414 by locking a set of latches 472 into a locked position or state. Should a subsequent material run be required using a different fluid, the latches 472 can be quickly unlocked or sprung to an unlatched state to remove, clean or replace the cassette 412 with another without having to unbolt, move or otherwise disturb the applicator system 410 as a whole. Therefore, all vertical and lateral adjustments relative to the machine 41 remain intact when and if it becomes necessary to remove or replace the cassette 412.

Also shown through a stock window 426, the cassette 412 includes at least one roller 444 for fluid treatment of stock material such as metal sheets. Here, one or more hoses or conduits 407 may be connected to a fluid source containing, for instance, a lubrication fluid that may be fed into the roller applicator head 412 and applied to the metal. Once the metal is lubricated or otherwise treated with the fluid, the metal exits the roller applicator head 412 through stock exit window 426 for stamping or the like by the machine 41.

While the present subject matter has been described in detail with respect to specific embodiments thereof, it will be appreciated that those skilled in the art, upon attaining an understanding of the foregoing may readily produce alterations to, variations of, and equivalents to such embodiments. Accordingly, the scope of the present disclosure is by way of example rather than by way of limitation, and the subject disclosure does not preclude inclusion of such modifications, variations and/or additions to the present subject matter as would be readily apparent to one of ordinary skill in the art.

Claims

1. A roller applicator being configured for modular mounting and including quick change features, the roller applicator comprising:

a base affixable to stamping equipment; and

a roller assembly configured for connection with the base in fluid communication with a fluid supply, the roller assembly including a handle for connecting the roller assembly to the base and opposing rings configured for passage of stock material therebetween for treatment with a fluid from the fluid supply;

wherein, upon treatment of the stock material with the fluid, the handle is activated to release the roller assembly from the base.

2. The roller applicator as in claim 1, wherein the base is affixed proximate a stamping line for treating the stock material.

3. The roller applicator as in claim 1, wherein the opposing rings form a nip therebetween through which the stock material travels.

4. The roller applicator as in claim 1, wherein the opposing rings are made from felt and at least one of rings has a plurality of elastomer rings disposed thereon.

5. A fluid applicator system, comprising:

a fluid applicator;

a quick release base for carrying the fluid applicator, the quick release base being configured to hold and release the fluid applicator;

a height adjustment assembly configured for positioning the fluid applicator; and

means for mounting the fluid applicator proximate a processing line.

6. The fluid applicator system as in claim 5, wherein the fluid applicator is a roller being configured to apply a lubricant to a stock material.

7. The fluid applicator system as in claim 5, wherein the roller is a plurality of rollers forming a nip therebetween through which a stock material travels.

8. The fluid applicator system as in claim 5, wherein the quick release base includes a catch having a spring constant, the catch in a first state holding the fluid applicator proximate the processing line, the catch in a second state releasing the fluid applicator.

9. The fluid applicator system as in claim 5, wherein the height adjustment assembly includes a slot therein and further comprising a mounting assembly connecting the quick release base to stamping equipment in the processing line, the mounting assembly being adjustable along the slot.

10. The fluid applicator system as in claim 5, wherein the means for mounting the fluid applicator proximate the processing line is a bracket for connection to the processing line.

11. The fluid applicator system as in claim 5, wherein the means for mounting the fluid applicator proximate the processing line is a magnet for connection to the processing line.

12. A fluid applicator system, comprising:

a fluid applicator;

a quick release base for carrying the fluid applicator, the quick release base being configured to hold and release the fluid applicator;

a height adjustment assembly configured for positioning the fluid applicator; and

means for mounting the fluid applicator proximate a processing line.

13. The fluid applicator system as in claim 12, wherein the fluid applicator is a roller configured to apply a lubricant to a stock material.

14. The fluid applicator system as in claim 13, wherein the roller is at least two rollers forming a nip therebetween through which the stock material travels.

15. The fluid applicator system as in claim 13, wherein the roller has a plurality of elastomer rings disposed along the roller to guide the stock material.

16. The fluid applicator system as in claim 13, wherein the quick release base includes a catch defining a spring constant, the catch in a first state being configured to hold the fluid applicator proximate the processing line, the catch in a second state being configured to release the fluid applicator from the processing line.

17. The fluid applicator system as in claim 13, wherein the height adjustment assembly includes a slot defined therein and further includes a mounting assembly connecting the quick release base to the quick release base, the mounting assembly being adjustable along the slot.

18. The fluid applicator system as in claim 13, wherein the fluid applicator is mounted using one of a bracket or a magnet for connection proximate the processing line.