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.

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.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0059] 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.

[0060] FIG. 1 is a schematic flow diagram of a prior art end closure conversion process;

[0061] 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;

[0062] FIG. 3 is a side elevation view of an orientation system according to one embodiment of the present invention;

[0063] FIG. 4 is a top plan view of the orientation system of FIG. 3; and

[0064] 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.

[0065] 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.

[0066] 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:

TABLE-US-00001 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

[0067] 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.

[0068] 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.

[0069] 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.

[0070] 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.

[0071] 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.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] 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.

[0076] 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.

[0077] 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.

[0078] 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.

[0079] 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.

[0080] 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.

[0081] 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.

[0082] 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.

[0083] 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.

[0084] 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.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] 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.

[0089] 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.

[0090] 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.

[0091] 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.

[0092] 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.

[0093] 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.

[0094] 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.

[0095] 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.

[0096] 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.

[0097] 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.

[0098] 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.

[0099] 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.

[0100] 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.

[0101] 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.

[0102] 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.

[0103] 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.

[0104] 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.

[0105] 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.

[0106] 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.

[0107] 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.

[0108] 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.

[0109] 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.

[0110] 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.

[0111] 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.

[0112] 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.

[0113] 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.

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] 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.