FLOW RESTRICTOR FOR A CUPPER AND CUPPER INCLUDING THE SAME

Abstract

A flow restrictor for a cupper having a riser and a die center structured to form a metal blank into a cup, wherein a continuous air passage having a first diameter is formed axially through the riser and the die center and is in fluid communication with a base of the die center, the flow restrictor includes a small diameter passage having a second diameter that is smaller than the first diameter, wherein the flow restrictor is structured to be disposed in and in fluid communication with the air passage of the cupper.

Claims

1. A flow restrictor for a cupper, said cupper having a riser and a die center structured to form a metal blank into a cup, wherein a continuous air passage having a first diameter is formed axially through the riser and the die center and is in fluid communication with a base of the die center, said flow restrictor comprising: a small diameter passage having a second diameter that is smaller than the first diameter, wherein the flow restrictor is structured to be disposed in and in fluid communication with the air passage of the cupper.

2. The flow restrictor of claim 1, further comprising: a large diameter opening having the first diameter; a transition section extending from the large diameter opening to the small diameter passage and fluidly coupling the large diameter opening and the small diameter passage, the transition section having an upstream end coupled to the large diameter opening and a downstream end coupled to the small diameter section, wherein the upstream end has the first diameter and the downstream end has the second diameter, wherein the transition section gradually reduces in diameter from the upstream end to the downstream end.

3. The flow restrictor of claim 1, wherein the flow restrictor is structured to be disposed in a portion of the air passage formed in the riser, the adapter, or the die center.

4. The flow restrictor of claim 1, wherein the cupper further includes an adapter disposed between the riser and the die center, wherein the air passage is formed axially through the adapter, and wherein the flow restrictor is structured to be disposed in the portion of the air passage formed in the adapter.

5. The flow restrictor of claim 1, wherein the flow restrictor is structured to be inserted into the air passage.

6. The flow restrictor of claim 5, wherein the flow restrictor is structured to be retained in the air passage by a friction fit or a threaded fit.

7. The flow restrictor of claim 1, wherein the first diameter is about 0.375 inches.

8. The flow restrictor of claim 7, wherein the second diameter is less than or equal to about 0.188 inches.

9. The flow restrictor of claim 7, wherein the second diameter is less than or equal to about 0.110 inches.

10. The flow restrictor of claim 1, wherein the flow restrictor is machined into the air passage.

11. A cupper comprising: a riser; a die center structured to form a metal blank into a cup; an air passage having a first diameter formed axially and continuously through the riser and the die center and is in fluid communication with a base of the die center, the air passage structured to receive a supply of air from an air supply; and a flow restrictor including: a small diameter passage having a second diameter that is smaller than the first diameter, wherein the flow restrictor is structured to be disposed in and in fluid communication with the air passage of the cupper.

12. The cupper of claim 11, wherein the flow restrictor further comprises: a large diameter opening having the first diameter; and a transition section extending from the large diameter opening to the small diameter passage and fluidly coupling the large diameter opening and the small diameter passage, the transition section having an upstream end coupled to the large diameter opening and a downstream end coupled to the small diameter section, wherein the upstream end has the first diameter and the downstream end has the second diameter, wherein the transition section gradually reduces in diameter from the upstream end to the downstream end.

13. The cupper of claim 11, wherein the air passage includes a riser air passage formed in the riser and a die center air passage formed in the die center, wherein the flow restrictor is disposed in one of the riser air passage and the die center air passage.

14. The cupper of claim 11, further comprising: an adapter disposed between the ram and the punch die, wherein the air passage is formed axially and continuously through the riser, the adapter, and the die center, wherein the air passage includes a riser air passage formed in the riser, an adapter air passage formed in the adapter, and a die center air passage formed in the die center, and wherein the flow restrictor is disposed in the adapter air passage.

15. The cupper of claim 11, wherein the flow restrictor is an insert in the air passage.

16. The cupper of claim 15, wherein the flow restrictor is retained in the air passage by a friction fit or a threaded fit.

17. The cupper of claim 11, wherein the first diameter is about 0.375 inches.

18. The cupper of claim 17, wherein the second diameter is less than or equal to about 0.188 inches.

19. The cupper of claim 17, wherein the second diameter is less than or equal to about 0.110 inches.

20. The cupper of claim 11, wherein the flow restrictor is machined into the air passage.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0007] A full understanding of the invention can be gained from the following description of the preferred embodiments when read in conjunction with the accompanying drawings in which:

[0008] FIG. 1 is a partial sectional view of a cupper;

[0009] FIG. 2 is sectional view of a punch assembly of the cupper of FIG. 1 in a depressed state;

[0010] FIG. 3 is sectional view of a punch assembly of the cupper of FIG. 1 in the process of ejecting a cup;

[0011] FIG. 4 is a sectional view of a punch assembly of the cupper of FIG. 1 after ejecting a cup;

[0012] FIG. 5 is a sectional view of a punch assembly for a cupper with a flow restrictor in accordance with an example embodiment of the disclosed concept;

[0013] FIG. 6 is a sectional detail view of a flow restrictor insert in accordance with an example embodiment of the disclosed concept; and

[0014] FIG. 7 is a sectional detail view of a machined flow restrictor in accordance with another example embodiment of the disclosed concept.

DETAILED DESCRIPTION OF THE INVENTION

[0015] FIG. 1 is a partial sectional view of a cupper 1. FIG. 2 is sectional view of a punch assembly of the cupper 1 of FIG. 1 in a depressed state. FIG. 3 is sectional view of a punch assembly 2 of the cupper 1 of FIG. 1 in the process of ejecting a cup 10. FIG. 4 is a sectional view of a punch assembly 2 of the cupper 1 of FIG. 1 after ejecting the cup 10.

[0016] Generally, and as shown partially in FIG. 1, a cupper 1 includes a punch assembly 2 including at least one movable, elongated riser 100 and a corresponding die center 104. While one punch assembly 2 is shown in FIG. 1, it will be appreciated that the cupper 1 may include multiple punch assemblies 2. In some example embodiments, the cupper 1 may include sixteen punch assemblies 2. In such an embodiment, the cupper 1 is able to for sixteen cups 10 at a time. Such a cupper may be referred to as a 16-out cupper. However, it will be appreciated that the disclosed concept may be employed in cuppers using any number of punch assemblies 2. In some example embodiments, an adapter 102 may be disposed between the riser 100 and the die center 104. However, it will be appreciated that in some example embodiments, the adapter 102 may be omitted and the riser 100 may be directly coupled to the die center 104. An operating mechanism (not shown) moves the riser 100, adapter 102, and die center 104 axially toward, and into, a die. A work piece (not shown), which may be a circular blank or a sheet of metal from which a circular blank is cut, is disposed between the die center 104 and the die. As the riser 100 pushes the die center 104 into the die, the work piece is formed into a cup 10. As the riser 100 withdraws the die center 104 from the die, the cup 10 remains disposed over the end of the die center 104.

[0017] The cupper 1 includes an air passage fluidly coupled to an air supply 20. The air supply 20 may be, for example and without limitation, an air compressor. The air supply 20 may provide continuous or intermittent flow of pressurized air. The air passage of the cupper 1 includes an inner punch holder air passage 110 disposed in an inner punch holder disposed at an upper part of the punch assembly 2 and fluidly coupled to the air supply 20. The air passage also includes a riser air passage 112 extending axially through the riser 100 and fluidly coupled to the inner punch holder air passage 110. The air passage of the cupper 1 also includes an adapter air passage 114 extending axially through the adapter 102 and fluidly coupled to the riser air passage 112. It will be appreciated that in some example embodiments, the adapter 104 and adapter air passage 114 may be omitted. The air passage of the cupper 1 further includes a die center air passage 116 extending axially through the die center 104 and fluidly coupled to the adapter air passage 114. Thus, the air passage provides a continuous air passage from the point where the inner punch holder air passage 110 is fluidly coupled to the air supply 20 to a distal end of the die center 104. The air supply 20 is structured to deliver a volume of gas to the distal end of the die center 104 via the air passage. When the volume of gas is introduced at the distal end of the die center 104, the cup 10 will be ejected from the die center 104.

[0018] It will be appreciated that in some example embodiments, the cupper 1 and each punch assembly 2 may include multiple air passages. For example and without limitation, each punch assembly 2 may include four air passages. That is, in some example embodiments, there may be four inner punch holder air passages 110, four riser air passages 112, four adapter air passages 114, and four die center air passages 116. It will be appreciated that any suitable number of air passages may be employed without departing from the scope of the disclosed concept. It will also be appreciated that multiple air supplies 20 may be employed without departing from the scope of the disclosed concept. For example and without limitation, one air supply 20 may supply air to some of the punch assemblies 2 in the cupper 1 and another air supply 20 may supply air to the remainder of the punch assemblies 2 in the cupper 1.

[0019] FIGS. 2-4 show the process of ejecting the cup 10 from the die center 104. In FIG. 2, the cup 10 is disposed over the end of the die center 104. In FIG. 3, the air supply 20 has provided a volume of gas to the air passage of the cupper 1 which ejects the cup 10 from the die center 104. The distal end of the die center 104 may be concave or convex and in fluid communication with the die center air passage 116, resulting in the volume of gas received from the air supply 20 being distributed across the distal end of the die center 104 and evenly pushing the cup 10 away from the die center 104. In FIG. 4, the cup 10 has completed it ejection from the die center 104.

[0020] The inner punch holder air passage 110, the riser air passage 112, the adapter air passage 114, and the die center air passage 116 are each bore holes having a similar diameter as each other. In some examples, the inner punch holder air passage 110, the riser air passage 112, the adapter air passage 114, and the die center air passage 116 each have a diameter of 0.375 inches. However, it will be appreciated that the inner punch holder air passage 110, the riser air passage 112, the adapter air passage 114, and the die center air passage 116 may each have any suitable diameter (e.g., without limitation, 0.3125 inches, 0.5 inches, etc.) without departing from the scope of the disclosed concept. In some examples, the air supply 20 provide a continuous flow of air at a pressure of 15 PSI to the air passage of the cupper 1. This results in 33.25 cubic feet per minute (cfm) of air flow provided by the air supply 20 to the punch assembly 2. In the case of a 16-out cupper with sixteen punch assemblies 2, the total air flow would be 532 cfm. This air is considered wasted air because it is not recaptured or otherwise used, but instead is just dissipated to the environment.

[0021] FIG. 5 is a sectional view of a punch assembly 2 for a cupper with a flow restrictor 200 in accordance with an example embodiment of the disclosed concept. To reduce the flow of air supplied by the air supply 20 to eject cups, the punch assembly 2 in the example embodiment includes a flow restrictor. In the example embodiment of FIG. 5, the flow restrictor is a flow restrictor insert 200. FIG. 6 is a sectional detail view of the flow restrictor insert 200 in accordance with an example embodiment of the disclosed concept. However, it will be appreciated that the flow restrictor may also be a machined flow restrictor 300, as is shown in a sectional detail view in FIG. 7.

[0022] The flow restrictor is structured to reduce the diameter of at least a portion of the air passage of the cupper 1. In the example embodiment shown in FIG. 5, the flow restrictor insert 200 is disposed in and reduces the diameter of a portion of the adapter air passage 114. However, it will be appreciated that the flow restrictor insert 200 may be disposed in and reduce the diameter of a portion of any of the inner punch holder air passage 110, the riser air passage 112, the adapter air passage 114, and the die center air passage 116. In some applications, it may be most cost effective to include the flow restrictor insert 200 in the adapter air passage 114 as the cost to modify or replace the adapter 102 may be less than the cost of modifying the inner punch holder, riser 100, or die center 104. In some example embodiments, the adapter 104 may be omitted and the flow restrictor insert 200 may be disposed in the inner punch holder air passage 110, the riser air passage 112, the adapter air passage 114, or the die center air passage 116.

[0023] Referring to FIG. 6, the flow restrictor insert 200 includes a large diameter opening 202. The large diameter opening 202 is disposed on an upstream end of the flow restrictor insert 200. As used herein, upstream means an end from which a component receives air flow from the air supply 20 and downstream means an end in which air flow from the air supply 20 exits the component. The diameter of the large diameter opening 202 corresponds to the diameter of the air passage the large diameter opening 202 is fluidly coupled to. In the example embodiment of FIG. 6, the large diameter opening 202 is fluidly coupled to the riser air passage 112 and has a diameter corresponding to the diameter of the riser air passage 112. In some example embodiments, the diameter of the large diameter opening 202 and the riser air passage 112 is 0.375 inches. The flow restrictor insert 200 includes a transition section 204. The transition section 204 reduces in diameter along a downstream direction from the large diameter opening 202. The transition section 204 extends to a small diameter passage 206. The small diameter passage 206 has a smaller diameter than the large diameter opening 202. The small diameter passage 206 also has a diameter that corresponds to the diameter of the downstream end of the transition section 204. The downstream end of the small diameter passage 206 is fluidly coupled to the air passage of the cupper 1. In the example of FIG. 6, the downstream end of the small diameter passage 206 is fluidly coupled to the adapter air passage 114. Air flow exiting the small diameter passage 206 continues along the air passage of the cupper 1 to the distal end of the punch die 104, where it is used to eject the cup 10.

[0024] The smaller diameter of the small diameter passage 206 restricts air flow through the air passage of the cupper 1. Depending on the diameter of the small diameter passage 206, the flow may be restricted by different amounts. For example, for a 16-out cupper with an air passage having a diameter of 0.375 inches, the flow restrictor insert 200 reduces air flow used to eject cups 10 by different amounts depending on the diameter of the small diameter passage 206. For a small diameter air passage 206 diameter of 0.188 inches, the air flow used to eject cups in the 16-out cupper (i.e., sixteen punch assemblies) is reduced from 532 cfm to 476 cfm, an air flow reduction of 11% with respect to the cupper 1 of FIG. 1. For a diameter of 0.144 inches, the air flow is reduced to 430 cfm, an air flow reduction of 19% with respect to the cupper of FIG. 1. For a diameter of 0.110 inches, the air flow is reduced to 308 cfm, an air flow reduction of 42% with respect to the cupper 1 of FIG. 1. The reduction in air flow reduces the amount of air the cupper 1 uses to eject the cup 10 from the die center 104. As described above, air used to eject the cup 10 from the die center 104 is wasted air. Thus, reducing the amount of air to eject the cup 10 from the die center 104 reduces the amount of wasted air. It will be appreciated that the diameter of the small diameter passage 206 may be optimized such that air flow is reduced to a minimal amount that is still sufficient for ejecting a cup 10. For example, many cuppers may operate, for example and without limitation, in a range of 100 to 350 strokes per minute. A cupper may start at around as slow as 100 strokes per minute and then gradually increase up to the desired production speed. Air used to ejects cups may be provided intermittently at lower operating speeds and then transition to being provided continuously at higher operating speeds. In some examples, at around 180 strokes per minute the air used to eject cups may transition from being provided intermittently to being provided continuously. The production speed of the cupper depends on many factors (e.g., demand, capability of the press, capability of downstream equipment, etc.), and can top out, in some example embodiments, in a range between 100 and 350 strokes per minute. The time to eject a cup 10 a such operating speeds is on the order of millisecond, and in some example embodiments can be around 30 milliseconds. The air used to eject the cup 10 may be optimized so that is reduced, but still sufficient to eject the cup 10 in a suitable amount of time.

[0025] In some example embodiments, the flow restrictor insert 200 may be inserted into an existing air passage, such as the riser air passage 112, adapter air passage 114, or die center air passage 116 of the cupper 1 of FIG. 1, so as to retrofit the cupper 1 to reduce air flow and wasted air for ejecting cups 10. The flow restrictor insert 200 may be disposed in an air passage by any suitable means. For example and without limitation, the flow restrictor insert 200 may have a friction fit to hold it in place in an air passage. In some example embodiments, the flow restrictor insert 200 may be threaded with corresponding threads om the air passage. It will be appreciated that any suitable means may be employed to secure the flow restrictor insert 200 in an air passage. The use of a flow restrictor insert 200 can be most cost effective as it does not require replacement or substantial modification of any part of the cupper 1. The flow restrictor insert 200 may also be changed out easily in case the cupper 1 is used in different applications requiring different minimum air flows to eject cups 10.

[0026] FIG. 7 is a detail section view of a machined flow restrictor 300 in accordance with an example embodiment of the disclosed concept. As discussed above, the flow restrictor may be a flow restrictor insert 200. However, the flow restrictor, in some example embodiments, may be a machined flow restrictor 300. The machined flow restrictor 300 includes a large diameter opening 302, a transition section 304, and a small diameter passage 306, similar to the flow restrictor insert 200. However, the machined flow restrictor 300 replaces the adapter air passage 114 in the example embodiment of FIG. 7. That is, the adapter 102, rather than having the adapter air passage 114 of the adapter 102 of FIG. 1, is instead machined to have the machined flow restrictor 300. The machined flow restrictor 300 is effective to reduce the air flow and wasted air used for ejecting cups 10. The machined flow restrictor 300 may be formed as part of a cupper when the cupper is made. Alternatively, the machined flow restrictor 300 may be retrofit to an existing cupper by replacing the adapter 102 with the adapter 102 having the machined flow restrictor 300. It will be appreciated that the machined flow restrictor 300, in some example embodiments, may be part of the inner punch holder, the riser 100, or the die center 104. However, it will be appreciated that the adapter 102 is often the most cost effective component to replace among these components and thus it would often be most cost effective to retrofit an existing cupper by replacing the adapter 102 with the adapter 102 having the machined flow restrictor 300.

[0027] In some example embodiments, the transition section 204,304 may be omitted from the flow restrictor insert 200 or the machined flow restrictor 300. That is, the small diameter passage 206,306 may be directly fluidly coupled to the air passage at its upstream and downstream ends.

[0028] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only and not limiting as to the scope of disclosed concept which is to be given the full breadth of the claims appended and any and all equivalents thereof.