CAN MANUFACTURING EQUIPMENT MONITORING AND CONTROL SYSTEMS AND METHODS

Abstract

A control system for can manufacturing equipment includes a number of sensors structured to monitor one or more characteristics of a machine in a can manufacturing line, and a controller structured to monitor and analyze the one or more characteristics monitored by the number of sensors.

Claims

1. A control system for can manufacturing equipment comprises: a number of sensors structured to monitor one or more characteristics of a machine in a can manufacturing line; and a controller structured to monitor and analyze the one or more characteristics monitored by the number of sensors.

2. The control system of claim 1, wherein the machine is a bodymaker, wherein the number of sensors includes at least one pressure sensor, wherein the one or more characteristics includes oil pressure in the bodymaker, and wherein the controller is structured to monitor and analyze the oil pressure in the bodymaker and to control one or more pumps in the bodymaker to adjust the oil pressure.

3. The control system of claim 2, wherein the one or more pumps includes a first pump and a second pump, wherein the first pump is structured to pressurize oil in an oil circulation circuit of the bodymaker, wherein the second pump is structured to recirculate oil in the oil circulation circuit, wherein the at least one pressure sensor includes a first pressure sensor and a second pressure sensor, wherein the first pressure sensor is structured to sense pressure at an output of the first pump, and wherein the second pressure sensor is structured to sense pressure at an output of the second pump.

4. The control system of claim 3, wherein the controller includes a first controller associated with and structured to control the first pump and second controller associated with and structured to control the second pump, wherein the first pump, the first controller, and the first pressure sensor are arranged in a first feedback loop, and wherein the second pump, the second controller, and the second pressure sensor are arranged in a second feedback loop.

5. The control system of claim 1, wherein the machine is a bodymaker, wherein the number of sensors includes at least one vibration sensor, wherein the one or more characteristics includes vibration in the bodymaker, and wherein the controller is structured to monitor and analyze vibration in the bodymaker.

6. The control system of claim 5, wherein the at least one vibration sensor includes a toolpack cradle vibration sensor disposed proximate a toolpack cradle and structured to sense vibration in the bodymaker at the toolpack cradle.

7. The control system of claim 5, wherein the at least one vibration sensor includes a rear airbag vibration sensor disposed proximate rear air bags of the bodymaker and structured to sense vibration in the bodymaker at the rear airbags.

8. The control system of claim 5, wherein the at least one vibration sensor includes a main motor vibration sensor disposed on a main motor of the bodymaker and structured to sense vibration in the bodymaker at the main motor.

9. The control system of claim 5, wherein the at least on vibration sensor includes a main motor vibration sensor disposed on a main motor of the bodymaker and structured to sense vibration in the bodymaker at the main motor, a pump vibration sensor disposed on a pump of the bodymaker and structured to sense vibration in the bodymaker at the pump, a flywheel vibration sensor disposed proximate a flywheeel of the bodymaker and structured to sense vibration in the bodymaker at the flywheel, and a support arm vibration sensor disposed on a support arm of the bodymaker and structured to sense vibration in the bodymaker at the support arm.

10. The control system of claim 9, wherein the at least one vibration sensor includes a toolpack cradle vibration sensor disposed proximate a toolpack cradle of the bodymaker and structured to sense vibration in the bodymaker at the toolpack cradle, a rear airbag vibration sensor disposed proximate rear air bags of the bodymaker and structured to sense vibration in the bodymaker at the rear air bags.

11. The control system of claim 5, wherein the at least one vibration sensor is a plurality of vibration sensors disposed at multiple locations on the bodymaker.

12. The control system of claim 1, wherein the controller is structured to generate a user interface including a number of selectable reports based on the one or more characteristics monitored by the number of sensors.

13. The control system of claim 12, wherein the number of sensors includes at least one vibration sensor, wherein the one or more characteristics includes vibration in the bodymaker, wherein the controller is structured to monitor and analyze vibration in the bodymaker, and wherein at least one of the number of selectable reports is based on vibration in the bodymaker.

14. The control system of claim 13, wherein the at least one vibration sensor is a plurality of vibration sensors disposed at multiple locations on the bodymaker, and wherein the at least one of the number of selectable reports is based on vibration in the bodymaker is a plurality of reports, each corresponding to one of the multiple locations on the bodymaker.

15. The control system of claim 1, wherein the one or more characteristics of a machine in a can manufacturing line is a plurality of characteristics including vibration, pressure, and energy.

16. The control system of claim 15, wherein the controller is structured to use machine learning to analyze the plurality of characteristics to determine characteristics indicative of a predicted failure.

17. A bodymaker for can manufacturing, the bodymaker comprising: a main motor; a flywheel; rear air bags; a support arm; and a control system including: a number of sensors structured to monitor one or more characteristics of bodymaker; and a controller structured to monitor and analyze the one or more characteristics monitored by the number of sensors.

18. The bodymaker of claim 17, wherein the number of sensors includes a number of vibration sensors structured to sense vibration in the bodymaker at one or more of the main motor, the flywheel, the rear air bags, and the support arm.

19. The bodymaker of claim 18, wherein the number of vibration sensors includes a main motor vibration sensor structured to sense vibration in the bodymaker at the main motor, a flywheel vibration sensor structured to sense vibration in the bodymaker at the flywheel, a rear air bag vibration sensor structured to sense vibration in the bodymaker at the rear air bags, and a support arm vibration sensor structured to sense vibration in the bodymaker at the support arm.

20. A bodymaker for can manufacturing, the bodymaker comprising: an oil circulation circuit; and a control system including: a first pump operable to pressurize oil in the oil circulation circuit; a first pressure sensor structured to sense pressure at an output of the first pump; a first controller structured to control operation of the first pump based on an output of the first pressure sensor and a desired pressure setting; a second pump operable to recirculate oil in the oil circulation circuit; a second pressure sensor structured to sense pressure at an output of the second pump; and a second controller structured to control operation of the second pump based on an output of the second pressure sensor and the desired pressure setting.

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 schematic diagram of a control system for controlling oil circulation in a bodymaker in accordance with an example embodiment of the disclosed concept;

[0009] FIG. 2 is a plot of monitored pressure, drive speed, and power usage for a pump in accordance with an example embodiment of the disclosed concept;

[0010] FIG. 3A is a detailed top view of a bodymaker including example vibration sensor locations in accordance with an example embodiment of the disclosed concept;

[0011] FIG. 3B is a detailed side view of the bodymaker of FIG. 3A;

[0012] FIG. 3C is a cross-sectional side view of the bodymaker of FIG. 3A;

[0013] FIG. 3D is a cross-sectional rear view of the bodymaker of FIG. 3B;

[0014] FIGS. 3E-3L are detail views of various vibration sensor locations on a bodymaker in accordance with an example embodiment of the disclosed concept;

[0015] FIG. 4 is an example output of a monitoring and control system for can manufacturing equipment in accordance with an example embodiment of the disclosed concept;

[0016] FIG. 5 is an example output of a monitoring and control system for can manufacturing equipment in accordance with an example embodiment of the disclosed concept;

[0017] FIG. 6 is an example output of a monitoring and control system for can manufacturing equipment in accordance with an example embodiment of the disclosed concept;

[0018] FIG. 7 is a view of a bodymaker including examples of sensor locations in accordance with an example embodiment of the disclosed concept; and

[0019] FIG. 8 is a schematic diagram of a bodymaker including various sensors in accordance with an example embodiment of the disclosed concept.

DETAILED DESCRIPTION OF THE INVENTION

[0020] Directional phrases used herein, such as, for example, left, right, front, back, top, bottom and derivatives thereof, relate to the orientation of the elements shown in the drawings and are not limiting upon the claims unless expressly recited therein.

[0021] As employed herein, the statement that two or more parts are coupled together shall mean that the parts are joined together either directly or joined through one or more intermediate parts.

[0022] As employed herein, the term processor shall mean a controller with analog and/or digital devices connected to it, that can store, retrieve, and process data; a microprocessor; a microcontroller; a microcomputer; a central processing unit; or any suitable processing device or apparatus.

[0023] Can manufacturing equipment includes various machines such as a cupper, a bodymaker, a trimmer, a necker, a decorator, a can washer, a can dryer, and a can oven, among others. In accordance with various example embodiments of the disclosed concept, sensors are provided to sense various parameters of the machines in a can manufacturing line and a controller is provided to monitor the output of the sensors, analyze the output, and/or control aspects of the various machines. Some examples of such monitoring, analysis, and control in accordance with the disclosed concept are described herein. By monitoring and analyzing various parameters of the machines themselves, issues with the machines may be identified and addressed more quickly resulting in reduced downtime for the can manufacturing line.

[0024] A bodymaker in a can manufacturing line requires oil or other lubricant for various parts of its operation. Existing bodymakers set pressure in the oil circulation circuit by selecting a size of a pump and reductions in the diameter of the oil circulation circuit. Making adjustments or corrections to the pressure in the oil circulation circuit in existing bodymakers is difficult and can require modifications or replacement of the pump or oil circulation circuit. FIG. 1 is a schematic diagram of a control system for controlling oil circulation in a bodymaker 10. The bodymaker 10 includes an oil circulation circuit which circulates oil or other lubricant through the bodymaker 10 such that the oil or other lubricant can be utilized by components of the bodymaker 10 that require oil or other lubricant. The control system includes a first pump 20 and a second pump 30. The first pump 20 is operable to pressurize the oil circulation circuit. The second pump 30 is operable to recirculate oil through the bodymaker 10. The control system includes a first pressure sensor 24 structured to sense pressure at an output of the first pump 20. The first pressure sensor 24 is configured to output the sensed pressure to a first controller 22. The first controller 22 is also operable to control operation of the first pump 20 via a first inverter 26. The first pump 20, the first pressure sensor 24, and the first controller 22 are arranged in a feedback loop. The output of the first pump 20 is provided to the second pump 30 in order to pressurize the oil circulation circuit in the bodymaker 10.

[0025] The control system further includes a second pressure sensor 34 structured to sense pressure at the output of the second pump 20. The second pressure sensor 34 is configured to output the sensed pressure to a second controller 32. The second controller is also operable to control operation of the second pump 30 via a second inverter 36. The second pump 30, the second pressure sensor 34, and the second controller 32 are arranged in a feedback loop. The output of the second pump 30 is coupled to the oil circulation circuit of the bodymaker 10 in order to recirculate oil or other lubricant through the oil circulation circuit. In some example embodiments of the disclosed concept, the first and second pumps 20,30 include variable frequency drives in order to be driven at various speeds.

[0026] The first and second controllers 22,32 may be communicatively coupled with a controller for the bodymaker 10. In some example embodiments, an operator may input a desired pressure to the controller for the bodymaker 10. The controller may then communicate the desired pressure setting to the first and second controllers 22,32 and the first and second controllers 22,32 may control the corresponding first and second pumps 20,30 such that the desired pressure in the oil circulation circuit is achieved. Since the first and second controllers 22,32, first and second pumps 20,30, and first and second pressure sensors 24,34 are arranged in feedback loops, the first and second controllers 20,30 may modify their control of the first and second pumps 20,30 so as to maintain the desired pressure. In some example embodiments, the desired pressure is maintained within a tolerance band.

[0027] In some example embodiments, the first and second controllers 22,32 are structured to monitor the speeds and loads of the first and second pumps 20,30. The first and second controllers 22,32 may also be structured to sense trends in the sensed speeds and load and may be structured to sense abnormal operation. For example and without limitation, the first and second controllers 22,32 may sense premature component wear, filter issues, or pump issues based on the sensed speeds and load. For example, an abnormally high drive speed to achieve the pressure set point can be indicative of premature wear on a pump. The first and second controllers 22,32 may further be structured to output an indication of a sensed abnormal operation such that an operator can then take remedial action. The first and second controllers 22,32 may also be structured to determine optimal run speeds of the first and second pumps 20,30 in order to achieve a desired pressure. The control system allows for the reduction of orifices in the system for oil delivered and allows the pumps to only be operated when needed, thus resulting in optimized energy usage. The control system also allows for pressure to be more easily set, maintained, and adjusted compared to existing bodymakers.

[0028] FIG. 2 is an example plot of parameters monitored by the first and second controllers 22,32. In the plot shown in FIG. 2, the pressure at the output of the first pump 20 (P1 Pressure) is plotted over a period of time. The speed (P1 Hz) and load (P1 Amps) are also plotted over the period of time. An error band corresponding to the speed and load is also plotted over time and represents threshold speeds and loads that can be indicative of abnormal operation. For example, if the sensed speed and/or load exceeds the corresponding error band, it can be indicative of abnormal operation of the pump. The control system may be configured to prompt a user of any abnormal operations so preventative action can be taken before a more significant failure.

[0029] In some example embodiments of the disclosed concept, vibration sensors may be employed to sense vibration of a bodymaker or other machines in a can manufacturing line, and an associated controller may monitor and analyze the sensed vibrations. The sensed vibration patterns may be analyzed to detect failure modes. In a machine such as a bodymaker, vibration affects performance. Changes in a vibration pattern will affect the performance of the machine and the product produced by the machine. In the case of a bodymaker, the bodymaker uses horizontal impacts to make aluminum can bodies from preformed cups. The impact force and the nature of the linkage in the machine causes the bodymaker to undergo heavy vibration during operation. In an example embodiment, the bodymaker includes eight vibration pads/mounts to support the machine on concrete pads (e.g., 42.5 inch concrete pads). The vibration pads and concrete foundation allow the machine to withstand the 7,200 lbs of vertical force and 16,200 lbs. of horizontal force caused by operation of the bodymaker.

[0030] In an example embodiment, vibration sensors are disposed at various locations on the bodymaker. Sensed vibrations may be analyzed by an associated controller to determine minute differences in the vibrations at different parts of the bodymaker, to determine abnormal operation from the sensed vibrations, and to predict a quality of the product from the sensed vibrations. For example, an excessive vibration on the toolpack cradle will indicate or affect the quality of the can forming process. The controller may prompt a user or automatically halt operation for certain excess or abnormal vibration on the toolpack cradle to avoid damage to ironing dies, and thus increase life of the tooling and save cost that would be incurred with replacing or grinding the dies more frequently. As another example, excess vibration of the motor indicates that the motor is pulling excess current, which indicates a problem with the motor, or that the belt that connects the motor and the flywheel is in excess tension. The controller may prompt a user when such excess vibration is detected so that the user can take remedial action such as repairing or replacing the motor or the belt that connects the motor and the flywheel. As another example, excess vibration detected on the rear airbags can indicate an airbag failure. It will be appreciated that vibration sensors may be used on other components of the bodymaker or other machines. It will also be appreciated that analysis for various other failures or for purposes of optimization or design improvements may be employed as well without departing from the scope of the disclosed concept. In some example embodiments, analyzing the vibration patterns assists with improving the life of the machine and avoiding catastrophic failures. Such analysis assists with catching and resolving an issue before it happens.

[0031] FIG. 3A is a detailed top view of a bodymaker 100 including example vibration sensor locations in accordance with an example embodiment of the disclosed concept. FIG. 3B is a detailed side view of the bodymaker 100 of FIG. 3A. FIG. 3C is a cross-sectional side view of the bodymaker 100 of FIG. 3A. FIG. 3D is a cross-sectional rear view of the bodymaker 100 of FIG. 3B. FIGS. 3E-3L are detail views of various vibration sensor locations on the bodymaker 100.

[0032] The bodymaker 100 includes a first pump 104 and a second pump 106. The bodymaker 100 further includes a main motor 102. The first pump 104 and the second pump 106 may be, for example, pumps for the oil circulation circuit for the bodymaker 100 similar to the first and second pumps 20,30 described with respect to FIG. 1. The first pump 104 may include a first pump vibration sensor 112 disposed on a top portion of the first pump 104 (shown in FIGS. 3A, 3B, and 3I). The second pump 106 may include a second pump vibration sensor 114 disposed on a top portion of the second pump 106 (shown in FIGS. 3A, 3C, and 3J). The main motor 102 may also include a main motor vibration sensor 110 disposed on a side of the main motor 102. The main motor vibration sensor 110, first pump vibration sensor 112, and second pump vibration sensor 114 may sense vibrations associated with the main motor 102, first pump 112, and second pump 114. Excess vibrations sensed by these sensors may be indicative of the main motor 102, first pump 104, or second pump 106 pulling excess current indicating abnormal operation. Excess vibrations sensed by the main motor vibration sensor 110 may be indicative of the main motor 102 pulling excess current or that the belt that connects the main motor 102 to the flywheel is in excess tension.

[0033] The bodymaker 100 further includes a flywheel vibration sensor 116 (shown in FIGS. 3A and 3E) disposed proximate a flywheel of the bodymaker 100. Excess vibration at the flywheel vibration sensor 116 may be indicative of a problem with the flywheel. The bodymaker 100 also includes a support arm vibration sensor 118 (shown in FIGS. 3B and 3F) disposed on a support arm of the bodymaker 100. The bodymaker also includes one or more footer vibration sensors 120 (shown in FIGS. 3B and 3G) disposed on one or more feet of the bodymaker 100. The bodymaker 100 also includes a central vibration sensor 122 (shown in FIGS. 3B and 3H) disposed on a central portion of the bodymaker 100. The bodymaker 100 also includes a toolpack cradle vibration sensor 126 (shown in FIGS. 3C and 3K) disposed proximate the toolpack cradle of the bodymaker 100. Excessive vibration on the toolpack cradle will indicate or affect the quality of the can forming process. A controller associated with the toolpack cradle vibration sensor 126 may prompt a user or automatically halt operation for certain excess or abnormal vibration on the toolpack cradle to avoid damage to ironing dies, and thus increase life of the tooling and save cost that would be incurred with replacing or grinding the dies more frequently. The bodymaker 100 also includes a rear airbag vibration sensor 128 (shown in FIGS. 3D and 3L) disposed proximate rear airbags of the bodymaker 100. Excess vibration detected by the rear airbag vibration sensor can indicate a failure of the airbags of the bodymaker 100. In some example embodiments, all vibration sensors are installed in the same direction (e.g., without limitation, in the direction where horizontal forces are acting).

[0034] The various vibration sensors may provide outputs to a controller of the bodymaker (see, for example FIG. 8). By sensing vibrations at various locations on the bodymaker 100, specific areas or components with excessive vibration can be identified and appropriate remedial action may be taken. The appropriate remedial action may be different depending on the location or component where the excess vibration was detected. For example, excess vibration at the toolpack cradle may require halting operation of the bodymaker 100 to avoid damage to ironing dies. Whereas, excess vibration at the first pump 104 may indicating that the first pump 104 is aging or a filter needs replacing.

[0035] While pressure sensing in the oil circulation circuit and vibration sensing at various locations on a bodymaker have been described herein, it will be appreciated that sensing of other parameters associated with the bodymaker may be employed without departing from the scope of the disclosed concept. It will also be appreciated that such sensors may be employed in association with other machines on a can manufacturing line. In accordance with example embodiments of the disclosed concept, various types of sensors may be employed to sense various characteristics of machines in a can manufacturing line. A controller may be associated with the sensors to monitor and analyze the characteristics sensed by the sensors. The controller may also output notifications or reports based on the monitored or analyzed characteristics. The controller may also control aspects of the machines based on the monitored or analyzed characteristics. FIGS. 4-6 are examples of reports that may be generated by the controlled based on the monitored or analyzed characteristics. For example, the controller may generate a user interface that allows a user to select and customize what monitored characteristic to display, what analysis of characteristics to display, or how to analyze and display the monitored characteristics. In this manner, the various sensors and controller may be used to monitor and analyze machines in a can manufacturing line, for example to detect or predict failures or abnormal operations, to monitor performance, or for other reasons. It will be appreciated that the controller may also control aspects of the machines based on the monitored or analyzed characteristics or at the direction of a user.

[0036] FIG. 4 shows user interface with an example report of cans made over various periods of time by the bodymaker. A sensor associated with the output of the bodymaker can be used to sense a number of cans output by the bodymaker. The user interface also includes selections for monitoring power usage, pressures, temperatures, speed, and vibrations. The bodymaker may include various sensors to sense these parameters and provide them to a controller to generate reports based on the sensed parameters. In FIG. 5, the user interface is shown with an example report of vibration over time in the bodymaker. Reports based on various vibration sensors, such as for example those described with respect to FIGS. 3A-3L, may be selected and displayed. Thus, a user may use the user interface to view vibrations at different locations on the bodymaker. In FIG. 6, the user interface is shown with an example report of power usage over time of the bodymaker. A corresponding sensor (e.g., without limitation, a current, voltage, or power sensor) may sense power usage of the bodymaker and provide it to the controller to generate the report. In accordance with embodiments of the disclosed concepts, various types of sensors may be included on the bodymaker and whose outputs may be provided to a controller. The controller may generate a user interface and generate various reports based on the sensed parameters to be selected and displayed on the user interface.

[0037] FIG. 7 is a view of a bodymaker 200 including examples of sensor locations in accordance with an example embodiment of the disclosed concept and FIG. 8 is a schematic diagram of the bodymaker 200. The bodymaker 200 may include sensors for vibration sensing 202, pressure and flow sensing 204, energy sensing 206, flywheel sensing 208, tooling sensing 210, and oil and coolant sensing 212. The various sensors may provide outputs to a controller 214. The controller 214 may be structured to generate a user interface including reports based on the sensed parameters such as, for example and without limitation, the reports shown in FIGS. 4-6. The controller 214 may be further structured to analyze outputs of the various sensors. It will be appreciated that various sensors may be employed on other machines as well. Vibration sensing may be used, for example, to evaluate faults or abnormal operation from vibration patterns. Vibration sensing may be provided by, for example and without limitation, vibrations sensors such as those described with respect to FIGS. 3A-3L. Energy sensing may be used, for example, to determine cause and effect of energy usage and to quantify savings. Coolant and oil sensing may be used to analyze spoilage. Coolant and oil sensing may include, without limitation, sensors configured to sense the quality of coolant and oil in the bodymaker. Pressure and flow sensing may be performed by pressure sensors such as those described with respect to FIG. 1. The pressure and flow sensing may be used to set and adjust the pressure in the oil circulation circuit of the bodymaker, to set and adjust the speeds of pumps associated with the oil circulation circuit, and/or to analyze and identify any abnormal operations associated with the oil circulation circuit. Tooling sensing may be analyze to, for example, monitor a domer of the domer. Outputs of flywheel sensing may be analyzed with clutch and brake analytics. It will be appreciated that the sensors and controller may be integrated into regular machine input/output interfaces.

[0038] In some example embodiments, the controller 214 may be configured to use machine learning to analyze the monitored characteristics. For example, machine learning may be used to determine characteristics indicative of a predicted failure. The machine learning may generate connections between datasets. For example, a combination of vibration characteristics and energy usage characteristics may indicate a particular failure mode or a particular area for energy optimization. Artificial intelligence may also be employed to analyze monitored characteristics, for example to predict events based on the monitored characteristics. The monitored characteristics may also be used to generate more accurate key performance indicators, and to evaluate key performance indicators versus downtime events. It will be appreciated that the monitored characteristics may be used for predictive maintenance, data collection and data analytics, visual performance digital twins, and reporting capability, and that the controller may be configured to provide any of these functions. In some example embodiments, the controller 214 may be remote, such as a cloud server, and the various sensors may provide their outputs to such a cloud server via a gateway or directly.

[0039] In some example embodiments, the controller 214 may be configured to provide remote access to various machines in the can manufacturing line. For example, a user may remotely access data monitored and analyzed by the controller 214. A user may also remotely control aspects of the machines. In some example embodiments, the controller 214 may be configured to transmit monitored data to a remote location, such as cloud storage.

[0040] 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.