Method and system for changing product specifications in a corrugation machine

A corrugation machine, comprising:

• a rotary shear for cutting notches of selected lengths at edges of a continuous corrugated board web in the width direction of said web perpendicular to a running direction of said web through said machine;
• slitter-scorer means including slitter means for forming slit grooves in said web for dividing the web into separate product sheets and scorer means for forming score lines on said web, said slitter-scorer means for receiving said continuous corrugated board web and capable of forming slit grooves and score lines in said web while said web passes through said slitter-scorer means;
• a plurality of sheet length cut-off devices for cutting said web into sheets of desired lengths, said plurality of cut-off devices being downstreams of said slitter-scorer means, said plurality of cut-off devices including at least first and second cut-off devices which are vertically disposed with respect to each other at different heights, wherein said web devices after passing through said slitter-scorer means and divided portions of said web pass to different cut-off devices, so that the first cut-off device receives a first portion of the divided web, and the second cut-off device receives a second portion of the divided web;
• a cutting apparatus, including:
• means for cutting a transitional slit groove in an order change region of said continuous corrugated board web, wherein the order change region extends from trailing ends of sheets produced according to a first production order to leading ends of sheets to be produced according to a second production order, said cutting means configured to form said transitional slit groove so as to join a central slit groove separating sheets of said first production order with a central slit groove separating sheets of said second production order, wherein said central slit grooves divide said web into said first and second web portions which are received by respective first and second cut-off devices;
• and
• means for controlling said cutting means so as to form said transitional slit groove at a desired one of range of angles with respect to the width direction of said sheets perpendicular to a running direction of said web through said corrugation machine so as to maintaining continuity of each of said first and second web portions without completely severing and separating a product sheet from one of said web portions;
• wherein said slitter-scorer means is configured for cutting trim grooves between said notches for removing peripheral trim sections from said web;
• and
• wherein the corrugation machine further includes means for removing and disposing of said trim sections.

A method for changing over product orders in a corrugation machine which produces corrugated board sheets having various widths and lengths according to specifications of said product orders from a single continuous corrugated board web running through said machine, comprising the steps of:

• providing slitter-scorer means including slitter means for forming slit grooves in said web for dividing the web into separate product sheets and scorer means for forming score lines on said web, said slitter-scorer means for receiving said continuous corrugated board web and capable of forming slit grooves and score lines in said web while said web passes through said slitter-scorer means;
• providing a plurality of sheet length cut-off devices for cutting said web into sheets of desired lengths, said plurality of cut-off devices being downstream of said slitter-scorer means, said plurality of cut-off devices including at least first and second cut-off devices which are vertically disposed with respect to each other at different heights, wherein said web divides after passing through said slitter-scorer means and divided portions of said web pass to different cut-off devices, so that the first cut-off device receives a first portion of the divided web, and the second cut-off device receives a second portion of the divided web;
• forming an order change region free of a central slit groove in said web, wherein said region extends from trailing ends of sheets produced in a first product order to leading ends of sheets to be produced in a second product order;
• and
• forming a transitional slit groove in said order change region of said web connecting a central slit groove of said first order to a central slit groove of said second order, wherein said central slit grooves divide said web into said first and second web portions which are received by respective first and second cut-off devices, wherein continuity of each of said first and second web portions is maintained without completely severing and separating a product sheet from one of said web portions, and wherein said transitional slit groove forms a positive angle with respect to a width direction of said web, said width direction of said web being perpendicular to the running direction of said web.

An apparatus for a corrugation machine which produces a plurality of corrugated board sheets of various widths and lengths simultaneously from a single continuous corrugated board web, comprising:

• slitter-scorer means including slitter means for forming slit grooves in said web for dividing the web into separate product sheets and scorer means for forming score lines on said web, said slitter-scorer means for receiving said continuous corrugated board web and capable of forming slit grooves and score lines in said web while said web passes through said slitter-scorer means;
• a plurality of sheet length cut-off devices for cutting said web into sheets of desired lengths, said plurality of cut-off devices being downstream of said slitter-scorer means, said plurality of cut-off devices including at least first and second cut-off devices which are vertically disposed with respect to each other at different heights, wherein said web divides after passing through said slitter-scorer means and divided portions of said web pass to different cut-off devices, so that the first cut-off device receives a first portion of the divided web, and the second cut-off device receives a second portion of the divided web;
• and
• a transitional slit groove cutting apparatus for forming a transitional slit groove in an order change region from the trailing ends of sheets produced according to a first production order to leading ends of sheets to be produced according to a second production order, wherein said transitional slit groove cutting apparatus joins a central slit groove separating sheets of said first production order with a central slit groove separating sheets of said second production order, and wherein said central slit grooves divide said web into said first and second web portions which are received by respective first and second cut-off devices, the transitional slit groove cutting apparatus comprising:
• an oscillating plate having two ends and being pivotally mounted transverse to a running direction of the single continuous corrugated board web with one of the two ends on one side of the web and the other of the two ends on the other side of the web, the oscillating plate capable of pivoting about one of its ends to determine the angle of the transitional slit groove;
• a transitional slit groove length controller means, mounted on said oscillating plate, for controlling the length of the transitional slit groove and the location of the transitional slit groove along the oscillating plate so as to maintain continuity of each of said first and second web portions without completely severing and separating a product sheet from one of said web portions;
• and
• a cutting means for cutting a transitional slit groove in the continuous corrugated board web, the cutting means attached to said transitional slit groove length controller.