# Patent

## Title
Method for order transition on a plunge slitter

## Abstract

An order transition in a corrugated is accomplished by creating an overlap of the slits made by the slitting tools associated with the expiring (running) and new orders. However, the slit tool associated with the innermost slit between the upper and lower level outs is maintained in slitting contact with the board to extend the slit line into further overlap with the slits made by the new order tools to create an order change region. A lateral cut is made to connect the innermost slit between the upper and lower level outs on the new order and the slit created by the tool delayed from withdrawal in the running order.

## Background
CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application Ser. No. 60/616,109, filed Oct. 5, 2004.


BACKGROUND OF THE INVENTION
The present invention pertains to a system for facilitating an order change in the dry end conversion of a corrugated paperboard web. In particular, the invention relates to a method for maintaining web continuity on both levels of a double level dry end.
In a corrugator dry end, where a corrugated paperboard web is longitudinally scored and slit into multiple parallel output webs (or “outs”), the outs are directed through one or more downstream cutoff knives which cut the output webs into selected sheet lengths. When two cutoff knives are used, they are vertically separated and each is capable of cutting the full corrugator width web. A web selector positioned downstream of the slitter/scorer, divides the outs into two groups, one of which is directed to the upper cutoff knife and the other to the lower cutoff knife. Order changes must be effected while the upstream corrugated web end continues to produce and deliver the continuous web to the sitter/scorer. An order change will typically result in a change in widths of the output webs, requiring redirection of at least a central portion of the web from one knife level to the other and possibly changes in edge trim widths as well.
The prior art has developed two basic order change systems for corrugator dry ends utilizing double level cutoff knives. One system is known as a gapless or plunge style order change system. In this system, there are two slitter-sorer stations immediately adjacent one another in the direction of web movement and through both of which the web travels. At order change, one slitter/scorer, operating on the currently running order, will lift out of operative engagement with the web, and the other slitter/scorer which is set to the new order alignment plunges down into operative engagement with the web. The result is a small order change region of corrugated web with overlapping slits and scores for both the running and the new orders.
FIGS. 1-3 show different ways of sorting out the abutting slit lines to implement the order change. FIG. 1 shows a prior art order change according to European Patent 0 458 340 A2 involving an expiring (running) order with three slit webs U1 going to the upper level of a cutoff knife and one slit web L1 going to the lower level of the cutoff knife. The new order will have a single web U2 going to the upper level and two slit webs L2 going to the lower level. The order change is implemented by lateral cut N0 made in the center of the web connecting the innermost slit S14 between upper and lower level webs on the old order to the innermost slit S22 between upper and lower levels webs on the new order. This allows web selectors to reset as the running order passes.
This order change strategy has at least two significant problems. First, it is very difficult in practice to have the tools creating the slit lines plunge into and out of the web abruptly at contact with lateral cut line N0. Additionally, when the level transitioning from wide to narrow has outs narrower in width than the distance between the innermost slit line S14 on the running order and the innermost slit line S22 on the new order, one or more of the outs going to that level will be totally severed. This totally severed out can accelerate faster than its mating outs due to a slipping knife infeed pull roll. The totally severed out will then buckle and frequently jam in the knife.
FIG. 2 shows a different strategy for implementing the order changeover as disclosed in U.S. Pat. No. 5,496,431. This strategy involves creating an order change region that is formed between the front end of the new order sheets and the rear end of the running order sheets and creating a transitional slantwise slit, running at a predetermined angle with respect to the running direction of the continuous web, connecting the innermost slit between the upper and lower level webs in the running order to the innermost slit between the upper and lower level webs in the new order.
This order change method creates end of order waste that is of a different width and length from the expiring order outs. In addition, the pieces that are created when the waste goes through the cutoff knife may be small and angular shaped, creating potential for jam-up in the knife or at exit of the knife.
Yet another order change strategy, shown in FIG. 3, is disclosed in U.S. Pat. No. 6,092,452. With this strategy, an order change zone is created by lifting the slitting tools of the running order from the board line prior to plunging the tools of the new order into the board line. The concept then involves delaying the lift-up of one slitting tool associated with the innermost slit between the upper and lower levels of the running order and bringing forward the slitting tools associated with the innermost slit between the upper and lower knife levels of the new order into the order change zone. The effect of this is to create an overlap in the innermost slits on the running and new orders in the order change zone so that these slit lines can be connected by a lateral slit that may be perpendicular to the direction of forward travel of the web.
This order change method allows the connection of the slit lines defining the old and new orders with no severing of some of the outs going to the level with transition from wide to narrow outs. It avoids the problem of diagonal scrap pieces, but it also creates order change waste that is problematic. The photograph of FIG. 4 shows waste removed from a stacker that was created on the upper and lower levels with this order change strategy. The waste is wider and longer than the sheets being discharged at the tail of the old order. As a consequence, the waste must be removed from the stacker transport conveyor prior to its entrance to the stacker or it will jam at the stacker bay. This is difficult for the stacker operator to accomplish and constitutes a large amount of waste sheet.
SUMMARY OF THE INVENTION
In accordance with the present invention, an order transition is accomplished by creating an overlap of the slits created by the tools associated with the expiring (running) and new orders. The slit tools associated with the running order are lifted from the board line after they create slits that established an overlap region with the slit lines made by the slit tools of the new order, except for the running order tool associated with the innermost slit between the upper and lower level outs. Lift-up of this slit tool is delayed, extending the slit line into further overlap with the slit lines created by the new order tools to create an order change region. A lateral cut is then made in the web generally perpendicular to the direction of board travel, connecting the innermost slit between the upper and lower level outs on the new order and the slit line created by the tool delayed from lifting out in the running order. This order transition strategy allows a continuous web to be maintained to both levels of the knife with no severing of one of the outs going to the level changing from wide to narrow, even if the width of those outs are narrower than the distance between the innermost slits on the running and new orders. The method of the present invention, when implemented with knife synchronization described in U.S. Pat. No. 6,893,520, will result in order change waste that is the same width as the outs of the expiring (running) order and shorter in length so that it can be discharged onto the top of the stack for subsequent removal by operators. No unusually-shaped pieces will be created that can jam the cutoff knife.



BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic top view of the order change region of prior art technology.
FIG. 2 is a schematic top view of the order change region of additional prior art technology.
FIG. 3 is a schematic top view of the order change region of yet further prior art technology.
FIG. 4 is a photograph of waste in and around the order change zone associated with an order change made using the technique of FIG. 3.
FIG. 5 is a schematic top view of the order change region of the present invention.
FIG. 6 is a schematic top view of the order change region of the present invention showing a special case of narrow webs in the new order.
FIG. 7 is a schematic top view of the top level of the web of FIG. 5 showing how knife cuts define the waste at order change.
FIG. 8 is a schematic top view of the lower level of the web of FIG. 5 showing how knife cuts define the waste at order change.
FIG. 9 is a schematic side view of a stacker with scrap sheet diverter.
FIG. 10 is a schematic side view of a stacker with scrap sheet diverter.



DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is described through a series of FIGS. 5-10. FIG. 5 shows a portion of a traveling web of corrugated board from the top view as it would appear after exit from a slitter/scorer. The slitter/scorer is of the tandem station variety with plunge slit axes. One station of the slitter/scorer would have slitting tools operatively engaged in the corrugated web for a running order, creating slit lines S11-S15 as shown in FIG. 5. The slit lines of this running order extend to an order change region, to be described, at the end of the order. The slitting tools of the other stations of the tandem slitter plunge into the board line, through the order change region, to extend beyond (in the downstream direction) the ends of the running order slit lines, and overlapping with the running order slit lines S11-S15 to create new order slit lines S21-S24.
The slit line S14 of the running order comprising the innermost slit between the outs going to the upper level, U1, and the outs going to the lower level, L1, is extended by delaying the removal from the board line of the slitting tool creating this slit. By delaying the removal of this slit head, an order change region is created, upstream of the region of slit overlap, where it is possible to connect the slit line S14 to the innermost slit S22 between the upper level new order outs and the lower level outs using a perpendicular lateral cut S0 in the web, without severing any of the outs going to the upper level on the running order U1. This solves a critical problem as pointed out with respect to U.S. Pat. Nos. 5,496,431 and 6,092,452. As will be shown, there are advantage to this approach to order transfer related to minimizing waste at order change as well as improving operational reliability of the corrugated line by facilitating waste removal.
A special case of application of the present invention is shown in FIG. 6. In this case, the outs L2 on the new order, on the level in which the total width of the outs is transitioning from narrow to wide (i.e. the lower level L), are narrower in width than the distance between the innermost slits on the new and running orders. In this case, the delayed slit head removal of running order slit head S14 and the connection of the innermost slits on the new order S22 to the innermost slit on the running order S14 with lateral slit S0 perpendicular to the direction of board travel, will cause the new order out to the lower level I2, created by slits S22 and S23, to be totally severed. This is normally not a significant problem. The majority of prior art slitters using a gap-style order change have all of the outs severed at order change. Although the continuous concept is now regarded as superior in eliminating jam-up at order change, the probability of jam-up of a single severed out on the new order is very small. Indeed, the frequency of occurrence of this situation is normally quite low. On the other hand, having one of the webs on the running order severed while the adjoining outs are not is a serious problem likely to create a jam-up with high probability. Delaying the end position of the innermost slit of the running order solves this problem.
There are substantial benefits associated with the present invention in terms of minimizing problems with order change waste. FIG. 7 shows a top view of the top portion of the order of FIG. 5 as it would appear proceeding through the cutoff knife. The lateral cut line CN-1 is the second last cut in the old order at the knife. The cut CN is the last cut creating a good sheet at the end of the old order. Cut C0 is synchronized to cut on the wide to narrow order transition line S0. This is accomplished using the method and apparatus as described in U.S. Pat. No. 6,893,520. The benefit of the present invention, in conjunction with this '520 patent invention, is the creation of scrap pieces that can be minimized in length according to the procedures described in the '520 patent and of a format that will always be of a width such that the scrap pieces can fit into the top of the stack discharged from the stacker bay. Alternatively, this well-conditioned scrap sheet could be diverted using the apparatus according to this invention shown in FIG. 9.
FIG. 8 shows a top view of the bottom portion of the order of FIG. 5 as it would appear proceeding through the cutoff knife. The lateral cut CN-1 would be the second to last cut in the running order on the lower level. The cut CN is the last cut creating a good sheet of the end of the running order. Cut C0 is synchronized to cut lined up with the narrow to wide transition line S0 using the method and apparatus of U.S. Pat. No. 6,893,520. Again, the scrap sheet shown in cross-hatched line can be minimized in length and is exactly the same width of the expired order so that it can fit onto the top of the stack discharged.
A schematic of the cutoff knife and downstacker is shown in FIG. 9. The stacker transport system 10 conveys the shingled sheets from the orders to the stacker bays 20. The scrap piece from the order change 30 can be segregated in the transport conveyors 10 using well known speed switching techniques and diverted onto scrap discharge conveyor(s) d1 using scrap diverter b1 on both the top and bottom levels. A close-up of the stacker diverter is shown in FIG. 10.

## Claims

1. A method for minimizing scrap in a gapless order change for a corrugator, said corrugator including a plunge slitter having multiple slitting tools, each operable to be moved vertically into slitting engagement with a continuous corrugated paperboard web at the start of a new order to provide longitudinal slit lines in the web, the slit lines dividing the web into a plurality of output webs of selected widths, said slitting tools operable to be moved vertically out of slitting engagement with the web at the end of a running order, a pair of vertically separated cut-off knives downstream of the slitter for receiving and cutting the output webs into selected sheet lengths, said knives including an upper knife and a lower knife, and a web selector device between the slitter and the cut-off knives for selectively separating the output webs along a common innermost slit line into an upper output web portion and a lower output web portion for said respective upper knife and lower knife, said method comprising the steps of:
(1) operating the slitter to start a new order while continuing to slit the running order to create an overlap region in the web where all running order and new order slits overlap;
(2) maintaining the slitting tool for the common innermost slit line of the running order in slitting engagement with the web for a selected distance beyond the overlap region to define with the new order slit lines an order change region upstream of and outside the overlap region; and,
(3) partially severing the web upstream of the web selector device to provide a generally transverse slit in the order change region to connect the common innermost slit line of the running order web portions and the common innermost slit line of the new order output web portions.

2. The method as set forth in claim 1 comprising the steps of:
(1) after separating the output web portions, sensing a transverse edge of a web portion defined by said transverse slit and generating an edge location signal; and,
(2) operating one of the cutoff knives in response to said transverse edge location signal to cut one of the web portions on the line of said transverse slit.

3. The method as set forth in claim 2 wherein the step of partially severing the web comprises slitting the web intermediate the opposite edges of the web.

4. The method as set forth in claim 3 including the steps of:
(1) sensing a transverse edge of the other web portion defined by said transverse slit and generating a second edge location signal; and,
(2) operating the other cut-off knife in response to said second edge location signal to cut said other web portion on the line of said transverse slit.