CONTROLS FOR PAPER, SHEET, AND BOX MANUFACTURING SYSTEMS
First Claim
1. A system for making corrugated box structures using a corrugator, the system comprising:
- a corrugated board web comprising at least a first order section and a second order section, wherein the first order section includes at least one standard cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one first box structure, wherein the second order section includes at least one standard cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one second box structure, wherein the first order section is different than the second order section, wherein the corrugated board web further comprises an order change section positioned between the first order section and the second order section, wherein the order change section includes at least one colored cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web, wherein the at least one colored cut-to-mark marking defines a color that is different than the standard cut-to-mark markings;
a cutting arrangement comprising at least one knife, wherein the knife is configured to cut the corrugated board web;
at least one detector that is configured to detect a color of one or more cut-to-mark markings on the corrugated board web, wherein the at least one detector is positioned upstream of the at least one knife; and
a controller configured to;
operate one or more components of the corrugator according to a first set of order instructions corresponding to the first order section, wherein the first set of order instructions are obtained from a corrugator plan;
determine, based on data received from the at least one detector, the occurrence of at least one colored cut-to-mark marking, wherein the occurrence of at least one colored cut-to-mark marking is determined by the at least one detector detecting the at least one colored cut-to-mark marking of the order change section, wherein the order change section of the corrugated board web followed the first order section of the corrugated board web as the corrugated board web passes through the corrugator;
determine, in response to determining the occurrence of the colored cut-to-mark marking, a next set of order instructions for a next order in the corrugator plan, wherein the next set of order instructions is a second set of order instructions corresponding to instructions for operating one or more components of the corrugator for the second order section;
determine, based on the second set of order instructions, one or more instructions for operating the at least one knife; and
cause operation of the at least one knife according to the one or more instructions.
1 Assignment
0 Petitions
Accused Products
Abstract
Systems for providing efficient manufacturing of sheet or box structures, corrugate sheets, or other products of varying size and structure often with pre-applied print (“pre-print”) are provided herein. The systems include various features and modules that enable automated control of the corrugator, including the knives, slitters, scorers and cut-to-mark detection system(s), are contemplated. Colored markings may be used to indicate an order change section between two order sections of a roll plan for the manufacturing process. The colored markings are detected as the corrugator runs and, once detected, a controller determines a next set of order instructions—e.g., to match the upcoming order. Thus, an order change may occur, thereby enabling automated control of the corrugator based on the new order instructions. Computer readable markings may enable checking of the actual position in the roll plan to an intended position, enabling stopping or changing of the corrugator operation if needed.
22 Citations
21 Claims
-
1. A system for making corrugated box structures using a corrugator, the system comprising:
-
a corrugated board web comprising at least a first order section and a second order section, wherein the first order section includes at least one standard cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one first box structure, wherein the second order section includes at least one standard cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one second box structure, wherein the first order section is different than the second order section, wherein the corrugated board web further comprises an order change section positioned between the first order section and the second order section, wherein the order change section includes at least one colored cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web, wherein the at least one colored cut-to-mark marking defines a color that is different than the standard cut-to-mark markings; a cutting arrangement comprising at least one knife, wherein the knife is configured to cut the corrugated board web; at least one detector that is configured to detect a color of one or more cut-to-mark markings on the corrugated board web, wherein the at least one detector is positioned upstream of the at least one knife; and a controller configured to; operate one or more components of the corrugator according to a first set of order instructions corresponding to the first order section, wherein the first set of order instructions are obtained from a corrugator plan; determine, based on data received from the at least one detector, the occurrence of at least one colored cut-to-mark marking, wherein the occurrence of at least one colored cut-to-mark marking is determined by the at least one detector detecting the at least one colored cut-to-mark marking of the order change section, wherein the order change section of the corrugated board web followed the first order section of the corrugated board web as the corrugated board web passes through the corrugator; determine, in response to determining the occurrence of the colored cut-to-mark marking, a next set of order instructions for a next order in the corrugator plan, wherein the next set of order instructions is a second set of order instructions corresponding to instructions for operating one or more components of the corrugator for the second order section; determine, based on the second set of order instructions, one or more instructions for operating the at least one knife; and cause operation of the at least one knife according to the one or more instructions. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
-
-
15. A method for making corrugated box structures using a corrugator, the method comprising:
-
providing a corrugated board web comprising at least a first order section and a second order section, wherein the first order section includes at least one standard cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one first box structure, wherein the second order section includes at least one standard cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one second box structure, wherein the first order section is different than the second order section, wherein the corrugated board web further comprises an order change section positioned between the first order section and the second order section, wherein the order change section includes at least one colored cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web, wherein the at least one colored cut-to-mark marking defines a color that is different than the standard cut-to-mark markings; providing a cutting arrangement comprising at least one knife, wherein the knife is configured to cut the corrugated board web; providing at least one detector that is configured to detect a color of one or more cut-to-mark markings on the corrugated board web, wherein the at least one detector is positioned upstream of the at least one knife; operating one or more components of a corrugator according to a first set of order instructions corresponding to the first order section, wherein the first set of order instructions are obtained from a corrugator plan; determining, based on data received from the at least one detector, the occurrence of at least one colored cut-to-mark marking, wherein the occurrence of at least one colored cut-to-mark marking is determined by the at least one detector detecting the at least one colored cut-to-mark marking of the order change section, wherein the order change section of the corrugated board web followed the first order section of the corrugated board web as the corrugated board web passes through the corrugator; determining, in response to determining the occurrence of the colored cut-to-mark marking, a next set of order instructions for a next order in the corrugator plan, wherein the next set of order instructions is a second set of order instructions corresponding to instructions for operating one or more components of the corrugator for the second order section; determining, based on the second set of order instructions, one or more instructions for operating the at least one knife; and causing operation of the at least one knife according to the one or more instructions.
-
-
16. A system for making corrugated box structures using a corrugator, the system comprising:
-
a corrugated board web comprising at least a first order section and a second order section, wherein the first order section includes at least one cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one first box structure, wherein the second order section includes at least one cut-to-mark marking that is used to signal an initiation of a cut of the corrugated board web to help form at least one second box structure, wherein the first order section is different than the second order section, wherein the corrugated board web further comprises an order change section positioned between the first order section and the second order section, wherein at least one of the first order section, the second order section, or the order change section includes at least one readable marking; at least one readable mark detector that is configured to read data from one or more readable markings on the corrugated board web; a display; and a controller configured to; operate one or more components of the corrugator according to a set of current order instructions corresponding an order section of the corrugated board web, wherein the set of current order instructions are obtained from a corrugator plan; determine a detected current position of the corrugated board web in the corrugator based on data read by the at least one readable mark detector from the one or more readable markings on the corrugated board web; determine a theoretical current position of the corrugated board web based on at least the current set of order instructions from the corrugator plan that are being utilized in operation of the corrugator; and cause display of both a representation of the detected current position of the corrugated board web and a representation of the theoretical current position of the corrugated board web to enable an operator to compare the detected current position of the corrugated board web and the theoretical current position of the corrugated board web. - View Dependent Claims (17, 18, 19, 20)
-
-
21. A web of printed material for forming corrugated board web, wherein the web comprises:
-
a first order section, wherein the first order section includes at least one cut-to-mark marking that is used to signal an initiation of a cut of the web to help form at least one first box structure; a second order section, wherein the second order section includes at least one cut-to-mark marking that is used to signal an initiation of a cut of the web to help form at least one second box structure, wherein the first order section is different than the second order section; and an order change section positioned between the first order section and the second order section; and at least one colored cut-to-mark marking included within at least one of the first order section, the second order section, or the order change section, wherein the at least one colored cut-to-mark marking, when read by a mark detector, is configured to trigger a change in order instructions for a corrugator.
-
Specification