Abstract: In an operating machine, one example of a method for monitoring operation of operating machinery includes converting an actual sound pattern generated by the machine into an audio signal and digitizing the audio signal to create a real-time acoustic fingerprint unique to the actual sound pattern. A reference database contains a plurality of stored acoustic fingerprints, each stored acoustic fingerprint in the plurality of stored acoustic fingerprints representing a unique sound pattern associated with a particular operating condition. A controller compares the real-time acoustic fingerprint to the stored acoustic fingerprints in the reference database and generates an output in response to detection of a match between the real-time acoustic fingerprint and one of the plurality of stored acoustic fingerprints. One example of the machine is a corruptor machine that converts paper webs into corrugated paperboard sheets.

Abstract: A method and a non-transient computer readable medium for sorting orders to be run on a multi-section slitter/scorer at a corrugator dry end includes collecting specifications of orders in current, prior, and/or subsequent paper group queues. Run times and slit/score head recovery times for orders in the current paper group queue are calculated using the specifications. Those orders for which recovery time exceeds run time are flagged as short orders. For a given short order, pairs of preceding and following orders that would require recovery times less than the short order's run time are determined and flagged as potential bracketing pairs. The current paper group queue is searched to determine if a bracketing pair can be formed from its orders, and if so, the orders in the current paper group queue are reorganized such that the orders in the bracketing pair immediately precede and follow the given short order.

Abstract: A block of a solid lubricant material, such as PTFE, is biased continuously or intermittently against the cutting edge of a rotary slitting blade for corrugated paperboard. The solid lubricant block prevents the build up of starch adhesive and biasing movement compensates for wear of the block and wear of the cutting blade edge.

Abstract: A Stein Hall cup for measuring the viscosity of a starch adhesive is automated to provide viscosity measurement in real time using a PLC or other data gathering and control processor. Temperature of the adhesive is measured concurrently with viscosity and temperature signals are processed with the timed viscosity signal to provide a temperature compensated value of starch viscosity.

Abstract: Tension spikes in a running web slit to direct output webs to respective upper and lower cutoff knives are minimized by anticipating the increased tension in the web when the lead edge enters an outfeed nip and offsetting the tension spike with a decrease in the force imposed by the infeed pull roll nip, whereby the sum of the web tensions is substantially uniform through the cutting cycle and the sheets are cut to a consistent length.

Abstract: A method for automatically setting the rider roll/glue applicator roll gap for the single face web on a glue machine senses a forward drag that the single face web, operating at corrugator speed, exerts on the glue applicator roll, driven at an underspeed, after bringing the flute tips of the single face web into contact with the glue applicator roll by adjusting the position of the rider roll. Changes in forward drag exerted on the glue applicator roll are monitored and related directly to glue applicator roll drive current to provide a slight compression of the single face web between the rider roll and the glue applicator roll. Preferably, the glue applicator roll uses a regenerative drive and the target drive current command in a feedback control system to cause the gap to be adjusted to achieve the desired slight compression of the web flutes and to maintain the glue applicator roll under speed.

Abstract: In an operating machine, one example of a method for monitoring operation of operating machinery includes converting an actual sound pattern generated by the machine into an audio signal and digitizing the audio signal to create a real-time acoustic fingerprint unique to the actual sound pattern. A reference database contains a plurality of stored acoustic fingerprints, each stored acoustic fingerprint in the plurality of stored acoustic fingerprints representing a unique sound pattern associated with a particular operating condition. A controller compares the real-time acoustic fingerprint to the stored acoustic fingerprints in the reference database and generates an output in response to detection of a match between the real-time acoustic fingerprint and one of the plurality of stored acoustic fingerprints. One example of the machine is a corruptor machine that converts paper webs into corrugated paperboard sheets.

Abstract: A method and a non-transient computer readable medium for sorting orders to be run on a multi-section slitter/scorer at a corrugator dry end includes collecting specifications of orders in current, prior, and/or subsequent paper group queues. Run times and slit/score head recovery times for orders in the current paper group queue are calculated using the specifications. Those orders for which recovery time exceeds run time are flagged as short orders. For a given short order, pairs of preceding and following orders that would require recovery times less than the short order's run time are determined and flagged as potential bracketing pairs. The current paper group queue is searched to determine if a bracketing pair can be formed from its orders, and if so, the orders in the current paper group queue are reorganized such that the orders in the bracketing pair immediately precede and follow the given short order.

Abstract: A method and apparatus for performing an order change in a corrugator uses a minimum slit head configuration with all slit heads carried on two sides of a single tool support structure. A single robot is operable on the support structure to independently reset the positions of slit heads during a running order to prepare for subsequent order change in a most efficient manner, utilizing order scheduling that eliminates order changes that cannot be formed with the minimum slit head configuration.

Abstract: A method for minimizing cross-machine direction variations in temperature and moisture content of a web running through a corrugator single facer. The method includes running the web through a web preheater station of the single facer and capturing an image representing an actual temperature of the web downstream of the preheater station in the cross-machine direction with a thermal imaging device. The method includes sending the image to a programmed process controller that applies thermal pattern recognition to the image and determining with the controller if the actual temperature of the web deviates from a desired temperature range. The method also includes determining with the controller a corrective action that will bring the actual temperature of the web within the desired temperature range and generating and sending a control signal with the controller to vary an operating condition of the preheater station so as to bring about the corrective action.

Abstract: A block of a solid lubricant material, such as PTFE, is biased continuously or intermittently against the cutting edge of a rotary slitting blade for corrugated paperboard. The solid lubricant block prevents the build up of starch adhesive and biasing movement compensates for wear of the block and wear of the cutting blade edge.

Abstract: A block of a solid lubricant material, such as PTFE, is biased continuously or intermittently against the cutting edge of a rotary slitting blade for corrugated paperboard. The solid lubricant block prevents the build up of starch adhesive and biasing movement compensates for wear of the block and wear of the cutting blade edge.

Abstract: Tension spikes in a running web slit to direct output webs to respective upper and lower cutoff knives are minimized by anticipating the increased tension in the web when the lead edge enters an outfeed nip and offsetting the tension spike with a decrease in the tension from the infeed pull roll nip, whereby the sum of the web tensions is substantially uniform through the cutting cycle and the sheets are cut to a consistent length.

Abstract: A method for automatically setting the rider roll/glue applicator roll gap for the single face web on a glue machine senses a forward drag that the single face web, operating at corrugator speed, exerts on the glue applicator roll, driven at an underspeed, after bringing the flute tips of the single face web into contact with the glue applicator roll by adjusting the position of the rider roll. Changes in forward drag exerted on the glue applicator roll are monitored and related directly to glue applicator roll drive current to provide a slight compression of the single face web between the rider roll and the glue applicator roll. Preferably, the glue applicator roll uses a regenerative drive and the target drive current command in a feedback control system to cause the gap to be adjusted to achieve the desired slight compression of the web flutes and to maintain the glue applicator roll under speed.

Abstract: A method and apparatus for performing an order change in a corrugator uses a minimum slit head configuration with all slit heads carried on two sides of a single tool support structure. A single robot is operable on the support structure to independently reset the positions of slit heads during a running order to prepare for subsequent order change in a most efficient manner, utilizing order scheduling that eliminates order changes that cannot be formed with the minimum slit head configuration.

Abstract: In a sheet downstacker of a corrugator dry end, sheets are delivered by a drive system driving both the bottom and top nip rolls with a single motor that also drives the last flat belt sheet conveyor to the nip.

Abstract: In a sheet downstacker of a corrugator dry end, sheets are delivered by a drive system driving both the bottom and top nip rolls with a single motor that also drives the last flat belt sheet conveyor to the nip.

Abstract: A method for automatically setting the rider roll/glue applicator roll gap for the single face web on a glue machine senses a forward drag that the single face web, operating at corrugator speed, exerts on the glue applicator roll, driven at an underspeed, after bringing the flute tips of the single face web into contact with the glue applicator roll by adjusting the position of the rider roll. Changes in forward drag exerted on the glue applicator roll are monitored and related directly to glue applicator roll drive current to provide a slight compression of the single face web between the rider roll and the glue applicator roll. Preferably, the glue applicator roll uses a regenerative drive and the target drive current command in a feedback control system to cause the gap to be adjusted to achieve the desired slight compression of the web flutes and to maintain the glue applicator roll under speed.

Abstract: A method and apparatus for performing an order change in a corrugator uses a minimum slit head configuration with all slit heads carried on two sides of a single tool support structure. A single robot is operable on the support structure to independently reset the positions of slit heads during a running order to prepare for subsequent order change in a most efficient manner, utilizing order scheduling that eliminates order changes that cannot be formed with the minimum slit head configuration.

Abstract: A Stein Hall cup for measuring the viscosity of a starch adhesive is automated to provide viscosity measurement in real time using a PLC or other data gathering and control processor. Temperature of the adhesive is measured concurrently with viscosity and temperature signals are processed with the timed viscosity signal to provide a temperature compensated value of starch viscosity.