Corrugator Stop Point Position & Cuff Start Number

What: Getting the stop point and setting the number accurately allows for highly repeatable cuff maps for each diameter and allows the Operator to “see” clearly the outcomes of minor adjustments

When to Use: At each diameter change to set the stop point and number by line for that diameter.

Why to Use: The stop point and number, once set for all diameters, is the input into the cuff map diagram and provides the settings for each diameter’s program.

Steps:

  1. Position the mold block positional count to approximately 6,000 and prepare to stop the corrugator. Stop the corrugator when the first two mold blocks within the mold tunnel are completely closed at the upstream or die end.
  2. Raise the top blocks three-quarters of an inch (3/4”).
  3. Move the corrugator over the die. Position the leading edge of the first completely closed mold block upstream beyond the outer wall caliper exactly 1.5 blocks (12”). This is the point where you will want to be sure the corrugator stops by positioning the corrugator mechanical stop appropriately. Note the mechanical stop position measurement. Record this value within the Cuff Map Program spreadsheet. Also record the corrugator distance to die stand measurement within the Cuff Map Program spreadsheet Corrugator Position tab.
  4. Slowly run the corrugator around to Cuff Block A. Once this block is detected the counter will reset to 0.
  5. As Cuff Block A approaches the mold tunnel, slow the corrugator down to almost 0.
  6. Run the corrugator until the last valley prior to the bell is centered on the outer wall caliper. Take note of the corrugator count position as it will be used to initiate the cuff process.
  7. Enter this number within the cuff map setup sheet labeled as “O1”.
  8. The cuff map setup sheet will automatically provide you with positional counts for Air Process, Cuff Process, Cuff Speed, & Vacuum control. Enter these values in the corrugator touchscreen PLC per diameter.
  9. Repeat this process for every diameter on each line for verification purposes each time a diameter is set for production.
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