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Datasheet · documentation status

PQMex® technical data

Specifications, installation, commissioning and conformity

All technical data of the PQMex® at a glance — compiled from the datasheet and the operating manual. For planning, tendering and preparing the installation.

PQMex Inline-Qualitätsmesssystem // PQMex®
[ 01 ]At a glance

The key figures of the PQMex®

Camera resolution

4096 px · 25 µm

Line rate

25 kHz

Thickness sensor (option)

± 1 µm

Screw, L/D

Ø 25 mm · 30:1

Max. process temperature

240 °C

Heating zones (barrel 1–3, mould 1–2)

5

[ 02 ]Process

From granulate to quality grade

The PQMex® extrudes a sample of the material under test into a blown film and inspects it directly in the running web.

Process schematic: hopper, extruder with three barrel zones, die with two zones, film bubble, line-scan camera with LED lighting, haul-off and winder, and evaluation in CAMEN.
Schematic sequence: hopper, extruder with three barrel zones, die with two zones, film bubble, line-scan camera with LED illumination, haul-off and winder, and the evaluation in CAMEN.
Line-scan camera principle: each sensor pixel captures a rectangle of width B and length L on the film
Each pixel of the line sensor covers a rectangle of width B on the film; the length L results from the web movement during exposure.

How the line-scan camera inspects

The PQMex® uses a line-scan camera in transmitted light: camera and lamp face each other across the film. The camera captures one line at a time; the complete image is built up as the film moves past.

The average brightness of each rectangle is evaluated. Above the upper tolerance value the system detects a bright defect; below the lower one, a dark defect.

[ 03 ]Technical data

Specifications in detail

General
Machine dimensions (L × W × H)
1850 × 700 × 2000 mm
Weight
300 kg
Hopper volume
2 l
Heating zones
5 (barrel 1–3, mould 1–2)
Max. process temperature
240 °C
Drive and screw
Maximum screw speed (mechanical)
57 rpm
Screw motor
1440 rpm · 2.2 kW · 50 Hz
Screw gear ratio
1:25
Screw diameter
Ø 25 mm
Screw L/D ratio
30:1
Haul-off and winder
Maximum haul-off speed
6 m/min
Sample material
Pellets and flakes
Analysis cycle
A new quality grade every minute
Haul-off / winder motor
1200 rpm · 40 W · 50 Hz
Haul-off / winder gear ratio
1:50
Film width
75 – 125 mm
Camera and lighting
Camera interface
GigE Vision
Camera resolution
4K: 4096 pixels · 25 µm; alternatively 2K, 6K, 8K or 12K
Line rate
25 kHz
Viewing width
max. 100 mm
LED length
300 mm
Illuminance
500,000 lx
Sensor accuracy
Fill-level sensor
± 2 mm
Bubble-diameter sensor
± 0.3 mm
Thickness sensor (option)
± 1 µm
Software
CAMEN
Version 12
vSTAT
Version 1 (optional module)
Industrial PC (IPC)
Memory (RAM)
32 GB
SSD
1 TB
Environment and setup
Operating temperature
0 – 45 °C
Humidity
5 – 95 %, non-condensing
Site requirements
Flat, load-bearing, clean and dry; no foundation required; indoor installation only
Electrical supply
Voltage and frequency
400 V · 50 Hz · three-phase
Power consumption
max. 7.5 kW · average 4.0 kW
Connection type
CEE 400 V / 16 A / 3~, industrial socket outlet
Compressed air supply
Air pressure
7 – 10 bar
Flow rate without venturi
10 l/min
Flow rate per venturi
420 l/min
Quality
Oil-free and dry
Connection type
Quick-connect coupling NW 7.2
Communication and utilities
Network
RJ45 Ethernet (industrial network, segregated segment recommended)
Data archiving
Internal SQL database; reports via the optional vSTAT module
First venturi unit
Mounted directly on the PQMex®
Each additional venturi unit
max. 20 m hose distance between the units

All data refer to the standard configuration. Values are nominal unless a tolerance is stated. Subject to technical change without notice; these data are not a guarantee of properties.

[ 04 ]Installation

Installation and commissioning

Site

Flat, level and load-bearing surface. No structural foundation is required.

Environment

Clean and dry. The PQMex® is intended for indoor use only.

Clearances

1 m on each side of the machine for operation, maintenance and escape routes.

Mobility

Fully relocatable unit — can be positioned flexibly within your facility.

Connectivity

Electrical, compressed air and network supply are designed as plug-and-play connections.

PQMex® in three views with positions A to J
Layout of the PQMex®: base cabinet, measuring tower and monitor stand. Film path and screen at the front, drive at the rear, all external connections on the right.

Layout and interfaces

A
Top of the tower – Haul-off and optional thickness-measurement probe
B
Front film path – Line-scan camera and lamp in transmitted light, winder
C
Centre of the tower – Die with bubble, bubble guide and bubble-diameter sensors
D
Monitor stand – Touchscreen and emergency-stop switch
E
Extruder – Feed hopper, screw, heated barrel with five heating zones, drive at the rear
F
Right side wall – Main switch, mains, Ethernet and compressed-air connections
G
Right door – Industrial PC, lockable
H
Left door – Lockable, with R.A.M. logo
I
Left side wall – Type plate
J
Base cabinet – Pneumatic components and other utilities

Pre-start checks

Before first commissioning, and again after every relocation, check that:

  • the machine stands level and stable on a flat, load-bearing floor and cannot move under load
  • the clearances of 1 m on each side required for operation, maintenance and escape routes are maintained
  • the supply voltage, frequency and upstream fuse protection match the electrical supply data, the machine is connected to the protective earth, and the required residual-current protection is present
  • the compressed air is oil-free and dry and is within 7 – 10 bar
  • all guards, covers and doors are fitted and close correctly, and the type plate and all safety labels are present and legible
  • the emergency-stop device functions: press it, confirm that the screw drive, the haul-off and the winder stop, then unlatch it and confirm that the drives do not restart by themselves
  • the extrusion die has been calibrated in accordance with the calibration manual, if it was removed for transport or maintenance
  • the operating and maintenance personnel have been instructed and the CAMEN access levels have been assigned

Record the commissioning and the results of these checks. A machine showing transport damage must not be commissioned. In all cases, the operating manual supplied with the machine takes precedence.

[ 05 ]Conformity

Directives and standards

2006/42/EG

Machinery Directive

2014/30/EU

Electromagnetic compatibility

2011/65/EU

Restriction of hazardous substances (RoHS)

2012/19/EU

Waste electrical and electronic equipment (WEEE)

The PQMex® bears the CE marking. The EU declaration of conformity, stating the legislation and harmonised standards applied, is supplied with every machine as a separate document. Unauthorised modifications void CE conformity.

EMC notice: the machine is Class A equipment in accordance with EN 55011 and EN IEC 61000-6-4. It is intended for industrial electromagnetic environments and is not intended for use in residential environments.

[ 06 ]Documentation

Applicable documents

Documentation supplied
Operating manual
MAN-PQMEX-EN-001 / DE-001 / PL-001
Calibration manual
MAN-PQMEX-EN-002 / DE-002 / PL-002
Calibration record
MAN-PQMEX-EN-002-F01 / DE-002-F01
Cleaning and routine maintenance
MAN-PQMEX-EN-003 / DE-003 / PL-003
vSTAT user manual (optional module)
MAN-VSTAT-EN-001 / DE-001 / PL-001

The English version is the original instructions within the meaning of Directive 2006/42/EC, Annex I, item 1.7.4.1; the German and Polish versions are translations of the original instructions.

This page summarises technical data and does not replace the documentation supplied with the machine. Operation, calibration and maintenance are governed exclusively by the manuals accompanying the machine. The complete documentation is available from our service department.

[ 07 ]Scope of supply

Standard equipment and options

Standard

  • Bubble diameter measurement
  • Material level – required for auto start/stop
  • Speed monitoring – on haul-off and winder
  • Reverse buttons – on haul-off and winder
  • Over-temperature protection
  • Pneumatic contact pressure – automatic opening and closing of the haul-off rollers
  • Acrylic glass enclosure
  • Antistatic brush – removes static charges from the extruded film
  • CAMEN version 12 – measurement and evaluation software with recipe management, defect classification and roll reporting
  • Internal SQL database – archiving of measurement data on the industrial PC

Options

  • Thickness measurement
  • Autofeeding (Venturi) – automatic pellet feeding into the hopper; hose length up to 10 m or over 10 m, from one or two sources
  • Silo control – for quality-based sorting
  • Automatic recipe switching – via PLC inputs
  • Variable bubble cooling
  • Winding core with spring tensioner – winding of the film web for later inspection
  • Production-environment version – contamination protection for the base through additional enclosure and forced ventilation
  • Signal light
  • RAID – additional storage solution
  • Additional inputs and outputs – as required
  • vSTAT version 1 – freely configurable reports and statistics
[ 08 ]Maintenance

Maintenance intervals and operating supplies

TaskIntervalResponsibility
General service / inspection
Once per year
R.A.M. Kunststofftechnik GmbH
Routine maintenance
Every 8,000 operating hours or once per year, whichever comes first
Operator
Mechanical calibration of the extrusion die
Every 8,000 operating hours or once per year; additionally after every removal, burn-out or adjustment
Operator (WP)
Thickness-sensor zero calibration
Recommended before each inspection
Operator (MF)
Cleaning
After each extrusion or material change
Operator
General cleaning
As required, according to the degree of contamination
Operator
Operating supplies and consumables
Compressed air
Oil-free and dry; 7 – 10 bar; NW 7.2 quick-connect
Cleaning / purging compound
R.A.M.-approved cleaning granulate or purging compound
Corrosion-protection oil
Approved anti-corrosion oil — for screw and barrel during long-term storage
Lubricants (gearbox / mechanics)
Approved lubricants; serviced by R.A.M. Kunststofftechnik GmbH
Processed material
Virgin and recycled (PCR) PE: LDPE, MDPE, LLDPE, HDPE; max. process temperature 240 °C

Record-keeping duty: every routine maintenance operation, every cleaning operation carried out because of a material change or a fault, and every oil change must be recorded with operating hours, date, work carried out, parts and operating supplies used, and the name of the person who carried out the work (BetrSichV § 3, DGUV Vorschrift 1). The records form part of the machine documentation and are presented at the annual service.

Only the operating supplies specified here, or supplies expressly approved by R.A.M., may be used. Unsuitable supplies can damage the machine, impair measurement accuracy and void the warranty. Observe the safety data sheet of every substance used.

The annual service and all repairs are carried out by R.A.M. Kunststofftechnik GmbH. The detailed procedures for cleaning, maintenance and calibration are given exclusively in the accompanying manuals MAN-PQMEX-DE/EN-002 and -003.

To service →

PQMex® calibration set in an IP67 case with the R.A.M. logo
Calibration set in an IP67 case (500 × 410 × 190 mm).

Calibrating the extrusion die

Mechanical calibration uses a dedicated calibration set: die calibration unit, torque wrench and tools, housed in a dust-tight IP67 case that protects the calibration unit against impact, dust and moisture.

The procedure is described in the calibration manual MAN-PQMEX-EN-002.

Our team of experts is ready to help

Questions about the technical data?

We will review connection values, space requirements and integration into your line with you — and provide the complete documentation.