EXTRUDER, PLASTIC MOLDING PLANT OR COMPOUNDING PLANT AND METHOD FOR OPERATING SUCH A PLANT

Abstract

An extruder, such as a double-screw extruder includes a double cylinder and a double-lead screw arranged therein with a drive train for the screw. The drive train has a coupling with the screw. The extruder includes a sensor for recording a moment load having torque and/or bending moment and for generating electronic data from the recorded moment load. A controller is provided in operative connection to a drive for the drive train and the sensor is in data connection with the controller. The controller is adapted to evaluate the data on the recorded moment load and to trigger a protective action if a threshold value set in the controller is exceeded. The evaluation includes a bending moment calculation. A plastic molding plant produces a film with the extruder along with a nozzle unit and a cooling and wind-up unit or a compounding plant. A method for operating such a plant for manufacturing a film includes the extruder.

Claims

1. An extruder having a cylinder and a screw arranged therein and a drive train for the screw, the drive train having a coupling with the screw and the extruder, having a sensor for recording a moment load comprising torque and/or bending moment and for generating electronic data from the recorded moment load, a controller being provided which is in operative connection to a drive for the drive train, the sensor being in data connection with the controller, the controller being adapted to evaluate the data on the recorded moment load and to trigger a protective action if a threshold value set in the controller is exceeded, and the evaluation including a bending moment calculation.

2. The extruder according to claim 1, wherein an averaged offset of the bending moment is calculated.

3. The extruder according to claim 1, wherein an amplitude of the bending moment is calculated.

4. An extruder comprising a double-cylinder and a double-lead screw arranged therein, as well as a drive train for the screw, the drive train having a coupling with the screw and the extruder, having a sensor for recording a moment load comprising torque and/or bending moment and for generating electronic data from the recorded moment load, a controller being provided which is in operative connection to a drive for the drive train. the sensor being in data connection with the controller, the controller being adapted to evaluate the data on the recorded moment load and to trigger a protective action if a threshold value set in the controller is exceeded, and the evaluation comprising a frequency calculation.

5. The extruder according to claim 4, wherein the frequency calculation comprises an amplitude calculation.

6. The extruder according to claim 4, wherein the protective action is a braking or a stopping of the drive train and/or an opening of the coupling.

7. The extruder according to claim 4, wherein the extruder has a first coupling and a second coupling between the drive train and the screw, the first coupling being arranged on the drive train side of the gear and the second coupling being disposed on the screw side of the gear.

8. The extruder according to claim 4, wherein the protective action is the output of a wear warning, with the controller offering an acknowledgement with an authorization.

9. The extruder according to claim 4, wherein several different threshold values are provided to which the controller is adapted to assign different protective actions.

10. The extruder according to claim 4, wherein the sensor has a wire strain gauge.

11. The extruder according to claim 4, wherein the sensor has an optical system

12. The extruder according to claim 4, wherein a magnetic or inductive sensor is provided.

13. The extruder according to claim 4, wherein the controller is in data connection to a database which can be updated externally.

14. The extruder according to claim 4, wherein the controller has an input interface for recording manually input geometrical measurement and/or optical values concerning the screw and/or the cylinder.

15. The extruder according to one of the above claim 4, wherein the controller has a corrective algorithm for adapting the threshold value or the parameter for calculating the threshold value using the manually input values.

16. A plastic molding plant for producing a film by means of an extruder according to claim 1 and by means of a nozzle unit and a cooling and wind-up unit; or a compounding plant with the extruder.

17. A method for operating a plant according to claim 16, the method including the following steps: a. recording a torque and/or a bending moment in the extruder by means of a sensor; b. transferring data on the recorded moment load to the controller; and c. evaluating the data by means of the controller, comprising i. a frequency calculation and/or ii. a bending moment calculation.

18. The method according to claim 17, wherein in the calculation, data are grouped in classes.

19. The method according to claim 18, wherein the amplitude of the class is monitored.

20. The method according to claim 18, wherein for two classes, the amplitudes are computed and monitored.

21. The method according to claim 17, wherein the amplitude of at least a class around 5 Hz to 6 Hz is computed.

22. The method according claim 17, wherein the data of one frequency bandwidth are grouped in one class.

23. The method according to claim 17, wherein an offset of the bending moment is monitored for reduction so as to detect a wear of the extruder.

24. The method according to claim 17, wherein an amplitude of the bending moment is monitored for reduction so as to detect wear of the extruder.

25. The method according to claim 17, wherein the coupling is set so as to be triggered more sensitively with increasing wear.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0097] FIG. 1 schematically shows a system description of a double-screw extruder 1 having a double-lead screw 2, connected to a drive train 6 with a motor via measurement couplings 3, a gear 4 and a safety friction clutch 5.

[0098] FIG. 2 allows a better view of the measurement couplings, which are arranged between the gear 4 and the screw shafts 7, 8. Wire strain gauges (identified by way of example) are attached to the measurement couplings 3.

[0099] FIG. 3 worn (right) and new (left) kneading block

[0100] FIG. 4 worn (right) and new (left) conveying element

[0101] FIG. 5 amplitude of left torque with prototype

[0102] FIG. 6 amplitude of right torque with prototype

[0103] FIG. 7 offset of left torque with prototype

[0104] FIG. 8 offset of right torque with prototype

[0105] FIG. 9 amplitude of left bending moment with prototype

[0106] FIG. 10 amplitude of right bending moment with prototype

[0107] FIG. 11 offset of left bending moment with prototype

[0108] FIG. 12 offset of right bending moment with prototype

[0109] FIG. 13 average torque, variation of specific throughput of prototype

[0110] FIG. 14 amplitude of torque, variation of specific throughput of prototype

[0111] FIG. 15 amplitude of torque, variation in pressure at screw tip of prototype

[0112] FIG. 16 amplitude of torque, variation in absolute throughput of prototype

[0113] FIG. 17 average of bending moment, variation in absolute throughput of prototype

[0114] FIG. 18 frequency spectrum of right bending moment

[0115] FIG. 19 frequency spectrum of left bending moment

[0116] FIG. 20 torques of the test points

[0117] FIG. 21 variation of specific throughputs

[0118] FIG. 22 variation of cylinder temperature

[0119] FIG. 23 variation of absolute throughputs

[0120] FIG. 24 torques of the test points

[0121] FIG. 25 variation of specific throughputs

[0122] FIG. 26 amplitudes of torques of screw plug-in mounts 1, 2 and 3 at 400 kg/h

[0123] FIG. 27 averages of torques of screw plug-in mounts 1, 2 and 3 at 400 kg/h

[0124] FIG. 28 amplitudes of bending moments of screw plug-in mounts 1, 2 and 3 at 400 kg/h

[0125] FIG. 29 averages of bending moments of screw plug-in mounts 1, 2 and 3 at 400 kg/h

[0126] FIG. 30 amplitude torque, variation of absolute throughput

[0127] FIG. 31 average torque, variation of absolute throughput

[0128] FIG. 32 amplitude bending moment, variation of absolute throughput

[0129] FIG. 33 average bending moment, variation of absolute throughput

[0130] FIG. 34 torque left screw (frequency range)

[0131] FIG. 35 left bending moment (frequency range)

[0132] FIG. 36 torques and bending moments left (over a time range)

[0133] FIG. 37 amplitudes of the bending moments over the test points, right bending moment

[0134] FIG. 38 corresponding left bending moment

[0135] FIG. 39 offset of bending moments over the test points, right bending moment

[0136] FIG. 40 corresponding left bending moment

[0137] FIG. 41 bending moments with variation of specific throughput, amplitude of bending moment

[0138] FIG. 42 corresponding average of bending moment

[0139] FIG. 43 torques with variation of pressure at the screw tip, amplitude bending moment

[0140] FIG. 44 corresponding average of bending moment

[0141] FIG. 45 bending moments with variation of absolute throughput, amplitude of bending moment; and

[0142] FIG. 46 corresponding average of bending moment

DETAILED DESCRIPTION OF THE DRAWINGS

[0143] At the same time, a rotor antenna 10, arranged directly above a stator antenna 11, rotates together with the screw shafts 7, 8.

[0144] Torque measurement and bending moment measurement take place by means of wire strain gauges 9 attached to the measurement couplings 3. In case of torsion or bending of the screw shafts 7, 8, the ohmic resistance of the wire strain gauges 9 changes. By means of a full bridge, a measurement voltage is created by the change in resistance, which voltage is proportional to the torque or the bending moment, respectively. The measurement voltage is then amplified by a signal amplifier and converted into a bit sequence by an analog/digital converter. Via the rotor antenna 10, the digitized sensor values from the measurement couplings 3 are then wirelessly transferred to the stator antennae 11.

[0145] From the stator antennae 11, the data are then transmitted via cable to an evaluation unit (not shown here). Via a digital/analog converter, an analog output signal is again output which can either be transferred to a PC via an analog/digital converter, or the measurement system used here can read in and process the data directly.

[0146] The measurement system used was a system by Manner Sensortelemetrie GmbH, 78549 Spaichingen, Germany.

[0147] In the following, excerpts from the trials performed by the inventors will be presented which better explain the disclosure to the person skilled in the art:

[0148] Protocol Excerpts From the Trials

[0149] The sensor technology used makes it possible to gain an insight into the current load states of the screws. For examination of wear, the task is to find out whether the sensor technology used is also suitable to detect screw wear.

[0150] For this purpose, the torque and bending moment signals of a new-value screw are to be recorded so that they can subsequently be used as reference signals. In the subsequent measurements, a wear on individual segments, which is at first relatively strong, is to be simulated. For this purpose, individual segments which, as experience has shown, are regularly subject to greater wear, are mechanically reworked. The employed kneading blocks and screw segments are reduced by approximately 10 mm in diameter so as to represent a strong state of wear (see FIG. 3 and FIG. 4).

[0151] Subsequently, the same test points are to be measured as in the reference measurements so as to ensure comparability of the results. A comparison of the measured values is then supposed to allow a conclusion on whether it is possible to signal a screw wear by alterations of the measured values.

[0152] Test Procedure

[0153] Both for the reference measurements and for the subsequent tests, PP-MF1-3 is used as the raw material.

[0154] A test procedure is set up in which the absolute throughput is varied as well as the specific throughput and the pressure on the screw tip (see Table 1). Thus, alterations of the measured values due to variation of the machine parameters can be directly compared to any alterations caused by wear.

[0155] To facilitate any subsequent statistic tests, a test point with an absolute throughput of 400 kg/h, a specific throughput of 2.7 kg*min/h and a pressure of 60 bar is defined as the central point (line no. 1 of the table). Starting from this test point, the absolute throughput, the specific throughput and the pressure at the screw tip will all be varied (specific throughput in lines 3 and 4; pressure in lines 5 and 6 and absolute throughput in lines 7 and 8). The test points for the examinations on wear are listed in Table 1. Also, the second test point is measured with the same parameters as the first one for an examination of the variations in case of repeated measurement at one test point.

TABLE-US-00001 TABLE 1 test plan for examinations on wear AD SD P T D no. [kg/h] [kg*min/h] [bar] [° C.] [rpm] 1 400 2.7 60 240 148.1 2 400 2.7 60 240 148.1 3 400 2.3 60 240 173.9 4 400 3.1 60 240 129.0 5 400 2.7 40 240 148.1 6 400 2.7 80 240 148.1 7 300 2.7 60 240 111.1 8 500 2.7 60 240 185.2 AD: absolute throughput SD: specific throughput P: pressure T: temperature D: rotational speed

[0156] First, each test point is stabilized over a certain period of time. Then, the torques and bending moments are recorded by means of a Ganter measurement system over a period of five minutes. The measured values are low-pass-filtered by means of the measurement system with a cut-off frequency of 500 Hz and scanned with a scanning frequency of 5000 Hz. Thus, the scanning rate is at least 10 times higher than the maximum frequency occurring in the signal, so as to prevent aliasing as far as possible.

[0157] Aliasing errors are errors caused by the occurrence of frequencies within the signal which are above the Nyquist frequency (half of the scanning frequency). They cause the original signal to be distorted after scanning. The higher the selected scanning rate, the higher the precision of the reconstructed digitized signal. However, this is also linked to greater calculation efforts and a larger amount of data.

[0158] The measuring results from the test series are first transferred into the frequency range by means of a fast Fourier transformation (FFT; a fast Fourier transformation is a variant of the discrete Fourier transformation which is optimized in terms of computing time). In the frequency spectra, the frequencies occurring within the signal, the corresponding amplitudes and the offset of the torque and bending moment oscillations are then evaluated. For performing the fast Fourier transformation, a Scilab program code is written. The amplitudes of the FFT are standardized so that the amplitudes of the individual oscillation components can be directly read from the frequency spectrum. Also, the measured values are multiplied by the Hanning window function. The offset of the oscillations and the amplitudes of the basic frequency can be directly read out from the variable browser of the simulation program and do not have to be analyzed with great effort within the time range. Also, in this way it becomes possible to read all other frequency components below the cut-off frequency of 500 Hz from the frequency spectrum with the corresponding amplitudes.

[0159] The simulation program Scilab is a universal Open-Source software package with functions very similar to those of Matlab. The programming language also is very similar to that of Matlab.

[0160] Test Results

[0161] First, the amplitudes and average values of the torques of the eight test points, on the left and on the right screw shaft, are examined. As can be seen in FIG. 6, the right screw shaft of the worn-out screw has a larger amplitude than the new-value screw shaft. For the left screw shaft (see FIG. 5), the opposite is the case; the new-value screw shaft has a larger amplitude than the worn one. This applies to nearly all test points; therefore, the test points numbered 2 in FIGS. 6 and 7 in FIG. 5 are first regarded as runaway values. Also, it becomes clear that in the new-value screw, the left screw shaft has a larger amplitude than the right screw shaft. In the worn-out screw, the opposite is the case.

[0162] As far as the average torque values are concerned, the worn-out screw shaft is subjected to a higher load than the new-value screw, both on the right and on the left side (see FIGS. 7 and 8). The average values of the right new-value screw shaft are slightly higher than those of the left one. This also applies to the worn-out screw; there, however, the difference between the left and the right screw shaft is less pronounced.

[0163] All diagrams show clearly that the change in average and amplitude between the worn-out screw and the new-value screw is relatively small. The variations in amplitude and average value between the individual test points are much higher so that it is always necessary to refer to the current operating state in order to be able to give a statement on wear. Also, it is at first still unknown how large the variations are if a test point is measured repeatedly. If the operating parameters, such as material, temperature profile, throughput etc., are changed frequently, the possibility of reliably determining screw wear from amplitudes or changes in average of torque values, is deemed to be relatively small.

[0164] Subsequently, the amplitudes and average values of the bending moment signals are evaluated. As can be clearly seen in FIGS. 9 and 10, the amplitude of the worn-out screw shaft strongly rises on the right side whereas it slightly drops on the left side.

[0165] Regarding the average values of the bending moments, it becomes obvious that the offset of the right screw shaft hardly changes whereas the average value of the worn-out left screw shaft is only approximately 50% of that of the new-value screw (see FIGS. 11 and 12). This applies to all test points.

[0166] As with the torques, it is also with the bending moments that the amplitude increases with wear in case of the right shaft and is reduced in case of the left shaft.

[0167] On first sight, the amplitude of the bending moment of the right screw shaft seems to be very well-suited for wear measurement. The change in amplitude caused by screw wear is relatively pronounced in comparison to the change between the individual test points (see FIG. 10). At first, however, this applies only to the present screw plug-in mount and to the predefined strong wear of kneading block and conveying segment. Therefore, it cannot be excluded that with a different screw plug-in mount, a different position of the worn-out segments or use of a different raw material, the amplitude of the bending moment again proves not to be useful. On the other hand, the tests with different plug-in mounts show results similar to those of the measurements with the new-value screw for all three plug-in mounts, although with PET a different raw material was processed. Nevertheless, additional tests are regarded as recommendable in order to verify the strong change in amplitude also for other conditions and to exclude any measurement errors.

[0168] With the left screw shaft, the amplitude is less significant. However, the average of the bending moment shows a clear reduction by approximately 50% in the worn-out screw as compared to the new-value screw (see FIG. 11). The value of the latter, like the amplitude of the right screw shaft, is only subject to slight variations over the different test points. On the other hand, the change in average value of the left screw should be verified by additional tests as well.

[0169] In addition, as in the preceding trials, any possible dependencies of the measured values on operating parameters, such as temperature profile, absolute throughput, specific throughput and pressure, should be examined.

[0170] The specific throughput is varied with a constant absolute throughput of 400 kg/h and a constant pressure of 60 bar at the screw tip. If the specific throughput is increased, as can be seen in FIG. 13, a clear and nearly linear rise in average values of the torques results. For the amplitudes, no clear dependency can be seen. Whereas the amplitudes of the right new-value screw and of the left worn-out screw continuously rise with increase of the specific throughput, those of the right worn-out screw and of the left new-value screw drop (see FIG. 14). Thus, it is not possible to make a clear statement about a change in amplitude. For the amplitudes of the bending moments, as for those of the torques, it is not possible to make an unambiguous statement. The average values of the bending moments remain relatively constant. The results can be seen in the test protocol on wear measurements, which is included in the annex.

[0171] Furthermore, in the trials, the pressure at the screw tip was varied with a constant specific throughput of 2.7 kg*min/h and a constant absolute throughput of 400 kg/h. The amplitudes of the torques first show a rise with an increase from 40 to 60 bar and then, with a further increase in pressure from 60 to 80 bar, they drop to the lowest point (see FIG. 15). The average values of the torques, on the other hand, continuously rise with increasing pressure.

[0172] The amplitudes of the bending moments exhibit a different behavior depending on whether one looks at the worn-out or at the new-value screw. For the new-value screws, the amplitude drops in case of a pressure increase from 40 to 60 bar and then slightly rises again with an increase from 60 bar to 80 bar. For the worn-out screw, on the other hand, the amplitude slightly rises with an increase to 60 bar and then slightly drops again in case of a further increase to 80 bar. The average values of the bending moments slightly rise with the increase in pressure. The average value of the left new-value screw is a runaway value since it slightly drops with an increase from 60 bar to 80 bar.

[0173] In addition to the pressure and the specific throughput, the absolute throughput was also varied with a constant pressure of 60 bar and a constant specific throughput of 2.7 kg*min/h.

[0174] With the worn-out screw, all three test points could be measured. As with the variation in pressure, the amplitudes of the torques also slightly rise, from 300 kg/h to 400 kg/h, with an increase in absolute throughput and then drop quite strongly with a further increase to 500 kg/h (see FIG. 16). The behavior of the amplitudes of the bending moment signals is roughly comparable.

[0175] The average values of the torques continuously rise with an increase in absolute throughput. The average values of the bending moments remain relatively constant, as in all other diagrams. The only runaway value is the average value of the left new-value screw (see FIG. 17).

[0176] Finally, the different frequency components are examined which occur in the torque and bending moment signals at the various test points. The different amplitudes of the fundamental frequency of the reference signal and of the signal of the worn-out screw segments can be clearly distinguished (see FIG. 18).

[0177] The other frequency components are largely harmonic oscillation components of the fundamental frequency. In advance, it had been hoped that, as in a bearing damage, an oscillation would occur in the worn-out screw which oscillation would not be a harmonic of the fundamental frequency. However, this was not confirmed by the measured values. Only the bending moments show a low amplitude at a frequency of approximately 51 Hz, which, however, can partly also be observed both in the reference signal and in the signal of the worn-out segments (see FIG. 19).

[0178] It is also probable that a power-line frequency of 50 Hz may influence the bending moment signals.

[0179] Summary and Outlook

[0180] The tests of the examinations on wear show that an online wear measurement by means of the employed sensor technology might well be possible.

[0181] Whereas the measurement data for the torques are of less significance concerning screw wear, clear changes in the measured values of the bending moment signals due to the use of worn screw segments can be seen.

[0182] Thus, for the right screw shaft, use of the worn-out segments leads to an increase in amplitude of approximately 400% to 600% as compared to the reference signal, with a relatively low dependency on throughput, pressure etc. However, this change in amplitude cannot be seen with the left screw shaft; here, the amplitude is even slightly reduced by the use of the worn segments. What is relatively clear for the left screw, however, is a change in offset. Whereas the offset of the right screw remains nearly unchanged, the offset of the left screw is reduced by approximately 50%. Similar to the amplitude of the right screw shaft, the offset of the left shaft shows only a slight dependency on the set machine parameters.

[0183] As in the preceding trials for the prototype, the bending moment of the right screw exhibits a changing load and that of the left one exhibits an increasing load. In the new-value screw segments, both the average value and the amplitude of the left screw are significantly higher than those of the right screw.

[0184] With use of the worn-out segments, the load on the right screw shaft then rises whereas the load on the left screw clearly decreases. However, a changing load on the right screw and an increasing load on the left screw shaft can still be observed.

[0185] Other than the bending moments, the torques exhibit only minor changes in the measurement data with the use of worn-out segments. Also, a strong dependency on throughput, pressure etc. can be seen which substantially limits the use of the torques for online wear measurement.

[0186] The behavior of the bending moments, above all, therefore promises success as the basis for determining wear.

[0187] Furthermore, the influence of different raw materials, different screw plug-in mounts and different positions of the worn-out segments on the measured values should possibly be examined as well. However, the tests with different PET screw plug-in mounts on the prototype exhibit a similar behavior of the bending moments. Thus, the screw plug-in mount does not seem to have a particularly strong influence on the bending moments.

[0188] It must also be kept in mind that the simulated wear must at first be regarded as being idealized. This wear is symmetrical over the circumference, constant over the length of the screw segments and equally strong on both screw shafts, which in no way represents realistic conditions. Therefore, it cannot be excluded that long-time trials may be necessary since the real wear behavior will differ from the one in the tests.

[0189] If, however, future trials should indicate similarly strong changes in the bending moments if worn-out segments are used, it can be assumed that a reliable early recognition of worn-out screw segments by means of online wear measurement is basically possible. It would, for instance, be conceivable to periodically perform a measurement in which the amplitudes and median values of the bending moments are evaluated. In case defined threshold values are exceeded, for instance, a warning signal could indicate a worn-out screw shaft. The main challenge for this situation would be to make a meaningful distinction between a worn-out screw and a screw which is not worn-out.

[0190] Additional Tables:

[0191] Measurements RZE 70 PP-Granula

TABLE-US-00002 TABLE 2 author date material — plant P. Michels Apr. 10, 2014 polypropylene (PP) granulate RZE 70

[0192] Experimental Design:

TABLE-US-00003 TABLE 3 temperature specific rotational setting throughput throughput speed test no. screw [° C.] [kg/h] [kg*min/h] [rpm] 1 left 220 189 1.97 96 right 2 left 220 399 2.04 196 right 3 left 220 409 1.73 237 right 4 left 220 391 2.34 167 right 5 left 190 362 1.96 185 right 6 left 250 387 2.02 192 right

[0193] Test Results

TABLE-US-00004 TABLE 4 period torque period duration torque motor motor devia- torque duration screw average current current tion ampli- torque rotation no. [Nm] [%] [%] [%] tude [s] [s] 1 L 1170 55% 1225.5 4.5 67.5 0.32 0.625 R 1155 5.8 67.5 0.32 2 L 1408 66% 1503 6.3 76.5 0.16 0.31 R 1391 7.5 77.5 0.15 3 L 1296 60% 1387 6.6 81.5 0.127 0.25 R 1243 10.4 79.5 0.125 4 L 1578 72% 1665 5.2 86 0.175 0.36 R 1531 8 81.5 0.178 5 L 1507 70% 1618 6.9 88 0.171 0.32 R 1478 8.4 84.5 0.168 6 L 1338 61% 1443 6.6 77.5 0.16 0.31 R 1304 9 75 0.15

[0194] Variation of Specific Throughputs:

TABLE-US-00005 TABLE 5 spec. through- torque put torque motor change change [kg* average change change current amplitude amplitude amplitude no. min/h] [Nm] [Nm] [%] [Nm] [Nm] [Nm] [%] 2 L 2.04 1408 — — 1503 76.5 — — R 1391 — — 77.5 — — 3 L 1.73 1296 −112.00 −7.95 1387 81.5 5.00 6.54 R 1243 −148.00 −10.64 79.5 2.00 2.58 4 L 2.34 1578 170.00 12.07 1665 86 9.50 12.42 R 1531 140.00 10.06 81.5 4.00 5.16

[0195] Variation in Temperature:

TABLE-US-00006 TABLE 6 torque torque motor change temp. average change change current amplitude change amplitude no. [° C.] [Nm] [Nm] [%] [Nm] [Nm] amplitude [%] 2 L 220 1408 — — 1503 76.5 — — R 1391 — — 77.5 — — 5 L 190 1507 99.00 7.03 1618 88 11.50 15.03 R 1478 87.00 6.25 84.5 7.00 9.03 6 L 250 1338 −70.00 −4.97 1433 77.5 1.00 1.31 R 1304 −87.00 −6.25 75 −5.00 −3.23

[0196] Variation of Absolute Throughputs:

TABLE-US-00007 TABLE 7 torque through- torque motor change put average change change current amplitude change amplitude no. [kg/h] [Nm] [Nm] [%] [Nm] [Nm] amplitude [%] 1 L 189 1170 — — 1225.5 67.5 — — R 1155 — — 67.5 — — 2 L 399 1408 238.00 20.34 1503 76.5 9.00 13.33 R 1391 236.00 20.43 76.5 10.00 14.81

[0197] Measurements PET Flakes:

TABLE-US-00008 TABLE 8 author date material — plant P. Michels Aug. 18, 2014 polyethylene terephthal- flakes RZE 3.0 ate (PET)

[0198] Experimental Design:

TABLE-US-00009 TABLE 9 temperature absolute rotational test setting spec. throughput throughput speed no. screw [° C.] [kg*min/h] [kg/h] [rpm] 1 left 285/270 2.74 460 168 right 2 left 285/270 2.74 494 180 right 3 left 285/270 2.68 475 177 right 4 left 285/270 2.25 477 212 right 5 left 285/270 3.28 469 143 right 6 left 285/270 2.67 800 300 right 7 left 285/270 2.66 770 290 right 8 left 285/270 2.65 795 300 right

[0199] Test Results Torques:

TABLE-US-00010 TABLE 10 spec. through- abs. torque put through- torque motor motor period period temp. [kg* put average current current duration duration no. [° C.] min/h] [kg/h] [Nm] [%] [Nm] torque [s] screw [s] 1 L 285/270 2.74 460 1757 67 2043.5 0.175 0.36 R 1796 0.175 2 L 285/270 2.74 494 1771 63 1921.5 0.16 0.33 R 1822 0.16 3 L 285/270 2.68 475 1785 66 2013 0.16 0.34 R 1807 0.16 4 L 285/270 2.25 477 1828 56 1693 0.15 0.28 R 2006 0.15 5 L 285/270 3.28 469 1956 71 2165.5 0.21 0.42 R 2052 0.21 6 L 285/270 2.67 800 1965 68 2059 0.09 0.20 R 2008 0.095 7 L 285/270 2.66 770 1966 70 2135 0.09 0.21 R 1988 0.093 8 L 285/270 2.65 795 1967 60 1830 0.107 0.20 R 1984 0.105

[0200] Test Results Bending Moments:

TABLE-US-00011 TABLE 11 spec. period period temper- through- abs. bending duration dura- ature put through- bending moment bending tion setting [kg* put moment ampli- moment screw no. [° C.] min/h] [kg/h] [Nm] tude [s] [s] 1 L 285/270 2.74 460  −20/−160 70 0.35 0.36 R +40/−60 50 0.36 2 L 285/270 2.74 494  −20/−160 70 0.33 0.33 R +40/−60 50 0.33 3 L 285/270 2.68 475  −20/−160 70 0.33 0.34 R +40/−60 50 0.33 4 L 285/270 2.25 477  −40/−180 70 0.3 0.28 R +40/−60 50 0.3 5 L 285/270 3.28 469   0/−150 75 0.42 0.42 R +50/−60 55 0.42 6 L 285/270 2.67 800  +20/−130 75 0.19 0.20 R +50/−70 60 0.19 7 L 285/270 2.66 770  −20/−160 70 0.18 0.21 R +40/−70 55 0.19 8 L 285/270 2.65 795  −20/−160 70 0.21 0.20 R +40/−60 50 0.21

[0201] Variation of Spec. Throughputs

TABLE-US-00012 TABLE 12 spec. temper- through- abs. ature put through- rotational torque bending torque test setting [kg* put speed average moment change no. screw [° C.] min/h] [kg/h] [rpm] [Nm] [Nm] [%] 4 left 285/270 2.25 477 212 1828 −40/−180 — right 2006 +40/−60  — 3 left 285/270 2.68 475 177 1785 −20/−160 −2.35 right 1807 +40/−60  −9.92 5 left 285/270 3.28 469 143 1956  0/−150 7.00 right 2052 +50/−60  2.29

[0202] Measurements With Different Plug-In Mounts:

TABLE-US-00013 TABLE 13 author date material — plant P. Michels Feb. 26, 2015 (PET) granulate RZE 3.0

[0203] Experimental Design:

TABLE-US-00014 TABLE 14 spec. through- through- put test put [kg* temperature profile [° C.] plug-in point [kg/h] min/h] 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 mount VP1 400 2.7 285 285 285 285 285 270 270 270 270 270 (1) 7641001 VP1 400 2.7 285 285 285 285 285 270 270 270 270 270 (2) 7641005 VP1 400 2.7 285 285 285 285 285 270 270 270 270 270 (3) 7641006 VP2 600 2.7 285 285 285 285 285 270 270 270 270 270 (1) 7641001 VP2 600 2.7 285 285 285 285 285 270 270 270 270 270 (2) 7641005 VP3 800 2.7 285 285 285 285 285 270 270 270 270 270 (1) 7641001 VP3 800 2.7 285 285 285 285 285 270 270 270 270 270 (2) 7641005 VP4 1000 2.7 285 285 285 285 285 270 270 270 270 270 (1) 7641001

[0204] Test Results:

TABLE-US-00015 TABLE 15 bend- bend- through- ing ing test put plug-in amplitude torque moment torque moment point [kg/h] mount offset R R L L VP1 400 (1) amplitude 51 24 61.7 51.3 7641001 offset 1736.7 5.8 1697.1 170.9 VP1 400 (2) amplitude 24.6 22.2 44.2 46 7641005 offset 1781.4 11.9 1733.5 82.3 VP1 400 (3) amplitude 40.75 23.89 36.44 50.69 7641006 offset 2095.9 17.15 2069.2 82.3 VP2 600 (1) amplitude 44.7 23.7 50.7 47.7 7641001 offset 1933 3.2 1911.8 148.1 VP2 600 (2) amplitude 30.6 16.4 34.9 35.5 7641005 offset 2074.5 11.8 2040.6 79.4 VP3 800 (1) amplitude 38.2 17.6 44.2 32.9 7641001 offset 2031.5 5.8 2046.1 125.26 VP3 800 (2) amplitude 24.5 17.4 28.6 28.4 7641005 offset 2124.9 13.3 2151.3 144.2 VP4 1000 (1) amplitude 42.9 16.9 48 32.1 7641001 offset 2016.1 8.1 2059.8 115.2

[0205] Protocol on Wear Measurements:

TABLE-US-00016 TABLE 16 author date material — plant P. Michels Feb. 25, 2015 polypropylene granulate RZE 3.0 (PP) MFI3

[0206] Experimental Design:

TABLE-US-00017 TABLE 17 spec. abs. through- through- put put [kg* pressure temperature [° C.] torque no. [kg/h] min/h] [bar] 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 [rpm] VP1 400 2.7 60 200 200 240 240 240 240 240 240 240 240 148.1 VP2 400 2.7 60 200 200 240 240 240 240 240 240 240 240 148.1 VP3 400 2.3 60 200 200 240 240 240 240 240 240 240 240 173.9 VP4 400 3.1 60 200 200 240 240 240 240 240 240 240 240 129.0 VP5 400 2.7 40 200 200 240 240 240 240 240 240 240 240 148.1 VP6 400 2.7 80 200 200 240 240 240 240 240 240 240 240 148.1 VP7 300 2.7 60 200 200 240 240 240 240 240 240 240 240 111.1 VP8 500 2.7 60 200 200 240 240 240 240 240 240 240 240 185.2

[0207] Measurement Results:

TABLE-US-00018 TABLE 18 deviation bending bending between moment torque moment test points torque deviation R deviation L deviation L deviation T.R. B.R. T.L. B.L. no. Nm] [%] [Nm] [%] [Nm] [%] [Nm] [%] [%] [%] [%] [%] 1 amplitude new 65.00 — 8.40 — 73.90 — 43.40 — — — — — worn 73.80 13.54 60.90 625.00 58.70 −20.57 28.40 −34.56 — — — — offset new 1828.00 — 14.20 — 1811.00 — 208.10 — — — — — worn 1886.00 3.17 10.90 −23.24 1880.00 3.81 88.90 −57.28 — — — — 2 amplitude new 68.60 — 9.60 — 80.00 — 45.60 — 5.54 14.29 8.25 5.07 worn 66.30 −3.35 58.50 509.38 54.00 −32.50 27.70 −39.25 −10.1 −3.94 −8.01 −2.46 offset new 1829.80 — 14.00 — 1805.10 — 205.90 — 0.10 −1.41 −0.33 −1.06 worn 1871.60 2.28 11.20 −20.00 1870.60 3.63 89.50 −56.53 −0.76 2.75 −0.50 0.67 3 amplitude new 43.40 — 9.30 — 53.40 — 40.00 — −33.23 10.71 −27.74 −7.83 worn 55.00 26.73 58.10 524.73 45.90 −14.04 30.60 −23.50 −25.47 −4.60 −21.81 7.75 offset new 1645.70 — 13.00 — 1615.50 — 199.10 — −9.97 −8.45 −10.80 −4.32 worn 1705.10 3.61 11.00 −15.38 1692.60 4.77 87.80 −55.90 −9.59 0.92 −9.97 −1.24 4 amplitude new 72.40 — 9.50 — 69.00 — 51.90 — 11.38 13.10 6.63 19.59 worn 72.90 0.69 55.40 483.16 62.80 −8.99 25.00 −51.83 −1.22 −9.03 6.98 −11.97 offset new 2026.60 — 15.90 — 2003.70 — 196.10 — 10.86 11.97 10.64 −5.77 worn 2069.40 2.11 11.90 −25.16 2062.10 2.91 89.10 −54.56 9.72 9.17 9.69 0.22 1 amplitude new 57.00 — 11.90 — 66.50 — 50.00 — −12.31 41.67 −10.28 15.21 worn 61.90 8.60 56.80 377.31 54.80 −17.35 27.50 −45.00 −16.12 −6.73 −6.64 −3.17 offset new 1805.50 — 12.60 — 1775.10 — 183.20 — −1.23 −11.27 −1.95 −11.97 worn 1802.50 −0.17 10.60 −15.87 1804.30 1.64 81.40 −55.57 −4.43 −2.75 −4.03 −8.44 2 amplitude new 55.70 — 10.90 — 63.90 — 45.60 — −14.31 29.76 −13.53 5.07 worn 58.40 4.85 57.20 424.77 51.70 −19.09 27.80 −40.13 −20.87 −6.08 −11.93 −3.07 offset new 1915.00 — 15.90 — 1882.80 — 194.20 — 4.76 11.97 3.95 −6.68 worn 1922.00 0.37 11.50 −27.67 1915.70 1.75 90.90 −58.19 1.91 5.50 1.90 2.25 3 amplitude new 36.50 — 8.30 — 39.10 — 34.40 — −43.85 −1.19 −47.09 −20.74 worn 61.40 −68.22 56.30 −578.81 54.30 38.87 29.90 −13.08 −16.80 −7.55 −7.50 5.28 offset new 1764.60 — 14.00 — 1738.10 — 180.00 — −3.47 −1.41 −4.08 −13.50 worn 1756.40 −0.46 10.00 −28.57 1758.90 1.20 84.40 −53.11 −6.87 −8.26 −6.44 −5.05 4 amplitude new — — — — — — — — — — — — worn 50.10 — 47.88 — 46.08 — 23.50 — −32.11 −21.38 −21.50 −17.25 offset new — — — — — — — — — — — — worn 1930.10 — 11.69 — 1922.60 — 83.62 — 2.34 7.25 2.27 −5.94