PulseVault — Live Wall-Thickness Inference

ON SPEC Wall in the accepted band above ISO minimum — lean and safe. Baseline

Inferred cross-section vs ISO band

eₘᵢₙ — SCRAP line

accepted overbuild ceiling

eₘₐₓ — ISO max

Bore on the red line = wall at minimum (cross it = scrap). Between red & green = the accepted 2–3 mm margin. Past green = flagged overbuild.

Margin over eₘᵢₙ

+2.0 mm

within accepted band

Inferred wall

57.3 mm

ISO band 57.3–63.3 mm

Flagged overbuild — run total

0.0 kg

0.0 kg/hr · 0.0 kg per 12 m length

🐝QUEEN BEE NODE — LIVE INPUTSDIN-rail IoT gateway · streaming to PulseVault

Line speedQUEEN BEE

pulse counter (haul-off)

0.350m/min

Output rateQUEEN BEE

screw RPM / plug-in (R556)

2090kg/hr

Barrel tempQUEEN BEE

Type-K thermocouple #1

198°C

Die tempQUEEN BEE

Type-K thermocouple #2

205°C

Production run — 10 × 12 m lengths (120 m) at real speed

0.0 / 120.0 m produced · run time T+0:00:00 (plant) · 1 length ≈ 34 min at ×1

0good lengths

0scrapped

0scrap kg

0produced kg

Run setup — from ISO 4427 size table (not measured)

Material

Nominal Ø (dₙ)

SDR series

Pressure class

PN16

eₘᵢₙ — SCRAP line

57.3 mm

eₘₐₓ — ISO max

63.3 mm

Accepted overbuild

+ mm

Min mass / 12 m

1182 kg

dₙ and SDR from SANS ISO 4427 / ISO 11922-1. eₘᵢₙ = dₙ/SDR rounded up to 0.1 mm — the scrap line (wall below it loses the pressure class, the 12 m length is scrapped). Everyone accepts ~2–3 mm of wall over eₘᵢₙ; beyond the accepted figure is flagged as overbuild. Die is fixed, so OD/SDR are set, not measured — wall is inferred from the Queen Bee inputs.

The math — live inference from Queen Bee inputs

Min wall (ISO scrap line)eₘᵢₙ = dₙ/SDR ⌈0.1⌉

Min mass/metre(π/4)(dₙ²−ID²)·ρ

Queen Bee mass/metreOutput ÷ (speed×60)

Back-solved boreID = √(dₙ²−(4/π)·A)

Inferred wallWT = (dₙ−ID)/2

Margin over eₘᵢₙ+2.0 mm

Mass conservation: the Queen Bee output (kg/hr) ÷ line speed = the mass in every metre of wall. The inferred wall is the exact inverse of the ISO geometry — no wall sensor needed.

Exception rules — SANS ISO 4427 / ISO 11922-1

State	Rule (inferred wall)	Action
SCRAP	`wall < eₘᵢₙ` — below ISO minimum, pressure class lost	12 m length scrapped & counted (kg). Line never runs minus on purpose.
SCRAP RISK	`eₘᵢₙ ≤ wall < eₘᵢₙ + 0.5 mm` — drifting onto the scrap line	Early warning — lift the wall before it scraps.
ON SPEC	`eₘᵢₙ + 0.5 mm … eₘᵢₙ + 3.0 mm` — the accepted margin	None — running lean and safe.
OVERBUILD	`wall > eₘᵢₙ + 3.0 mm`, sustained — wasting PE100	Alarm after 60 s → operations. Mass over the accepted band counted (kg).
OVER-TOL	`wall > eₘₐₓ` — outside ISO dimensional tolerance	Flagged with the overbuild alarm.

The win: because the system warns as the wall drifts toward the scrap line, the operator can hold a tight, safe margin — saving kg on every length without ever scrapping. All alarms are debounced (Queen Bee sample → moving average → persistence → hysteresis); no single noisy reading raises one.

Exception monitoring — debounced alerting engine

Queen Bee sample rate 3 /sec · moving average 1.0 s · averaged margin +2.0 mm

Overbuild: trip > +3.0 mm sustained 60 s, clears when back inside the band

Scrap-risk: within +0.5 mm of eₘᵢₙ sustained 15 s · Scrap: wall < eₘᵢₙ (immediate)