By measuring its dynamic electrical curve, an atmospheric plasma process can be monitored and controlled No additional sensors are needed as a close analysis of the measured current and voltage values already reveals a multitude of process information

Real-time analysis of atmospheric plasma processes

By measuring its dynamic electrical curve, an atmospheric plasma process can be monitored and controlled. No additional sensors are needed as a close analysis of the measured current and voltage values already reveals a multitude of process information.

Intelligent process control

The most intelligent way for predictive maintenance and avoiding machine downtime is having an exact knowledge of the process flow as well as all relevant parameters.

Maintenance planning in particular faces the daily challenge of ensuring maximum machine availability while at the same time minimizing material consumption for maintenance and repairs. This is a requirement which most existing maintenance concepts cannot meet. The exit nozzles used in atmospheric plasma processes have a limited lifespan. Either, the nozzles are changed prophylactically at fixed intervals, accepting the fact that only about 70% of their potential life cycle is exploited, or the process is continued up to the point when it becomes apparent that the desired effect begins to lack in quality. In many cases, the latter is not acceptable as it involves the risk of producing substandard products or rejects.

Of course there are other conditions which influence process stability. For instance, fluctuations or faults in the system can be caused by the facility’s gas/compressed air supply system.

Our network capability solution

An integrated process network, often referred to using the term “Industry 4.0“, is one of the keys to success. Network capability as such is not effective without the specific ability of recognizing relevant patterns in the primary process data and consequently triggering events (e. g. maintenance or readjustments).

Our solution for predictive maintenance opens up new ways of recording the current state of your plasma process in real time, without the use of additional sensors potentially susceptible to faults. The data is screened for patterns which point to possible interferences. Any looming failures or malfunctions can be detected in advance and corrective measures can be planned and initiated in the best way possible in order to avoid unforeseen downtime and optimize the dedication of personnel and resources.

If the information is integrated into an MES (Manufacturing Execution System), there is a multitude of possibilities when it comes to maintenance planning, quality assurance and constant process documentation.