PlasmaBrush PB3
High-performance atmospheric plasma system
The PlasmaBrush PB3 is our high-performance plasma system for all inline processes in industrial and high-speed applications. The PlasmaBrush PB3 is widely used in the automotive, packaging and printing sectors. The focus here is primarily on plasma cleaning and surface activation. This is primarily used to prepare the products for further downstream processes such as bonding, painting or printing.
The PlasmaBrush PB3 is a combination of a particularly compact and long-term stable plasma generator in nozzle form, a unipolar pulsed high-voltage source and a vortex flow in the nozzle. The perfectly matched components in a robust industrial design are perfect for easy integration into any system.
Application technology
Field of application
- Automotive sector
- Printers and printing industry
- Packaging industry
Applications
- Ultrafine cleaning
- Reduction of oxide layers
- Surface functionalization
- Pre-activation for bonding, sealing, casting or printing
- Coating, laminating and sealing
- Germ reduction and sterilization
- Print pre-treatment
The table below shows the surface energy of different plastics. In each case, the surface energy is shown after treatment with the PiezoBrush PZ3, the PlasmaBrush PB3 (plasma high-performance system) and without prior plasma treatment.
Advantages
- Very compact design, also suitable for narrow grooves and hard-to-reach areas
- Easy integration even in small robots
- Suitable for compressed air, nitrogen and other gases
- Variable Power
- High start-stop dynamics
- Maximum operating reliability
Customer references
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PlasmaBrush PB3 in our Online Shop
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Rental unit PlasmaBrush PB31.000,00 € / 29 daysexcl. 19% VAT
zzgl. Versandkosten
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PlasmaBrush PB3
Technical Data
- Flow range: 35 to 60 l/min
- Weight plasma generator: 680 g
- Gas connector: 6 mm
- Treatment speed: 0,1 – 2 m/s
- Typical treatment distance *: 10 – 25 mm
- Typical treatment width *: 15 – 25 mm
- Power consumption power source PS2000: ~ 1000 W
*Typical treatment parameters depend strongly on the application, utilised nozzle and process gas.
Nozzles PlasmaBrush PB3
There are three different nozzles for the PlasmaBrush PB3 atmospheric pressure plasma generator. All nozzles are high performance nozzles which are operated with a Pulsed Atmospheric Arc (PAA®) Plasma Generator (PG31) and pulsed high voltage power supply (PS2000).
The nozzle achieves the following functions:
- focussing of the plasma flame
- acting as a grounded cathode to confine the highpower electric arc
- forming of the cavity to excite the process gas
Nickel-plated nozzles
Nozzle A 250
Field of application:
- Surface cleaning
- Surface activation
- Optimized for electric potential-free processes
Nozzle A 350
Field of application:
- Surface cleaning
- Surface activation
- Thermal treatment and reactive coating
- Optimized for sensitive materials
Nozzle A 450
Field of application:
- Surface cleaning
- Surface activation
- Thermal treatment and reactive coating
- Optimized for high process speeds
[su_button url=”https://www.relyon-plasma.com/wp-content/uploads/2022/02/2021_Data_sheet_A250_EN.pdf” target=”blank” style=”soft” background=”#943a8a” size=”6″ text_shadow=”1px 0px 0px #000000″]Nozzle A 250 >>[/su_button]
[su_button url=”https://www.relyon-plasma.com/wp-content/uploads/2022/02/2021_Data_sheet_A350_EN.pdf” target=”blank” style=”soft” background=”#943a8a” size=”6″ text_shadow=”1px 0px 0px #000000″]Nozzle A 350 >>[/su_button]
[su_button url=”https://www.relyon-plasma.com/wp-content/uploads/2022/02/2021_Data_sheet_A450_EN.pdf” target=”blank” style=”soft” background=”#943a8a” size=”6″ text_shadow=”1px 0px 0px #000000″]Nozzle A 450 >>[/su_button]
Although the copper nozzles originally used have very good properties in terms of burning behavior, there were customer requests to improve the oxidation resistance on the outside. This is essentially only an optical effect without any influence on the burning behavior, but it was nevertheless not possible to ensure that no oxide particles would detach from the nozzle and thus contaminate the workpiece. As a result, relyon plasma tested the copper nozzles again in a large-scale series of tests in order, among other things, to prevent the copper oxide from forming on the surface. For this purpose, very good results were achieved by nickel-plating the nozzles, which also prevents the formation of the surface oxides and the associated problems in the long term. In the tests it was shown that the coating does not lead to any impairment of the burning properties and the operating parameters. In the future, relyon plasma will therefore offer nickel-plated copper nozzles as a fully-fledged replacement for the copper nozzles offered to date.
Nozzles in our Online Shop
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Nozzle A250325,00 €
excl. 19% VAT
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Nozzle A350325,00 €
excl. 19% VAT
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Nozzle A450325,00 €
excl. 19% VAT
Carbide nozzles
The most commonly used nozzles in the PlasmaBrush PB3 so far are the copper nozzles. In processes where the arc is transferred to the substrates, e.g. when cleaning or reducing metal surfaces, the copper nozzles have a very long lifetime*. When polymers are surface activated, however, the arcs dock to the lip of the nozzle, resulting in a shortened service life due to erosion.
In order to extend the lifetime of the nozzles in this popular operating mode, relyon plasma has now developed the special nozzles with a carbide core.
Due to the material properties of carbide, the carbide nozzles are much more resistant to oxidation and erosion than the standard copper nozzles. Thus, even in the treatment of polymers, a 4-fold higher nozzle lifetime could be achieved than with the copper nozzles. Due to the significantly longer service life of the nozzles, the process now requires less maintenance, is more sustainable and more stable.
Another field of application for carbide nozzles is in the semiconductor industry, where the copper abrasion of standard nozzles is often problematic. This can also be prevented by using carbide nozzles.
*At this point we expressly refrain from publishing diagrams or tables of the life expectancy of nozzles determined under laboratory conditions. These data were misleading for the consumer, because different process influences as not calculable factors strongly impair the life span.
Nozzle A 351
Field of application:
- Surface cleaning
- Surface activation
- Thermal treatment and reactive coating
- Optimized for sensitive materials
Nozzle A 451
Field of application:
- Surface cleaning
- Surface activation
- Thermal treatment and reactive coating
- Optimized for high process speeds
Technology
Our PlasmaBrush can be adapted to fit process requirements spot-on through a wide variety of accessories. Thus, the quality of your processes and products can be optimized at minimal cost. You only use the components you really need. All components are coordinated perfectly and have been through extensive stress tests. This simplifies maintenance and servicing, and availability is ensured on the shortest possible time scale.
We have consciously adapted our high voltage power supply PS2000 to the independent industrial standard of CanOpen, which makes exceedingly reliable communication possible even under the more severe circumstances an industrial environment can bring about.
A great number of sensors or mass flow controllers operate using the same standard. Every prevalent industrial control worldwide provides a suitable interface. Up to 127 devices can be addressed via CAN node. Every PS2000 high power source can be controlled with a simple DIP switch in the address space of 0 to 99.
PS2000 High voltage source
The PS2000 High voltage source optimised for Pulsed Atmospheric Arc Technology (PAA Technology®). Due to the use of a unipolar pulsed high voltage, the arc is prevented from stabilising at “hot spots” in the nozzle. The latest IGBT switching technology and the use of high quality high voltage components ensure that the source is extremely reliable and efficient. Overloading is also not possible in continuous 24/7 operation. In the event of cable damage or short circuiting during critical operations the control unit intercepts all power fluctuations safely.
The capability of the PS2000 is particularly reflected in the fact that it can operate with variable loads and can effectively pump loads within a large potential range of up to > 12 kV. This special feature ensures continuous ignition performance across a wide power range and for different process gases. The high voltage source is switchable in a range of milliseconds at full load and therefore optimised for timed processes where highly precise timing is beneficial.
All communication is based on the reliable and fast CAN bus. Even in the event of a fault, the communication remains active. Integration into each automated production plant is simple and standardised, even in the case of several high voltage sources.
Performance features:
- Input voltage: 220 – 240 V AC, 50-60 Hz
- Max. input current: 6A
- Weight: 18 kg
- Power: 1,000 Watt
- Open circuit voltage: up to 20 kV
Integration packages PlasmaBrush PB3
In principle, you need a power supply, compressed air supply (alternatively, nitrogen or forming gas can also be used) and an extraction system for safe operation to commission the PlasmaBrush PB3 system. All other components you need for commissioning are available from us directly from a single source.
Emergency stop switch
An emergency stop switch is mandatory for the use of the PlasmaBrush PB3 system in order to ensure work safety. The emergency stop switch of the pre-existing system can be used here. Alternatively, the emergency stop switch can be purchased from relyon plasma and installed directly on the power source PS2000.
Gas supply package
The gas supply package includes a moisture filter, oil filter and a particle filter as well as a pre-adjusted throttle. This is the minimum requirement for regulating the gas flow. Please note that the gas supply package is not a flow regulator and therefore does not provide any process control.
Communication Package
The PlasmaBrush PB3 system can be operated as a basic system with one plasma generator PG-31 and one power source PS 2000 or as a multiple system with several plasma and power sources – depending on your individual requirements. In principle, the plasma can also be activated manually via the integrated toggle switch or controlled using a communication package. Various packages are available here.
Communication Package Digital I/O
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The Communication Package Digital I/O enables control via simple I/O signals. The CAN Open signals of the power sources PS2000 are converted into simple I/O signals. This is the simplest way of integrating into your existing automation and system control.
The following parameters can be controlled in this way:
– Plasma (on/off)
– Error messages
– Digital error acknowledgement
– Status enquiry (ready/not ready)
The performance parameters such as frequency setting or power throttling of the power source PS2000 are displayed on the small controller (EATON) and can also be changed here to deviate from the standard if the process requires this.
With the Communication Package Digital I/O, up to two power sources PS2000 and plasma generators PG-31 can be connected and controlled. It also enables the connection and evaluation of a flow sensor.
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Communication Package USB
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The Communication Package USB enables the plasma operating parameters to be controlled and displayed via the PC. The specially developed ‘plasma control’ software is installed and started on the PC. The software connects to the CAN bus of the power source PS2000 via USB using a hardware interface.
The software enables the following parameters to be controlled:
– Plasma (on/off)
– Error messages
– Digital error acknowledgement
– Status enquiry (ready/not ready)
– Power setting of the power source PS2000: Frequency adjustment and power throttling
In addition, the current data is displayed via x-t history and can therefore be easily monitored and analysed. All data can be saved in the standard csv format.
The USB communication package is particularly suitable for use in laboratories and as a test environment, as no integration into an existing system is required.
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Communication Package CAN
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The Communication Package CAN enables the control and display of all plasma operating parameters from your PLC (programmable logic controller). Various PLCs with a CAN bus connection or a CAN bus expansion card can be used for process control. This is the most common type of communication and therefore the ideal solution for complete integration.
The following parameters can be controlled in this way:
– Plasma (on/off)
– Error messages
– Digital error acknowledgement
– Status enquiry (ready/not ready)
– Power setting of the power source PS2000: frequency adjustment and power throttling
In addition, all data such as the temperature sensors can be read out and analysed in full.
With the Communication Package CAN, up to 64 power sources and plasma generators PG-31 can be connected and controlled. It also enables a flow sensor to be connected and analysed.
Integration and programming is carried out by the customer!
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Communication Package ProfiNet
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The Communication Package ProfiNet enables the control and display of all plasma operating parameters from your PLC (programmable logic controller). The plasma system is controlled via your existing ProfiNet network. The CAN Open signals from the power source PS2000 are converted into ProfiNet signals. This is the most modern type of communication and therefore the ideal solution for your own complete integration.
The following parameters can be controlled in this way:
– Plasma (on/off)
– Error messages
– Digital error acknowledgement
– Status enquiry (ready/not ready)
– Power setting of the power source PS2000: frequency adjustment and power throttling
In addition, all data such as the temperature sensors can be read out and analysed in full.
Up to 125 power sources PS 2000 and plasma generators PG-31 can be connected and controlled with the Communication Package ProfiNet. It also enables a flow sensor to be connected and analysed.
Integration and programming is carried out by the customer!
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FAQ
[su_accordion][su_spoiler title=”Which materials can be processed?” open=”no” style=”h2″ anchor=”” class=””]All Materials can be processed. Basically, all materials can be treated with the PlasmaBrush PB3. Conductive materials can be treated particularly effectively due to the transfer of the arc.[/su_spoiler]
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[su_accordion][su_spoiler title=”What is the temperature of the generated plasma?” open=”no” style=”h2″ anchor=”” class=””]The temperature distribution within the plasma flame is between 200 degrees and goes up to 1000 degrees, this differs greatly according to the particular nozzle types.[/su_spoiler]
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[su_accordion][su_spoiler title=”What is the optimum working distance?” open=”no” style=”h2″ anchor=”” class=””]For surface treatment, the optimum distance is typically between 6-25 mm.[/su_spoiler]
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[su_accordion][su_spoiler title=”How fast should I move the PlasmaBrush PB3 over the surface?” open=”no” style=”h2″ anchor=”” class=””]The optimum processing speed is very material-dependent, and can be calculated as a first approximation. Consult our application engineers.[/su_spoiler]
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[su_accordion][su_spoiler title=”What are the operating modes for the PlasmaBrush PB3?” open=”no” style=”h2″ anchor=”” class=””]For ordinary surface activation or fine cleaning to increase the wettability of a surface, the diffuse mode of operation is suitable, in which the plasma interacts with the substrate surface without any further measures. If one wants to remove an organic layer on the substrate, a so-called cathodic cleaning by means of a transferred arc is suitable. By grounding the substrate, the nozzle no longer acts as the cathode, but the substrate itself. Due to the greatly increased intensity of the treatment, thin layers of paint, for example, can be removed.[/su_spoiler]
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[su_accordion][su_spoiler title=”How long does the surface activation last?” open=”no” style=”h2″ anchor=”” class=””]The surface energy will decrease after the treatment on a timeframe of minutes to days. However the surface energy will allways remain higher than the initial value.[/su_spoiler]
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[su_accordion][su_spoiler title=”How can I make the activation effect visible?” open=”no” style=”h2″ anchor=”” class=””]In the simplest case, you will achieve good water wettability (72mN/m), which you can test with a simple water ink. Of course, there are also special test inks for a more precise analysis.[/su_spoiler]
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[su_accordion][su_spoiler title=”Can I overtreat a component?” open=”no” style=”h2″ anchor=”” class=””]Yes, you can cause thermal damage or the surface energy will decrease if the component is overtreated.[/su_spoiler]
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[su_accordion][su_spoiler title=”Can the PlasmaBrush clean components?” open=”no” style=”h2″ anchor=”” class=””]Yes, the PlasmaBrush is ideally suited for cleaning components. With suitable selection of the process parameters, oils, emulsions and release agents are removed.[/su_spoiler]
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[su_accordion][su_spoiler title=”Is a gas supply necessary?” open=”no” style=”h2″ anchor=”” class=””]Yes, operation is possible with industrial compressed air or nitrogen via a standardized Festo hose connection. The operator only has to ensure the appropriate gas flow in the range between 30-70 slm. A Festo MFM (Mass Flow Meter) can be used for this purpose, for example.[/su_spoiler]
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[su_accordion][su_spoiler title=”What power supply does the device require?” open=”no” style=”h2″ anchor=”” class=””]The PlasmaBrush can be operated via a standard household power socket.[/su_spoiler]
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[su_accordion][su_spoiler title=”How often should the nozzle and the electrode be exchanged?” open=”no” style=”h2″ anchor=”” class=””]In normal operation with air, a nozzle change is recommended every 500h. The electrode lasts approx. 1,000h.[/su_spoiler]
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[su_accordion][su_spoiler title=”Is the offered system ESD proof?” open=”no” style=”h2″ anchor=”” class=””]Yes, the A250 nozzle of our PlasmaBrush PB3 system is specifically designed for the treatment of ESD sensitive parts.[/su_spoiler]
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[su_accordion][su_spoiler title=”Can multiple plasma heads be used on one generator or does each head require a separate control unit?” open=”no” style=”h2″ anchor=”” class=””]Each PlasmaBrush PB3 system consists of the high voltage source PS2000 (compact design for integration in 19″ racks), 9 m of high voltage cable (suitable for robots and drag chains) and the plasma generator PG31 (very compact, weighing less than 1 kg).[/su_spoiler]
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[su_accordion][su_spoiler title=”How many different recipes/parameter settings are possible?” open=”no” style=”h2″ anchor=”” class=””]The PlasmaBrush PB3 allows for power as well as frequency setting at the high voltage source. Other important parameter include the choice of nozzle, the choice of process gas (CDA, nitrogen, forming gas, etc.) and the gas flow (35-80 slm).[/su_spoiler]
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[su_accordion][su_spoiler title=”If several recipes/parameter settings can be used: What is the concept to import, load and use different internally stored recipes?” open=”no” style=”h2″ anchor=”” class=””]Since the most important process parameters are speed and nozzle-susbtrate distance we determine these in close coordination with the process owner. If changes have to be made to the parameters of the high voltage source these can simply be accessed via the communication interface.[/su_spoiler]
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[su_accordion][su_spoiler title=”Can recipes/parameter settings be imported via MES or the SPS of the production cell?” open=”no” style=”h2″ anchor=”” class=””]Yes, the PlasmaBrush PB3 system can communicate via CANopen (Standard), EtherCat, Profinet, Profibus, etc.[/su_spoiler]
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[su_accordion][su_spoiler title=”Are different nozzles / different nozzle designs available?” open=”no” style=”h2″ anchor=”” class=””]Three different standard noozle designs are available: A250 for ESD sensitive substrates, A350 for temperature sensitive materials and A450 for high-speed processes. We also offer long-life versions of our standard nozzles.[/su_spoiler]
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[su_accordion][su_spoiler title=”What’s the concept on how to exchange the nozzles?” open=”no” style=”h2″ anchor=”” class=””]Nozzles can be exchanged without tools by instructed personnel.[/su_spoiler]
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[su_accordion][su_spoiler title=”What’s the range of the possible treatment area / width?” open=”no” style=”h2″ anchor=”” class=””]The treatment width of the PlasmaBrush PB3 system ranges between 15 and 25 mm for one pass. Larger widths can either be achieved by the use of additional plasmagenerators or by meandering which is easily possbile due to high process speed and lightweight plasma head.[/su_spoiler]
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[su_accordion][su_spoiler title=”What’s the available power range?” open=”no” style=”h2″ anchor=”” class=””]The plasma jet output ranges from 480 – 770 W.[/su_spoiler]
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[su_accordion][su_spoiler title=”Which process parameters are controlled / monitored / tracked?” open=”no” style=”h2″ anchor=”” class=””]The PlasmaBrush PB3 system allows the control of power and frequency. Via the communication interface of the high voltage source PS2000 power, current and voltage of the plasma jet can be monitored in real time.[/su_spoiler]
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[su_accordion][su_spoiler title=”How is the PlasmaBrush PB3 controlled?” open=”no” style=”h2″ anchor=”” class=””]The standard communication is via CANopen. However, control via USB interface is also possible. We would be pleased to support you with the integration into your plant, e.g. with the control via Profi-Net, Profi-BUS, EtherCAT.[/su_spoiler]
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[su_accordion][su_spoiler title=”Which data can be sent through this interface? Which data formats are available?” open=”no” style=”h2″ anchor=”” class=””]The CANopen project directory is listed in the manual (see page 16-20) and includes object types (VAR, ARRAY, RECORD, etc.) and data types (VISIBLE_STRING, UNSIGNED8, etc.). The .eds-file is included in the scope of delivery.[/su_spoiler]
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[su_accordion][su_spoiler title=”Which process exhaust gases occur during the plasma process?” open=”no” style=”h2″ anchor=”” class=””]The PlasmaBrush PB3 system generates exhaust gases typical for high power jet plasma systems, like NOx and ozone. The quantities are dependent on the process gas. Detailed analysis are available.[/su_spoiler]
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[su_accordion][su_spoiler title=”Was the electromagnetical radiation measured for your system?” open=”no” style=”h2″ anchor=”” class=””]The PlasmaBrush PB3 system is CE certified and complies with all relevant regulations. Both certification and analysis are available.[/su_spoiler]
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[su_accordion][su_spoiler title=”How can the PlasmaBrush be mounted?” open=”no” style=”h2″ anchor=”” class=””]The compact and lightweight (approx. 0.5kg) plasma generator can be integrated into an existing system by means of a simple bracket. We will gladly send you the drawing files for this purpose.[/su_spoiler]
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[su_accordion][su_spoiler title=”What’s the typical size, weight etc. of the plasma system?” open=”no” style=”h2″ anchor=”” class=””]The PlasmaBrush PB3 is a modular system consisting of: high voltage source PS2000 for 19 inch rack (448x343x177,18 kg), high voltage cable suitable for robot and drag chain (9 m) and plasmagenerator PG31 (1 m cable length, 32 mm diameter, 680 g). Please find all relevant data in the manuals attached.[/su_spoiler]
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[su_accordion][su_spoiler title=”How safe is it to work with the PlasmaBrush?” open=”no” style=”h2″ anchor=”” class=””]Do not reach into the plasma flame during operation. The system can easily be integrated into the emergency stop circuit. The resulting emissions must be extracted, for this we recommend a volume flow of about 30m³ per hour.[/su_spoiler]
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[su_accordion][su_spoiler title=”Does the PlasmaBrush PB3 emit UV light?” open=”no” style=”h2″ anchor=”” class=””]Yes, but the UV emission using air is of low intensity and harmless at normal working distances of >200mm.[/su_spoiler]
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[su_accordion][su_spoiler title=”Does the PlasmaBrush PB3 emit dangerous gases?” open=”no” style=”h2″ anchor=”” class=””]Depending on process conditions the PB3 can emit ozone or nitroxides. We recommend to use an active filter or to exhaust the gas load into a hood.[/su_spoiler]
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[su_accordion][su_spoiler title=”Can the PlasmaBrush PB3 cause dangerous electric shock?” open=”no” style=”h2″ anchor=”” class=””]No, the amount of charge and the current are too low to be dangerous.[/su_spoiler]
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Downloads
Plasma generator PG31
| Description | Language | Download |
|---|---|---|
| PlasmaBrush PB3 Flyer | EN | Flyer |
| Plasma Generator PG31 Manual | EN | Manual |
| Plasma Generator PG31 Manual | ES | Manual |
| Plasma Generator PG31 Manual | FR | Manual |
| Plasma Generator Nozzle Change | EN | Nozzle Change |
| PlasmaBrush PB3 Paper | EN | Paper |
Plasma source PS2000
| Description | Language | Download |
|---|---|---|
| PS2000 Manual | EN | Manual |
| PS2000 Manual | DE | Manual |
| PS2000 Manual | ES | Manual |
| PS2000 Manuel | FR | Manuel |
| PS2000 Quick Start Guide | EN | Quick Start Guide |
| PS2000 Quick Start Guide | DE | Quick Start Guide |
| PS2000 Software (eds) | EN | PS2000 Software (eds) |
Communication packages
| Description | Language | Download |
|---|---|---|
| Manual Communication Package CAN | EN | Manual Communication Package CAN |
| Manual Communication Package CAN | ES | Manual Communication Package CAN |
| Manual Communication Package CAN | FR | Manual Communication Package CAN |
| Manual Communication Package USB | EN | Manual Communication Package USB |
| Manual Communication Package USB | ES | Manual Communication Package USB |
| Manual Communication Package USB | FR | Manual Communication Package USB |
| Software Communication Package USB | EN | Plasma control V2.6.1 |
| Manual Communication Package ProfiNet | EN | Manual Communication Package ProfiNet |
| Software Communication Package ProfiNet | EN | Software Communication Package ProfiNet |
| Manual Communication Package Digital I/O | EN | Manual Communication Package Digital I/O |
| Manual Communication Package Digital I/O | ES | Manual Communication Package Digital I/O |
| Manual Communication Package Digital I/O | FR | Manual Communication Package Digital I/O |
Nozzles
| Description | Language | Download |
|---|---|---|
| Data Sheet Nozzles | EN | Data Sheet Nozzles |
HVC Cable Extension
| Description | Language | Download |
|---|---|---|
| Cable Extension Manual | DE | Cable Extension Manual |
| Cable Extension Manual | EN | Cable Extension Manual |
| Cable Extension Manual | ES | Cable Extension Manual |
| Cable Extension Manual | FR | Cable Extension Manual |
| Cable Extension Manual | JP | Cable Extension Manual |
| Cable Extension Manual | IT | Cable Extension Manual |
| Cable Extension Manual | PT | Cable Extension Manual |
