plasmabrush® PB3 – High-performance system
High-performance atmospheric plasma system
plasmabrush® PB3 – High-performance plasma system
Our plasmabrush® PB 3 is a high power plasma system with Pulsed Atmospheric Arc Technology, for applications that require high performance and rapid processes. Perfectly coordinated components in robust industrial design: 19-inch high power voltage supply PS2000 and plasma generator PB3, connected through a flexible 10m cable for easy integration into every facility.
Thanks to many years of experience in arc load dynamics, fluid mechanics and power electronics, we have developed an atmospheric plasma system which is unique concerning its power density and function. Easy integration into industrial processes and ability to communicate were at the focus throughout the entire development of this universally applicable plasma unit.
Whether in precision cleaning or surface activation, whether in coating or sterilization processes: Our plasmabrush® PB3 fits every process environment – secure and reliable.
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Field of applications
- 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
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
- Compact Design
- Easy Integration
- Suitable for compressed air, nitrogen and other gases
- Variable Power
- High start-stop dynamics
- Maximum operating reliability
Customer references
Technical information
- Flow range 25 to 80 L/min
- Cable length 10 m
- Weight plasma generator 680 g
- Diameter plasma generator 32 mm
- Gas connector 6 mm
- Treatment speed 0,1 – 2 m/s
- Typical treatment distance 10 – 25 mm
- Typical treatment width 15 – 25 mm
Nozzles
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
Copper nozzles
Nozzle A 250
Field of application:
– 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
Although the copper nozzles 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. Last year, 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.
The nozzles on the picture had a burning time of 400 hours at the time of the photo the left picture shows a standard copper nozzle and the right one a copper nozzle with nickel plating
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.
*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.
Carbide nozzles
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.
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
Manifold application options for high power plasma systems
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.
Technical information
- Input voltage 220 – 240 V AC, 50-60 Hz
- Max. input current 6A
- Weight 18 kg
- Power 0 – 1,000 Watt (variable)
- Open circuit voltage up to 20 kV
Systems
Our plasmabrush® PB3 system can be operated as a basic system with one plasma source and high voltage source as well as a multiple system with several plasma and high voltage sources – according to your individual requirements:
plasmabrush® Basic System
Start the plasma process reliably and easily by the simple push of a button with preset operating parameters. All you need is a dry compressed air supply with adjustable system pressure.
Installation:
- PS2000 high voltage supply
- PB3 plasma generator equipped with fixed choke
- Air supply with constant pressure setting
- Optional gas supply package
Information: Simplified functional scheme
Connect your PS2000 to the main supply. Then adapt the air flow via your system pressure. A constant flow will be provided when using a throttle valve dependent on the system pressure. Ignite the plasma flame by pressing the button at a preset value of frequency and power.
plasmabrush® Multiple System
In a modern production environment, several plasma channels can be integrated intelligently and connected to any control solution you choose. We have developed flexible solutions for Siemens, Allen-Bradley/Rockwell, Beckhoff and equivalent control systems. Each of these manufacturers offers a CAN module. Simply download our driver (universal EDS file) and thus gain full process control in your system environment. Your system can be connected to easily, no matter the SPS manufacturer.
Installation
- PS2000 high power supply
- PB3 plasma generator
- Adjusted air supply
- Host controller
- CAN bus for PLC
Information: Simplified functional scheme
All processes are controlled via CAN bus by addressing up to 127 channels simultaneously. Thus, air pressure or gas supplies can be integrated without any difficulty. This system makes it very easy to monitor mass flow of air or any process gas mixtures. The entire system intelligence is implemented into the central control.
Communication Systems
For our plasmabrush® PB3 plasma system you can add different communication packages:
Digital Communcation System
All you need is a dry compressed air supply with adjustable system pressure and our small-sized I/O control. Your system is controlled using simple I/O signals from your facility. This solution works for several plasma channels simultaneously as well.
Installation
- PS2000 High Power Supply
- PB3 Generator equipped with preset valve
- Air supply at a constant pressure setting and magnet valve
- Digital I/O Communication package
Information: Simplified functional scheme
The first step is to set the inlet pressure at the air supply. This can be done, for example, via a simple solenoid valve. The fixed throttle valve on the plasma generator PB3 adjusts a constant flow according to the fixed characteristic curve. The performance parameters of the PS2000 are displayed on the small controller (EATON) and can also be changed here.
USB Communication System
In this system configuration, all plasma operating parameters can be controlled as well as displayed on a PC, which also makes it ideal as a test environment for technical service and customer service. Our program with its clear layout lets you comfortably connect to the PS2000 CAN bus via USB. All you need is a dry compressed air supply with adjustable system pressure, a Windows PC with USB port and our USB/CAN converter.
Installation
- PS 2000 high power supply
- PB3 plasma system supplied with fixed throttle
- Air supply with constant pressure adjustment
- PC with control and visualization adjustment
- USB interface for PC
- Optional gas supply package
Information: Simplified functional scheme
The first step is to set the inlet pressure at the air supply. The fixed throttle valve on the PB3 plasma generator is used to set a constant flow rate in accordance with the fixed characteristic curve. The “plasma control” software is installed and started on the PC for process control and visualization. The “plasma control” software uses a hardware interface to establish communication via USB to the CAN bus and enables the performance parameters of the PS2000 to be set on the PC. In the operating window of the software, the current data are displayed in x-ton format and can be saved in the common .csv format.
CAN Communication System
In this system configuration, all plasma operating parameters can be controlled and displayed on a PLC, which also makes it ideal as a test environment for technical and customer service or for use with different lots in in-line production.
Installation
- PS2000 High Power Supply
- PB3 plasma generator with fixed throttle
- Air supply with constant pressure adjustment and preset valve
- Superior PLC
- CAN Interface for PLC
Information: Simplified functional scheme
First, the system pressure is set at the air supply. About a permanently set throttle valve on the plasma generator PB3 is set according to the solid curve a constant flowrate. For process control, different PLCs can be used which have a CAN-Bus interface or a CAN-Bus expansion card. The integration is supplied by the customer.
ProfiNet Communication System
All you need is a connection for dry compressed air with adjustable inlet pressure and our ProfiNet communication package. You use it to control the system via the already existing ProfiNet network. The solution works for up to 125 plasma systems.
Installation
- PS2000 High Power Supply
- PB3 plasma generator with fixed throttle
- Air supply with constant pressure adjustment and preset valve
- ProfiNet communication system
- Existing ProfiNet network
Information: Simplified functional scheme
The first step is to set the inlet pressure at the air supply. This can be done, for example, via a simple solenoid valve. Via the fixed throttle valve on the plasmabrush® PB3 plasma generator, a constant flow rate is set according to the fixed characteristic curve. The performance parameters of the PS2000 high-voltage source are transmitted to the higher-level control system via the ProfiNet system. An adjustment of the parameters is thus possible, as well as the output of error messages and the resetting of the system.
