TECHNOLOGY
- Energy efficiency, reproducibility, and repeatability are essential factors in plasma processing, vacuum coating, and thin film fabrication. Automation and digitalization enable you to run, monitor, and interact with processes more conveniently, safely, and with fewer resources. A PLC-based control system can automate all steps of the fabrication process—pre-treatment, fabrication, and post-treatment across vacuum, plasma, or coating equipment, taking advantage of modern control technologies, digitalization, and connectivity.
- A PLC, or Programmable Logic Controller, is a computing device similar to a PC or a smartphone that monitors and controls the operation of industrial machines and equipment. PLCs monitor inputs (such as voltages), and an internal computer makes decisions based on logic to send commands to outputs (like relays) that, in turn, control the machines and equipment. While all PLCs are programmable, they vary from basic to more complex types. Additional computer applications, such as SCADA or cloud-based software, can also monitor PLCs. Recent advancements in PLC technology allow for excellent connectivity and integration with centralized management systems (CMS) and enterprise resource planning (ERP) systems. We exclusively utilize next-generation PLCs, which come equipped with built-in functional safety, cybersecurity features, connectivity to multiple devices or the cloud, and the processing power required for big data analysis.
- PLCs ensure a consistent supply of reliable process data at a sufficient scale to enable digitalization, machine learning, and AI-based autonomous control.
HOW WE APPLY IT
- We provide PLC automation solutions for vacuum treatment, plasma processing, and thin-film deposition systems. With over 15 years of experience in vacuum and plasma process technology, we have a deep understanding of your automation needs. Where necessary our well-established Inteleg® brand products complement and enhance the PLC/HMI by adding advanced process monitoring and control capacity tailored to your specific vacuum, plasma, and coating applications. We deliver optimal solutions and address challenges that range from research equipment to production machines in factories around the world.
- With years of experience, we know key processes like PVD, CVD, PECVD, and ALD, and support technologies such as thermal evaporation, electron beam evaporation, magnetron sputtering, and plasma etching.
CHALLENGE
- Reliability: Vacuum, plasma, and thin-film fabrication processes run time ranges from a few seconds to a few hours, often requiring careful production of multiple layers. Using a PLC to maintain stability throughout the processing cycles is crucial to achieving layer thickness and product property reproducibility.
- Diagnostics: Operating Vacuum, plasma, and thin-film fabrication plants demand advanced diagnostic capabilities. Process monitoring delivers insights into process quality (e.g., compromised gas composition) and stability (e.g., process oscillation) during both commissioning and production. Time trends of process data are available for detailed evaluations of the coating process, which can be utilized for process control and quality assurance.
- Efficiency: PLCs in factory settings significantly enhance both energy efficiency and human resource utilization. PLCs enable precise automation and control of machinery, allowing for optimized operation schedules. By automating repetitive tasks, PLCs free up human resources, enabling workers to focus on higher-value activities such as maintenance, quality control, and process optimization. PLCs facilitate real-time monitoring and data analysis, which help identify inefficiencies in production processes and energy use, leading to timely adjustments that save costs and resources.
- Cost: PLCs are a low-cost solution that enhances operational efficiency and improves productivity. PLCs lower labour costs and minimize human error. Their ability to integrate seamlessly with existing machinery allows for gradual upgrades rather than complete overhauls, which helps in managing expenses. Additionally, Real-time monitoring and data visualization enable quick decision-making and efficient troubleshooting, ultimately reducing downtime and resource wastage. PLC systems are a practical choice for manufacturers looking to enhance their operational capabilities without significant financial burdens.
SOLUTION
- The PLC we utilize is designed for high-performance compact machines. It provides versatile connectivity and exceptional performance, equipping your machine for Industry 4.0.
- The PLC is designed to handle advanced machine automation with a mixture of hardwired I/O and automation bus/communications with devices such as drives, motion, remote I/O and HMIs. The PLC has serial, ethernet and CANopen communication ports as well as USB and SD provisions. It comes with either 24 or 40 I/O points and is expandable with I/O modules to handle up to a few hundred I/O points.
BENEFITS
- Everything you need is embedded
- Fast and easy configuration
- Clear and intuitive operation
- Customised User Interface
- Manual control of individual components
- User-friendly and scalable visualization
- Easy data-logging and reporting
- Stability for time-critical processes
- Process reproducibility and long-term stability
- Automated operation and system health checks
- Dramatic process improvements
- Scrap and down-time prevention
- Connectivity
- Cost efficiency