Plasma Treatment Installation Segmentation for Utilization
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Solution Overview
Problem
Existing plasma treatment installations have low utilization levels due to the manual and time-consuming process of charging workpieces into workpiece carriers, which requires complex system technology and does not significantly reduce time effort.
Innovation Solution
A plasma treatment installation with at least two workpiece holders, each with a hood to form a sealed treatment space, where one holder is equipped with workpieces by a manipulator, allowing for alternating use of hoods and auxiliary devices like threading stations, to enhance the utilization of the manipulator and reduce effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual charging of workpieces into workpiece carriers is used, then operation simplicity is maintained, but productivity is reduced due to low utilization level
Solution Approach 1:
The installation is divided into multiple workpiece holders (at least two), each with its own hood forming separate plasma treatment spaces. This segmentation allows parallel processing of different workpiece batches, enabling one holder to be charged while another undergoes treatment, thereby improving productivity without requiring overly complex automated systems.
Solution Approach 2:
Workpieces are charged into workpiece holders outside the plasma reactor in advance, before treatment begins. This preliminary charging action separates the loading process from the treatment process, allowing the manipulator to focus on treatment operations while charged holders are ready for immediate processing, thus improving utilization level.
2Loss of time
If manual charging outside the reactor is used, then device complexity is reduced, but loss of time increases due to lengthy charging process
Solution Approach 1:
Multiple workpiece holders enable parallel operations where charging of one holder occurs simultaneously with treatment of another. This time overlap reduces the total charging time impact on production cycle, addressing the time loss issue without requiring complex in-reactor charging mechanisms.
Solution Approach 2:
The manipulator acts as an intermediary that efficiently transfers workpieces between holders and plasma treatment zones. By using a manipulator for charging operations, the system achieves faster and more efficient workpiece handling compared to purely manual methods, reducing time loss while avoiding the complexity of fully automated in-reactor charging systems.
3Productivity
If a single workpiece holder is used, then device complexity is minimized, but productivity is limited due to sequential processing
Solution Approach 1:
The installation uses at least two workpiece holders that can be independently charged and treated. This segmentation allows the manipulator to handle multiple holders in a systematic sequence, improving productivity through parallel processing while maintaining operational simplicity through standardized handling procedures for each holder.
Solution Approach 2:
Each workpiece holder is designed with universal features including a base adapted for sealing connection with hoods and standardized workpiece receiving capabilities. This universality allows the manipulator to handle all holders using the same operations and procedures, improving productivity without significantly increasing ease of operation complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution increases the utilization level of the plasma treatment installation by enabling efficient handling and processing of multiple workpieces with reduced technical effort, utilizing a manipulator to manage multiple plasma cells and auxiliary tasks, thereby optimizing the installation's operational efficiency.
Implementation Method 1
plasma treatment installation with workpiece holders for receiving workpieces to be subjected to a plasma treatment
Data Source
AI summary
A plasma treatment installation including at least two stationary workpiece holders adapted for controlled rotation about their respective axis and having supporting plates for supporting workpieces for the treatment thereof, at least one hood to be set on a workpiece holder that is adapted to enclose each of a plurality of workpiece holders to form a sealed treatment space, and a manipulator for automatically equipping the supporting plates of a workpiece holder with workpieces, while the other workpiece holder is covered by the hood to perform the plasma treatment of the workpieces.