IEEC - Corona Treatment systems and System Automation

The modular RFG 1 IEEC Corona Generator is a rugged piece that uses latest mixed-signal microcontroller, combined with the latest IGBT technology and PWM self tuning techniques for efficient corona generator output.
HIGHLIGHTS:
• Self tuning facility makes the generator compatible with all types of assemblies to ensure optimal power delivery.
• User-friendly operator panel with multi-functional large LCD displays various process parameters including audio-visual alarms for approximately 10 fault indications. This makes it easy to monitor and ensure minimum down time.
• Option for Constant Output Power or Proportional Output Power to the web speed (Auto / Manual mode).
• Provision for ozone extraction supply with interlocking inside generator panel.
• MODBUS - Rs485 / CAN BUS COMMUNICATION for Remote Control Operation or integrating generator with other systems.
• Rugged, modular design that's safe and easy to install and offers hassle - free operation on 24 x 7 basis.

The modular RFG 2 IEEC Corona Generator is a rugged piece that uses latest mixed-signal microcontroller, combined with the latest IGBT technology and PWM self tuning techniques for efficient corona generator output.
HIGHLIGHTS:
• Self tuning facility makes the generator compatible with all types of assemblies to ensure optimal power delivery.
• User-friendly operator panel with multi-functional large LCD displays various process parameters including audio-visual alarms for approximately 10 fault indications. This makes it easy to monitor and ensure minimum down time.
• Option for Constant Output Power or Proportional Output Power to the web speed (Auto / Manual mode).
• Provision for ozone extraction supply with interlocking inside generator panel.
• MODBUS - Rs485 / CAN BUS COMMUNICATION for Remote Control Operation or integrating generator with other systems.
• Rugged, modular design that's safe and easy to install and offers hassle - free operation on 24 x 7 basis.

The modular RFG 3 IEEC Corona Generator is a rugged piece that uses latest mixed-signal microcontroller, combined with the latest IGBT technology and PWM self tuning techniques for efficient corona generator output.
HIGHLIGHTS:
• Self tuning facility makes the generator compatible with all types of assemblies to ensure optimal power delivery.
• User-friendly operator panel with multi-functional large LCD displays various process parameters including audio-visual alarms for approximately 10 fault indications. This makes it easy to monitor and ensure minimum down time.
• Option for Constant Output Power or Proportional Output Power to the web speed (Auto / Manual mode).
• Provision for ozone extraction supply with interlocking inside generator panel.
• MODBUS - Rs485 / CAN BUS COMMUNICATION for Remote Control Operation or integrating generator with other systems.
• Rugged, modular design that's safe and easy to install and offers hassle - free operation on 24 x 7 basis.

The modular RFG 4 IEEC Corona Generator is a rugged piece that uses latest mixed-signal microcontroller, combined with the latest IGBT technology and PWM self tuning techniques for efficient corona generator output.
HIGHLIGHTS:
• Self tuning facility makes the generator compatible with all types of assemblies to ensure optimal power delivery.
• User-friendly operator panel with multi-functional large LCD displays various process parameters including audio-visual alarms for approximately 10 fault indications. This makes it easy to monitor and ensure minimum down time.
• Option for Constant Output Power or Proportional Output Power to the web speed (Auto / Manual mode).
• Provision for ozone extraction supply with interlocking inside generator panel.
• MODBUS - Rs485 / CAN BUS COMMUNICATION for Remote Control Operation or integrating generator with other systems.
• Rugged, modular design that's safe and easy to install and offers hassle - free operation on 24 x 7 basis.

With IEEC treaters, it is possible to provide excellent treat levels on both sides of the film, even at high speeds depending upon the structure of the film layers.

The IEEC treaters have been specially equipped with fin-type fixed electodes with superior machining.

This is devised after considering the curvature of the roller and the time under discharge (TUD) with respect to material composition and speed.

Segmented electodes are also available for treatment of sealant-specific jobs. The electodes are specially coated for enhancing the elctrode life and reducing corrosion.

The selection of high - grade Silicon Sleeves / Coating with excellent dielectric strength and dielectric constant ensures quality treatment levels at very high speed.

In addition to these features, IEEC Corona Treaters are equipped with online external air gap adjustment, which facilitates in altering the air gap as per the thickness of the substrates.

Extrusion coating applications involve a large variety of substrates that are used for lamination. These include: Paper, Aluminum Foil, Metallised Polyester, MET OPP, PE, PP, Metallised Paper.

With a widechoice of substrate material, naturally the coating process asks for equivalent versatility in substrate treatement. The IEEC Corona Treater offers a perfect solution to this process.

IEEC's Ceramic Electode technology allows a variety of materials to be treated even a t extermely high line-speeds. This is possible only with IEEC's Ridge Profile Ceramic Electodes.

The specially designed idge profile ceramic electodes help in treating substrates with the highest discharge efficiency. In addition, IEEC Corona Treaters are equipped with online external air gap adjustment, which facilitates in altering the air gap as per the thickness of the substrates. IEEC gurantees superior and strong bonding at high machine speeds.

For applications where corona treaters need to be placed in close proximity with hazardous inflammable coatings, it is essential to pressurize the corona treater.

This is where IEEC Corona Treater with pressurization facility comes into play. It ensures that no hazardous vapors / fumes are generated in the corona treating station.

With a differential pressure maintained between the positive purging and the negative exhaust, the vapors are blocked on entry of the corona treating station. Sufficient interlocking is provided at the treating station. thus making the system to suit the purpose.

In order to treat 3 Dimensional objects IEEC has introduced 3D Jet Corona. This treater works on a plasma principle where in a jet of plasma helps in enhancing the surface tension of the substrate. This would be typically used for the Bar Code printing application, Inkjet printing application, Pad Printing etc where the spot treatment of the substrate is required.

In the context of lamination, corona treatment serves as a kind of surface treatment for plastic films, where normal surface tension is not enough to permit good wetting. In the case of lamination, better bonding between two or more materials is required. The process of corona treatment makes the film receptive to lamination by providing molecular changes in the surface of the film. It is also observed that corona treatment reduces the curing time in case of solvent-less laminatino applications.

With IEEC treaters, irrespective of the lamination processes, be it solvent less or solvent based, excellent treat levels can be achieved, thereby increasing the donb strength between the laminates. This can be achieved only with IEEC'S Ridge Profile Ceramic Electodes. IEEC guarantees superior bond strength even at high machine speeds. The specially designed ridge profile ceramic electrodes help in treating substrates with the highest discharge efficiency. In addition to these features IEEC Corona Treaters is equipped with online external air gap adjustment that helps in altering the air gap as per the thickness of the substrates.

While all applications are unique, most narrow web applications are best served with IEEC’s narrow web width Corona treater. These systems are ideal for applications up to 400mm web width. With unique IEEC’s Ridge profile ceramic electrodes, conductive as well as non-conductive substrates can be treated at high speeds.

IEEC systems eliminate the need for a dielectric covering on the treater roll. This saves you money since a spare dielectric roll is not required. Narrow web systems are available in a variety of configurations depending on your application requirements.

For high-speed priting machines to have better printability, it is necessary to have corona treatment. The corona treatment is essential for refreshment of treat levels of substrates. As printing machines are universal for printing of both, conductive as well as non-conductive substrates, it is important for the corona treater to be universal, too.

This is where IEEC's Ridge Profile Ceramic Electrodes comes into picture. IEEC gurantees superior printability even at high machine speeds. The sprcially designed Ridge Profile Ceramic Electrodes help in treating substrates with the highest discharge efficiency. In addition to these features, IEEC Corona Treaters are equipped with online external air gap adjustment, which facilitates in altering the air gap as per the thickness of substrates.

IEEC introduces its state of art corona treatment systems for the treatment of sheets of higher thickness up to 7mm. The material can be both conductive as well as non conductive. IEEC corona treatment ensure excellent dyne levels at reasonably good speeds.

Wide Web Treaters are mainly used by extrusion film plants manufacturing BOPP, BOPET, BOPA, CPP, Lamination plant and slitting machine for high-speed application. IEEC treaters are specially designed with rugged frame structures.

The electrodes are custom-desinged to match this requirement. The electrodes are specially equipped to accommodate thermal expansion, thereby preventing the deformation across the web widths. Also, the geometry of electodes helps in deliverying good power oefficeients for the treatment of materials that are difficult to treat.

IEEC's special ridge profile ceramic electrodes help in achieving a good uniform corona discharge at an optimum power. These electrodes are fabricated with special metal strips unlike the metal powder filled elctrodes. Also the wider surface to which the potential is applied, helps in increasing the dwell time of the film under dircharge, thereby achieving good treatment levels.

The electrodes manufactured by IEEC are designed taking into consideration the output power to be delivered, Wrap angle of the film onto the treater roller and the time under discharge of the film so as to have a great treatment lelvels with high generator efficiency. These electrodes are machined with the help of computerised Numerical controlled machines taking into consideration tight design tolerances.

The IEEC corona generator can communicate with various touch screens available in the market the touch screen acting as modbus master communicating with rs485 and the generator panel as slave. Some of the sample front pages of the touch screens are as follows

DSI8000- SSD PARKER 10.4 INCHES TFT DISPLAY.
MODEL: TS8010

MONITOUCH HAKKO TOUCH OPERATION FLAT PANEL
MODEL: V606Ec20

The operator can control the operations of the generator panel from a remote location, setting all the required parameter details, with alarms and the fault diagnostic screens for fast fault finding and lower downtime

The main screen changes to the fault screen as soon as the fault occurs flashing the type of fault and the diagnostic help. As shown below in the two examples of assembly open and low speed of the treater backup roller.

In corona treatment the film is passed over the roller through the air gap between the fixed electrode and the dielectric whereby the film is exposed to a very high voltage potential at a very high frequency, which causes ionization of air. The equipment used to achieve this comprises of a generator, which converts the available 230V / 415V, 50Hz power supply a high voltage transformer and the treating station itself. Now under the influence of the electric field, the ionized air molecules are made to move about. As the electric field increases, so does the speed and hence the kinetic energy of the ionized air molecules. The random collision of these ions with other charged ions result in increase in the number of ions. Thus when sufficient electric field is developed, then the air gap can be said to have broken down into an ionized current carrying conductor. During this process the atmospheric oxygen is broken down into nascent oxygen and Ozone.

2O2 ---> O + O3

The ozone is extracted out of the system where as the active nascent oxygen immediately oxidizes the film.

Detailed process in the attached pdf

FREQUENTLY ASKED QUESTIONS

What is Corona Treatment: -
In corona treatment the film is passed over the roller through the air gap between the fixed electrode and the dielectric whereby the film is exposed to a very high voltage potential at a very high frequency, which causes ionization of air. The equipment used to achieve this comprises of a generator, which converts the available 230V / 415V, 50Hz power supply a high voltage transformer and the treating station itself. Now under the influence of the electric field, the ionized air molecules are made to move about. As the electric field increases, so does the speed and hence the kinetic energy of the ionized air molecules. The random collision of these ions with other charged ions result in increase in the number of ions. Thus when sufficient electric field is developed, then the air gap can be said to have broken down into an ionized current carrying conductor. During this process the atmospheric oxygen is broken down into nascent oxygen and Ozone.

2O2 -------> O + O3

The ozone is extracted out of the system where as the active nascent oxygen immediately oxidizes the film.

How do you size a corona treatment system?
1)Determine the type of basic material to be used onto which the corona treatment is to be done.
2)Specify whether the film is to be laminated / coated/ printed with which type of ink/covering also specify the initial dyne level of the film and whether the film is to be treated single side or double side.
3)Specify the maximum web speed (meters per minute) and maximum web width (mm).
4) Specify the maximum and the minimum thickness of the web.
5)Specify the basic electric supply and the variation.

How do you determine the generator power required?
Referring to the graph below, the power faction ( w/m2/min) is calculated.

Generator power required (KW) = Line Speed (m/min) x Treat width (m) X Power factor (w/m2/min) x no of sides
1000

Finally taking into consideration the operating conditions the corona treater should be designed in such a way that the systems is of robust design and operator friendly.

What are the consequences of Over/Under Treatment Of the Film?
For better post Treatment results the film, surface energy should be adequately optimized. In case of over treatment which is quite possible in case of PE substrates during the extrusion process, Blocking of the film may take place which would then hamper the subsequent unwinding and tension controlling process. Also over treatment reduces the heat seal ability of the film incase the treated side need to be sealed with some other substrate.

In case of under treatment the film may have low wet ability and correspondingly low dyne levels which would then cause ink peeling in case of printing or delamination in case of lamination process.

How do you avoid over/under treatment of the films?
Over/under treatment of the films can be avoided by selecting appropriate resins which specific slip additives. During extrusion process, start the production with lower speed, keeping low power of treatment. Establish the treatment level for that particular speed, width, composition of the films. Once this watt density is achieved then correspondingly increases the power output.

How can the dyne level of the Treated / Non treated Substrates be determined?
Although dyne testing pens are easily available in the market, the better way of testing the dyne level of the substrates would be, by using a freshly made uncontaminated dyne solutions.

What is the acceptable treatment level for good printing?
Basically printing is an adhesion phenomenon between the substrates and the ink. It is not easy to determine the surface tension of the inks. The basic thumb rule should be that the surface tension of the Substrate which is to be printed should be 7 dynes/cm higher that that of the ink which is to be applied.

What is Back Side Treatment? How can it be avoided?
During high speed treatment process, if the substrate wrap angle is less than 180 degrees then because of the venturi effect, a differential pressure sets in which tries to lift us the substrate from the roller. As a result of this air, beneath the substrate also gets ionized and the opposite side gets treated which sometimes is not desirable incase of heal seal application. Also back side treatment can be caused, if the surface of the roller is kept unclean or if there are dents or pits formed onto the surface of the roller due to corrosion. Backside treatment can be avoided by using a nip roller at the entry of the film onto the Treater roller which ensures that a good wrap angle is established between the substrate and the treater roller. Also the surface of the treater roller needs to be kept clean at all times to prevent the unwanted backside treatment.

Is web tension essential in corona treatment application?
Improper web tension can lead to wrinkles in the substrate which in turn would lead to the undesired back side treatment. Also if proper web tension is not maintained, the wrap angle of the Substrate with roller gets hampered.

How can a Corona Treater be maintained?
General preventive maintenance schedule needs to be followed as instructed in the operation manual. Also incase of universal treater where in ceramic electrodes are used, proper cleaning and maintenance of these electrodes is essential. The electrodes and the electrode holding blocks need to be cleaned with the help of Acetone/Iso Propyl Alcohol solutions. Improper maintenance of the ceramic electrode can lead to premature failure or cracks. Also ensure that the Ozone extraction system is properly maintained and a good negative static pressure is maintained in the ducting chamber. Proper cleaning of the Treater roller is essential to prevent corrosion or contamination with the external dust or foreign particles.

INTRODUCTION:
In the recent years, IEEC has proved themselves as one of the leading manufacturers of high voltage high frequency pinning unit generators which are used for contactless nipping in BOPET, BOPA and BOPS plants. Extremely low ripple, very fast recovery and high frequency operation with latest IGBT technology has made it to establish unparallel reputation in the global market of BOPET, BOPA and BOPS films.

IEEC PINNING UNIT:
IEEC Pinning unit helps in achieving greater chill roll speed thereby increasing the productivity. It also helps in achieving excellent clarity of the film and also enhanced film characteristics. In the voltage control mode, the ripple factor is less than ± 0.05% RMS of the rated voltage which improves the pinning quality tremendously. With the current control mode of operation, the consistency of pinning can remain constant. With provisions to select either of the above modes the line speed can be effectively increased to provide higher output without lowering the quality of the film.

SPECIFICATIONS:
•Supply Voltage: 230V AC ± 5%
•Supply Frequency: 50 HZ ± 5%
•Output Voltage: 5 to 15 kV DC
•Output % ripple: Less than 0.05% RMS of rated voltage
•Output recovery time: Less than (2)mSecs
•Maximum output current: 30mA
•Current limit action: 1 to 20 mA adjustable
•Inverter frequency: 30 KHz

INDICATIONS IN MMI:
•Digital Output DC voltage
•Digital Output mA

CONTROLS
•START / STOP
•Voltage Set
•Current limit set
•Provisions to operate in voltage control or current control modes

PROTECTIONS
•Intermittent short circuit trip with auto start & indication for trip
•Force auto cooling instrument fan
•High temperature trip for heat sink
•Fuses

ALARMS
•Audio Hooter
•Motorized Flasher

PINNING WIRE HEATING:
The pinning wire heating system is an additional attachment for the existing pinning system. During polyester extrusion process oligomers get accumulated on pinning wire and pinning quality deteriorates. To avoid plant stoppage, the oligomers need to be melted by heating the wire by passing constant ripple free DC current.

SPECIFICATIONS:
•Supply Voltage: 230V AC ± 10%
•Supply Frequency: 50 HZ ± 5%
•Output Voltage: 0 to 50 Volts DC
•Maximum output current: 10A
•Inverter frequency: 20 KHz
•Output voltage isolation: 30 kV DC

INDICATIONS IN MMI:
•Output DC voltage
•Output Amperes

CONTROLS
•START / STOP
•Voltage set
•Current set

PROTECTIONS
•Force auto cooling instrument fan
•High temperature trip for heat sink
•Fuses

ALARMS
•Audio Hooter for wire break

In Flexible packaging industry, maintaining precise tensions of the substrates at the uncoiling end is very most important. This can be achieved by integrating Thyristorised DC drives or a variable frequency drive. It can also be achieved by using Magnetic Particle brakes/Pneumatic brakes, a pair of load cells and a micro processor based tension controller.

Designed specifically to provide extremely accurate web measurement of web tension so that running tension corrections can be made (for example, using the Digital Tension Controller). These Strain Gauge based Tension Sensors are available in multiple load ratings of 25Kgs, 50 Kgs, 100 Kgs, 150 kgs, and 200 kgs ratings, with or without flange mounts. They are ruggedly constructed, robust units specifically designed to endure production environments. The units have excellent thermal linearity and hysteresis characteristics and dual sealing.

TENSION SENSORS:
The flange mounted range of load cells are designed to be mounted directly onto the ends of the tension measuring roll and are able to indicate with high precision the resultant tension forces being applied. The commercial success of this model, designed for tension control with laminates, is due to the combination of its compact size which allows its use in confined spaces, and it’s very high level of quality and reliability.

Typically when the torque limitations exceed above 25 Kg-m Pneumatic brakes offer excellent and precise tension to the substrates. With the specially designed brake pads and with efficient cooling of the discs uncoiling of thick substrates such as Aluminum foils and paper becomes an easy task. These brakes come in the sets of 4-Pads, 6-pads, 8-Pads, 12 Pads systems. The Feed back to these brakes are given by IEEC’s highly intelligent micro processor based tension controllers which gets the signal from the tension sensors. This close loop systems keeps the precise tensions in the uncoiling of the substrates.

TENSION CONTROLLERS:
The fully solid-state version is specially designed for Electromagnetic power brakes. Depending upon the difference between required tension as set on the “Tension Set potentiometer” and actual value as measured by the load cells, the magnetizing current of the electromagnetic powder brakes is controlled by this tension controller such that the difference is made negligible. With the unique PID control action, the tension controller provides the smooth and steady closed loop control of tension.

The electromagnetic Powder Coupling combines the resilience of a fluid coupling with the locked-in stability of a friction clutch. Torque is transmitted by a specially alloyed dry ferromagnetic powder, the apparent viscosity of which may be changed by modulation of the field coil current . The couplings can sustain continuous slip (within their empirically estabilished heat ratings) at a precise and stable torque value, which is determined by excitation level.

Slip between input and output members is not necessary in order to transmit torque, and provided load torque does not exceed the torque for which a unit is excited to transmit, locked-in synchronous operation will take place. Conversely, if load torque exceeds the energised torque level, slip will occur in an absolutely smooth manner at the predetermined torque value. For all practical purposes, static and dynamic coefficients of friction are sensibly equal, also, output torque is independent of speed, or slip speed. Powder performance is unaffected by temperature rise at the working surfaces, and couplings will, at all times, have the characteristic that transmitted torque is directly proportional to current. It should be noted that use of a dry powder rather than a fluid-suspended powder medium promotes consistency and accuracy of torque control.

Briefly, the coupling comprises two concentric members, the body or input member containing the field coil, and within it, and separated by a small annular gap, an inner rotor, or output member. The annular gap contains a ferromagnetic powder which is activated when the coil is energized. The resultant flux which is generated, passes through the powder, causing it to align with the flux path, and thereby creates a driving bond between input and output members, the strength of which is solely determined by the value of d.c. current applied to the field coil.

IEEC make Hot runner systems continue to gain popularity in injection molding. A hot runner’s main advantages are speed and yield: reducing cycle times, achieving better part quality thanks to tighter control of temperature and pressure, generating less scrap and no material waste from the sprue and runner system.
The key parameters that make up good temperature control are:
• Temperature measurement: The best results require the measurement to be fast, accurate and free of any noise component.
• Output power calculation: The best results require the parameter values used in the control algorithm to match the process time
constants for each zone.
• Delivery of the output power: The best results require the best resolution of the output power over the shortest time period.
One of the fundamental criteria of IEEC Hot Runner Temperature is controlling the temperature as accurately and consistently as possible with respect to the required process setpoint

Having developed India’s first Solid state temperature controller way back in the year 1969,IEEC’s Temperature Controllers have a reputation for high accuracy. Our temperature controllers are know for fast, precise, reliable measurement of temperatures.

PBJ Temperature Controller includes one sensor input that supports a PR100, or thermocouple sensor.

PBJ sensors are intrinsically safe and immune to electromagnetic interference. These systems operate within a -200°C to 500°C range. IEEC sensors key applications can be done in plastic extrusion, packaging, R&D, chemical sample digestion, power transformers to help eliminate overheating, reducing power outages and ensuring operation within safe load limits. IEEC sensors and thermocouples are chemically inert and are unaffected by extremely high voltages, magnetic fields and high temperature caustic oil baths.