HOPEWELL Glass industry

  • hopewell vacuum magnetron sputtering glass coating system

    technical parameter Technical Parameter:

    The coating line is mainly used for the automatic production of glass vacuum coating and the control system is mainly used for the automatic control of the production line. The electrical control system of the production line adopts the SCADA structure. The controller uses Rockwell / Allen-Bradley‘s Logix 5000 platform, a set of Beckhoff motion control system and SEW servo drives and motors to complete the movement control of the glass. Each sputtering section is equipped with an independent Logix 5370 control system. The molecular pump uses Devicenet bus and Logix 5370 for communication. Within the molecular pump station, Logix 5370 and the server uses optical fiber Ethernet for communication; The cathode uses upper air supply, the MFC and power supply of cathode uses Devicenet bus and Logix 5370 for communication, within the cathode position, Logix 5370 and the server uses optical fiber Ethernet for communication. The vacuum system is equipped with three sets of Logix 5380 to control the vacuum pumps, butterfly valves, gate valves, and vent valves in the entrance section, sputtering section, and exit section respectively. The Logix 5380 and the server use optical fiber Ethernet to communicate. Befu soft PLC system is mainly used for  the automatic control of glass transmission of the entire line, and realizes the accurate control of glass transmission.
    According to function, the entire control system can be divided into host computer SCADA system, MES system, transmission system control, molecular pump position control, cathode magnetron sputtering control, vacuum bleeding system control, and cooling water circulation system, cold trap and front cleaning machine, loading and unloading table control and communication, system Safety interlock control, power distribution system, etc.. Among them, the cooling water circulation system, the loading area(including the front cleaning machine) control system, the unloading area control system, the cold trap, etc. are independent control systems, they can complete the control function of the corresponding area, this control system and the above-mentioned independent control system can achieve communication, implement monitoring, synchronous linkage.
    ·Glass transmission system: Through transmission servo motor of the control line, transmission of glass has smooth transmission as required.
    ·Vacuum acquisition system: the required vacuum of the line is obtained by controlling various vacuum pumps and air valves.
    ·Magnetron sputtering system: The magnetron sputtering process is realized by controlling cathode power supply, cathode and working gas.
    ·Safety interlocking system: interlocking protection control is adopted for important equipment and large-power equipment such as servo motors, vacuum pumps, etc..
    ·Visual inspection system: defective products is eliminated through inspecting the appearance of glass with industrial cameras.
    ·Cooling system: Cooling cathode, vacuum pump and power supply.
    ·Compressed air system: supply compressed air for pneumatic components.
    ·Loading / unloading system: assisting the loading and unloading of glass.
    ·Cold trap system: Capture condensable vapors from the vacuum chamber and reflux vapors from the vacuum pump to increase vacuum degree and protect the vacuum pump.
    ·SCADA system: Configuration of the entire production line system: the operator can use the human-machine interface to monitor the entire glass coating line.
    ·MES system: using the feedback of site data from the system: allocate production resources efficiently and guide production reasonably.
     Hopewell vacuum magnetron sputtering glass coating system network topology
    ·Two servers are hot standby for each other, it collects data from PLC and controller on site and provide data services for each subsystem.
    ·Multiple operator stations which are equipped with SCADA system and MES system.
    ·The engineer station is equipped with debugging software for on-site equipment to facilitate the engineer's debugging and maintenance of the system.
    ·Enterprises can install enterprise management stations equipped with MES systems based on its need, and on-site data and production reports can be easily checked and production can be arranged reasonably .
    ·PLC and controller on site can access to the server via Ethernet, where the PLC of sputtering system accesses to the server through optical fiber, avoid interference of the high frequency power supply on site effectively.
    ·The Beckhoff controller of the glass transmission system communicates with the servo drive by using the real-time EtherCat bus.
    • The glass transmission system and the vacuum system need real-time interactive data in production. The four controllers of the two systems use Ethernet EtherNet/IP protocol for communication.
    • On-site equipments are using DeviceNet network for communications.
    • Having Reservaction of communication interface,  it’s suitable for a variety of mainstream communication protocols, peripheral auxiliary system can have seamless access.

    Characteristics of Hopewell vacuum magnetron sputtering glass coating system
    · Using DCS and SCADA technology, the control risk is dispersed, quantity of the data exchange is reasonably dispersed, the control function is more modularized and rationalized, and it nearly has unlimited expansibility.
    · Multiple control options and flexible control of production lines in various situations.
    ·Reasonable system design. The coating system is divided into various subsystems. Each subsystem can be independently controlled. Even if a failure occurs, it can minimize losses and failures can be checked and repaired quickly.
    • It’s equipped with the MES system, that is, the production process execution system, it can efficiently allocate production resources and guide production reasonably.
    ·It’s equipped with the security interlock function. The security connection is divided into hardware interlock and software interlock. When the system detects that the abnormity, it will start the protection program and protect the equipment.
    ·Communication of Field-bus uses optical fiber to avoid electromagnetic interference of medium and high frequency power supply in the site, which improves the reliability of the system.
    ·The system design applies various anti-noise technology, including photoelectric isolation, high common mode rejection ratio, reasonable grounding and shielding.
    ·The construction layout of the electric bridge frame is reasonable, the cable wiring is neat and clean, the electric cabinet are with mark and sign, and label of the cable are complete. The installation on site is beautiful.

    Hardware Configuration of Hopewell's Vacuum Magnetron Sputtering Glass Coating System
     The entire hardware control system consists of server/network cabinet, operator station, molecular pump control cabinet, cathode control cabinet, Beckhoff soft PLC control cabinet, MCC cabinet, pump control cabinet in inlet area, sputtering pump control cabinet, pump control cabinet in outlet area, Industrial Ethernet, fieldbus network And so on.
       Each PLC controller station completes various analog control, program control and data acquisition functions of the coating production line to meet the performance of various operating conditions and ensures the engineering safety and efficient operation of the system. The design of the Logix 5000 platform will use the card level self-diagnosis function to have high reliability. About the structure of SCADA, the systems are completely independent, the control risk is largely reduced, and the systems directly exchange data with the server. The interface data refreshing rate can be guaranteed within 500 milliseconds. Long distance communication and field with medium frequency interference require using optical fiber and fieldbus to reduce signal interference and improve the reliability of electrical performance. The system is equipped with five industrial control computers as operators’ and engineers’ stations, and five 54-inch liquid crystal displays. Using the server/client structure, each control system communicates only with the server via Ethernet, the client(operator station) and the server, and the server offers redundant hot standby.
    The system has a portable handheld wireless monitoring system. Operators and maintenance personnel can monitor the equipment next to it.
       The system has a WEB release that allows to monitor field operations and production summary reports through the World Wide Web, it supports mobile/mobile communication devices.
       The UPS uses the uninterrupted power supply system of the US APC company, the electrical control element uses the Schneider / ABB low-voltage electrical element, the servo drive control device uses the SEW series products, and the glass inspection tentatively uses the transparent glass reflection sensor KQ6002(IFM brand). The wiring terminal uses the Phoenix / Wago brand, the industrial plug-in adopts the Germany Harting brand, the cable adopts the domestic national inspection free product, and the remaining auxiliary components are from joint ventures or brands of well-known domestic manufacturers to ensure the reliability of the control system. All external devices need to be connected to the system through a separate terminal. All DO outputs should be isolated by relays. DI/DO rich points need to be done well with relays and connecting terminals.
       The control cabinet uses the Rittal cabinet system, and the AE series cabinets are used in the molecular pumping position/cathode position, using water-cooled methods. Server cabinet, vacuum suction cabinet, transmission control cabinet adopts Rittal TS8 cabinet, adopts special cabinet air conditioning. The Busbar system uses the Rittal SV/Woehner busbar system.
    Hopewell vacuum magnetron sputtering glass coating system technical parameters
    Standard Glass：
    		 2800mm X 4880mm
    Large panel glass： 2800mm X 7000mm
    Glass thickness:
    		 3-19mm
    Single silver speed：
    		 22second
    Double silver speed：
    		 30second
    Three silver speed：
    		 60second
    Transmission Precision：
    		 0.05mm
    Length per pot：
    		 4940mm
    Pot distance：
    		 30-50mm
    Maximum sputtering speed：
    		224.5mm/s
    Data refresh rate：
    		Less than500ms






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