Automating corona treatment

Vetaphone’s new iCorona treater is designed to maintain treatment parameters automatically during the run. Andy Thomas reports

 Vetaphone has launched its iCorona -1 ‘intelligent’ corona treater. The new machine series features a generator setup which utilizes highly efficient one GBT controlled resonance frequency power operation. The iCorona-1 offers output sizes from one to two kw, all based in one single generator cabinet for easy integration into narrow web presses.

The iCorona -1 is manufactured on a modular basis and the entire generator assembly can be easily addressed and quickly exchanged if required. This provides a way of upgrading power for future needs as well as reducing downtime on press in the event that a part needs replacing.

As standard the iCorona -1 comes with an easy-to-use operator panel with LED display. The panel has four individual control buttons with internal sub-menus for adjusting different operator settings. An optional seven inch LCD touch screen control panel provides a graphical overview of the whole system, and offers a range of intelligent automatic controls including auto-substrate matching and auto-proportional speed control. Production data can be downloaded via a USB link, which also allows for software upgrades.

Automation

iCorona stands for ‘Intelligent Corona’ and replaces Vetaphone’s established CP series, which has been on the market since year 2001.

Automation is the key theme for the iCorona technology, with its ability to auto- match system settings to substrates. This means the operator simply inputs the material type, width and thickness and the system chooses the optimum settings.

This auto matching of power to width and speed can also be described as watt density control.

Auto matching maintains a consistent treatment as line speed changes. If the line speed increases, the generator will automatically increase the power according to the material factor set by the operator. If the line speed drops, the generator will automatically lower the power, again according to the material factor set by the operator.

At minimum line speed the iCorona will automatically stop, and automatically restart when the speed goes up again.

The effectiveness of corona treatment depends on the matching settings to the material. The required treatment/intensity level (watt/min/m2) may vary within a wide range, and the iCorona takes account of material parameters, the required dyne-level, the machine speed and the number of sides to be treated.

Materials factors which affect this choice include age, width and whether the material has been pretreated.

The treatment level can be calculated by using the following formula:

Power (watt) = T • S • W • M

P =       Total Power (Watt) required

T =      Number of sides to Treat
            (single/double sided)

S =       Line Speed (in meters per minute)

W =     Film Width (in meters)

M =      Material factor (required Watt
            per m² per minute)

The exact value is best determined by testing a sample of the actual film that is used for a specific application. The only parameter to set before production is material choice. Parameter setting during running of the material is carried out automatically.

Quality control

The iCorona generators constantly monitor production in regards to material factor effect, speed, stops/breakdowns. All the data is automatically stored in the iCorona display unit ready to be extracted by a USB stick. This allows every batch produced to have a full report in regards to the performance of the iCorona system.

The iCorona generators also allow the production manager/operator to set auto maintenance schedules. This could be schedules for maintenance on electrodes, roller or ventilator, for example. All the maintenance schedules are entered on the touch panel or downloaded from a USB stick. When a scheduled maintenance time is reached, the iCorona touch display will show a system message informing the operator that maintenance is required on the next line stop.

Based on the intelligent maintenance schedules the system can show the operator where and how the work needs to be done. The spare part lists can be also be integrated with the auto maintenance schedules, and maintenance ‘how to’ videos can be run on the display panel.

Vetaphone has launched its iCorona -1 ‘intelligent’ corona treater. The new machine series features a generator setup which utilizes highly efficient one GBT controlled resonance frequency power operation. The iCorona-1 offers output sizes from one to two kw, all based in one single generator cabinet for easy integration into narrow web presses.

The iCorona -1 is manufactured on a modular basis and the entire generator assembly can be easily addressed and quickly exchanged if required. This provides a way of upgrading power for future needs as well as reducing downtime on press in the event that a part needs replacing.

As standard the iCorona -1 comes with an easy-to-use operator panel with LED display. The panel has four individual control buttons with internal sub-menus for adjusting different operator settings. An optional seven inch LCD touch screen control panel provides a graphical overview of the whole system, and offers a range of intelligent automatic controls including auto-substrate matching and auto-proportional speed control. Production data can be downloaded via a USB link, which also allows for software upgrades.

Automation

iCorona stands for ‘Intelligent Corona’ and replaces Vetaphone’s established CP series, which has been on the market since year 2001.

Automation is the key theme for the iCorona technology, with its ability to auto- match system settings to substrates. This means the operator simply inputs the material type, width and thickness and the system chooses the optimum settings.

This auto matching of power to width and speed can also be described as watt density control.

Auto matching maintains a consistent treatment as line speed changes. If the line speed increases, the generator will automatically increase the power according to the material factor set by the operator. If the line speed drops, the generator will automatically lower the power, again according to the material factor set by the operator.

At minimum line speed the iCorona will automatically stop, and automatically restart when the speed goes up again.

The effectiveness of corona treatment depends on the matching settings to the material. The required treatment/intensity level (watt/min/m2) may vary within a wide range, and the iCorona takes account of material parameters, the required dyne-level, the machine speed and the number of sides to be treated.

Materials factors which affect this choice include age, width and whether the material has been pretreated.

The treatment level can
be calculated by using
the following formula:

Power (watt) = T • S • W • M

P =       Total Power (Watt) required

T =      Number of sides to Treat
            (single/double sided)

S =       Line Speed (in meters per minute)

W =     Film Width (in meters)

M =      Material factor (required Watt
            per m² per minute)

The exact value is best determined by testing a sample of the actual film that is used for a specific application. The only parameter to set before production is material choice. Parameter setting during running of the material is carried out automatically.

Quality control

The iCorona generators constantly monitor production in regards to material factor effect, speed, stops/breakdowns. All the data is automatically stored in the iCorona display unit ready to be extracted by a USB stick. This allows every batch produced to have a full report in regards to the performance of the iCorona system.

The iCorona generators also allow the production manager/operator to set auto maintenance schedules. This could be schedules for maintenance on electrodes, roller or ventilator, for example. All the maintenance schedules are entered on the touch panel or downloaded from a USB stick. When a scheduled maintenance time is reached, the iCorona touch display will show a system message informing the operator that maintenance is required on the next line stop.

Based on the intelligent maintenance schedules the system can show the operator where and how the work needs to be done. The spare part lists can be also be integrated with the auto maintenance schedules, and maintenance ‘how to’ videos can be run on the display panel.

This article was published in L&L issue 5, 2012