Process Control for Plasma Systems: Stable, Measurable, Reproducible
What is a PCU? The Plasma Control Unit, or PCU for short, is Plasmatreat’s process control system. It supports the monitoring of relevant process parameters such as plasma generation, process gas flow, power, pressure, and plasma stability, and highlights deviations in the process.
In plasma pretreatment, the result usually cannot be seen inline—that is, visually perceived—or directly verified: Whether a surface has actually been activated, cleaned, or reduced often only becomes apparent in the subsequent process—during gluing, painting, bonding, or coating. That is precisely why process control at Plasmatreat is not an add-on module, but part of our core promise: When you work with us, you’re not just buying a plasma system, but control over the process—the certainty that it will deliver in series production what it demonstrated in testing.
Why Process Control Is Crucial
Why does plasma need process control at all? Because that is precisely what sets us apart. Many suppliers sell plasma. Plasmatreat sells stable, measurable, and reproducible plasma processes.
In mass production, a process that works on the first day isn’t enough. What matters is whether it still delivers the same treatment quality after a hundred or ten thousand cycles—and whether any deviation is detected before it leads to defective components.
Process control at Plasmatreat fulfills three functions:
- Documentation: Operating parameters are continuously recorded and logged as evidence for quality assurance and audits.
- Detection: Deviations from the defined target values are displayed before they affect the treatment result.
- Prevention: The recorded values serve as an early indicator of maintenance needs and help prevent unplanned equipment downtime.
This transforms a plasma system into a process that production and quality assurance can rely on—without having to constantly check it themselves.
A Control Principle for Openair-Plasma® and AURORA-Plasma
Whether a component is treated directly in the production flow or multiple components are treated together in a controlled chamber: This decision depends on the production conditions. However, both technologies share the same goal—to run plasma processes in a stable, measurable, and reproducible manner. Relevant process parameters are monitored, documented, and made available for quality assurance and series production integration. In addition, optical emission spectroscopy (OES), for example, is used to analyze the plasma species generated—a sensor technology that is continuously being further developed.
Still unsure which technology is right for your application? The “Technologies at a Glance” page helps you determine which one is best; details on the technologies themselves can be found under Openair-Plasma® and AURORA-Plasma.
PCU Modules
The PCU combines multiple control, regulation, and monitoring functions in a compact, modularly scalable system—tailored to different performance requirements and chamber or jet types, including dual-rotation jets.
| Module | Function |
|---|---|
| PPM – Plasma Power Measurement Module | Measures current and voltage values directly at the plasma generator |
| LCM – Light Control Module | Continuously monitors plasma generation |
| FCM – Flow Control Module | Continuously adjusts the flow rate of the process gas |
| PCM – Pressure Control Module | Monitors the backpressure |
| RCM – Rotation Control Module | Monitors the jet rotation and provides information on the condition of the motor and bearings |
With Openair-Plasma®, these modules support the control of relevant process parameters directly at the generator and jet, thereby laying the foundation for reproducible treatment results. Each plasma jet can also be optionally equipped with triple process monitoring—voltage is measured not only at the generator but also at the jet itself or across multiple jets. In AURORA-Plasma, the PCU logic is implemented via the controlled low-pressure chamber process. The focus is on system control, sensor technology, process recipes, and process parameters such as gas flow, pressure, power, and process control.
The PCU ensures that a plasma effect is transformed into a reproducible manufacturing result.
Specific
Benefits
Both technologies share the same standards:
Stable. Measurable. Reproducible.
- Stable process windows: Relevant process variables are monitored and controlled.
- Reproducible treatment results: Process parameters can be defined, repeated, and evaluated.
- Greater transparency: Process data makes deviations traceable.
- Improved quality assurance: Documented values support approvals, audits, and production runs.
- Centralized operation for both Openair-Plasma® and AURORA-Plasma: touchscreen control panel, extensive recipe storage, multi-level user management, and remote maintenance via VPN.
FAQ
What is a PCU?
The Plasma Control Unit, or PCU for short, is Plasmatreat’s process control system. It monitors relevant process parameters such as plasma generation, process gas flow, power, pressure, and plasma stability, and highlights any deviations in the process.
Why is process control important in plasma treatment?
In plasma treatment, the result is often not immediately visible or verifiable inline. Whether a surface has been sufficiently activated, cleaned, or prepared often only becomes apparent in the subsequent process, such as during gluing, painting, bonding, or coating. Process control helps monitor relevant parameters and ensure reproducible treatment results.
How does process control differ between Openair-Plasma® and AURORA-Plasma?
The control principle is identical: Relevant process variables are monitored, documented, and utilized to achieve stable, measurable, and reproducible results. With Openair-Plasma®, this is implemented via PCU modules on the generator and jet. With AURORA-Plasma®, the same principle is applied to the chamber process—via system control, sensors, and recipe management.
Which process parameters does the PCU monitor?
With Openair-Plasma®, these include, among others, process gas flow, plasma power, optical plasma monitoring, pressure monitoring, and jet rotation. With AURORA-Plasma, the focus is on the process variables of the chamber process, such as gas flow, pressure, power, and recipe management.
How does the PCU support quality assurance?
The PCU highlights deviations in the process and provides process data that can be used for later evaluation and traceability—an important foundation for approvals and audits.
Peace of mind for your production
You don’t have to hope that the plasma process worked. You know it did—documented, measurable, and traceable. That’s the difference between a plasma system and a controlled process: a result that production and quality assurance can rely on, cycle after cycle.