This system is a new generation complete thermal spraying unit. It integrates perfectly into modern automated or robotic spray coating systems and provides unchallenged process control...
System consists of main spray coating equipment, manipulators for positioning workpiece and plasma gun during the spraying process, as well as peripheral components to ensure comfortable and safe working conditions.
Main Equipment
- Process control center: Control cabinet + HMI operator panel
- Gas management center
- Plasma power source
- Powder feeder
- Refrigeration unit
- Plasma guns
The main equipment is required to control the spraying process parameters. When selecting components of main equipment, it is necessary to take into account the various characteristics of these components, the sprayed material properties, the required characteristics of resulting coating, as well as the workpiece geometry.
Manipulators
- Positioners
- Manipulation robots
Manipulators are required to move and position the plasma gun and workpiece during the spraying process. When selecting manipulators, it is necessary to take into account the workpiece geometry. Reasonably selected characteristics of manipulators ensure high process performance and high-quality resulting coatings.
Peripheral Components
- Sound proof chamber
- Exhaust filter unit
Plasma spraying process produces large amounts of dust and plasma jet-generated heat, and is also characterized by high noise levels (115 dB). Sound proof chambers and exhaust filter units are used to ensure an acceptable noise level in the workplace, as well as to remove hot and dusty air from the work area.
Final configuration of each spray system depends on the specific process task and the customer’s requirements.
MAIN EQUIPMENT
Main equipment connection scheme
MP 3000 Process Control Center
Versatile platform for thermal spraying
This system is a new generation complete thermal spraying unit. It integrates perfectly into modern automated or robotic spray coating systems and provides unchallenged process control, flexibility and highly repeatable spray performance.
Single platform for 4 types of spraying processes: plasma spraying, HVOF spraying, flame spraying and electric arc spraying. Modular architecture allows the system to be configured in accordance with customer’s requirements, while integrating multiple spray technologies into a single unit.
Main Functions of Software
Graphical operator interface with process parameter visualization function
Spray guns library allowing operator to choose the most suitable device
VPN connection for remote system diagnostics
Options for saving and recalling control programs
Monitoring and control of external modules, such as a robot, exhaust filter unit (EFU), refrigeration unit, etc.
Multi-level access control system with "Operator", "Process Engineer" and "Service Engineer" access levels
On-line monitoring and recording of current process parameters
Servicing planning and control options
Resource consumption per piece/total resource consumption accounting
HMI Operator Panel
Operator colour touchscreen display
- Diagonal screen size up to 21’’
- Three versions available: for hanging bracket mounting, for mounting on control cabinet panel and for mounting on a separate portable stand
- Emergency stop buttons
Switching Module
Module designed to connect cooling water hoses and power cables that are connected directly to plasma gun. This module measures cooling water flow rate, water temperature at the inlet and outlet, and also includes the high-voltage arc ignition unit for plasma gun and other modules necessary for process monitoring and control.
- Cooling water circuit control (at the inlet and outlet)
- Plasma gun voltage control
- High-voltage arc ignition unit for plasma gun
Gas Management Center
Gas management center contains all the gas fittings for mixing and controlling the flow rate of process gases used in the operation. Depending on process requirements, the gas management center can be equipped to work with following plasma gases: argon (Ar), hydrogen (H2), nitrogen (N2), helium (He).
- Digital connection
- Process gas mass flowmeters (high-precision)
- In-line pressure regulators
- Gas pressure transmitters
- Gas microfilters
- Stainless steel pipes and fittings
- Fuel gas leakage detector
Powder Feeder
Powder feeder supplies sprayed material in powder form to plasma gun. Powder is poured into corresponding hopper, from which it is transferred to plasma arc zone using a carrier gas. Number of hoppers is selected depending on the number of powder types used and the required process productivity. In standard version, the system provides the ability to simultaneously use up to 4 independent powder feed lines connected to corresponding hoppers.
- Digital connection
- Carrier gas mass flowmeters
- Feeder type: volumetric
- Gravimetric powder supply (g/min): optional feature
- Powder hopper number: 1/2/3/4 pcs
- Powder hopper volume: 1.5 l/5 l
- Powder hopper version: high-pressure
- Heating device for powder hopper: optional feature
- Powder agitation function for powder hopper
- Quick change hopper system: standard feature
- Powder level control function for powder hopper: standard feature
Power Source
The latest generation inverter power source for plasma guns. Inverter technology offers obvious advantages over thyristor converters, such as ultra-low current ripple, eliminating plasma power fluctuations, and high efficiency rate, allowing energy consumption to be reduced by up to 40%.
- Digital connection
- Power source type: inverter type
- Ultra-low current ripple
- Efficiency: >90%
- Cos F: >0.95
- Typical power source capacity: 100 kW (1000 ADC/100 VDC or 500 ADC/200 VDC); max. voltage: 240 V
- Max. power source capacity: 200 kW (optional feature)
- Duty cycle: 100%
- Module for working with cascade plasma guns: optional feature
Refrigeration Unit
During operation, the plasma gun generates high thermal power, which requires forced water cooling. Refrigeration unit specially designed for plasma spraying process is the solution for these purposes.
Applicable Plasma Guns
Machine can operate with one or more plasma guns depending on current task. Control system stores preset operating parameters for each plasma gun, which helps prevent its premature failure due to improper operation.
| Process gases: | argon, hydrogen, nitrogen |
| Max. power: | 55 kW |
| Process gases: | argon, nitrogen, hydrogen |
| Max. power: | 80 kW |
TP210 Plasma Gun
| Process gases: | argon, hydrogen, nitrogen, helium |
| Max. power: | up to 130 kW |
| Process gases: | argon, hydrogen, nitrogen |
| Max. power: | 25 kW |
| Plasma gun length | 450 / 600 mm |
| Min. bore ID for spraying | 75 mm |
| Available spray angle versions | 45° / 90° |
2086A Plasma Gun
| Process gases: | argon, hydrogen, nitrogen |
| Max. power: | 30 kW |
| Plasma gun length | 305 / 610 / 914 / 1219 mm |
| Min. bore ID for spraying | 75 mm |
| Available spray angle versions | 45° / 90° |
Manipulators
Manipulators
Peripheral Components
Exhaust filter unit
Our Advantages
Customer Service and Support
24/7 Accessibility
Training and Technical Assistance
Equipment Operation Training and Commissioning Assistance
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