One of the most advanced and innovative solutions for operating a PVD coating line.

Software for vacuum coating lines.

EFAROVAC - a new label but over 15 years experience

Our solutions are unique because, above all,  we constantly adapt standard approaches to a given context.  Development never stays still.  Do we really need to hold on to rusted-out strategies?  Doesn’t modern technology offer new possibilities for dramatically increase efficiency and user-friendliness?  Why should you keep working like you did 20 years ago?  Your team deserves better!

 

PVD - What is it, actually?

Physical vapor deposition

Physical vapor deposition (PVD) is used to produce thin films and coatings. The most common PVD processes are sputtering and evaporation.

PVD coating is used to produce thin films for mechanical, optical, chemical, or electrical functions. A typical example is the glossy surface of water fixtures in bathrooms and kitchens.

In addition to improving appearance, PVD coatings are also used to make surfaces more scratch-resistant  or to impart completely new physical or chemical properties.  A drill coated with titanium nitride remains sharp for longer, for example.  The cutting surfaces of razor blades are coated with carbon atoms in an evaporator coating process, giving them diamond-like properties.

Equip your PVD coating line with our software solution - What can you expect?

Complete independence: Whether you want to upgrade a machine that has served long and reliably, or you want to design a completely new machine series.  We will assist you every step of the way, from the initial design stages to the final perfection of your project.

Easy to use

Let me guess – you know which button to push, right?

Reduce standstill

The user interface uses animation to direct user focus.

Maximum functionality

If it's possible, you can do it. For the experts among us.

Reporting engine

You've made quality? Prove it, undeniably.

Features

User interface

  • Our software is based on vb.net/C#, the most common programming language for complex software. With this, we work around the typical limitations of classical HMI systems. This allows us to provide services that a typical PLC programmer cannot offer.
  • Multi-threading ensures that the user interface reacts with speed.
  • Multi-screen technology. Plus, for a more useful overview, it allows you to configure what you see on each screen.
  • Unique, modern design with 3D elements and animation using studio trick technology.
  • WinForms and GDI+ technology which can operate with a standard graphic card: no powerful graphic cards required.
  • Integrated data logging and reporting (with unlockable options).
  • Language switching: German and English (US) are standard with other language options available upon request.
  • All-in-one solution, no further software packages necessary.
  • Windows 10 Enterprise LTSC operating system.  For the nerds among us, Windows 7 Professional is also available.

Handling

  • UI and UX-Design to maximize usability and user experience.
  • Intuitive. Simply structured, clean, not overloaded, with every detail easily accessible.
  • The software can be operated by novices as well as professionals desiring extensive possibilities for manipulation.
  • Multi-level authorization system based on Windows user control; domain login possible.
  • All features can be tested manually during commissioning and troubleshooting as well.
  • The recipe settings can be restricted or even locked for the operator so that values cannot be modified accidentally, potentially leading to a reduction in quality.  The operator has a unique interface for recipe control, on which only authorized values can be seen.

Diagnostics and troubleshooting

  • Very deep diagnostics – operator’s attention is focused on the problem with graphic animation and error messages.
  • Detailed, configurable error messages – each discrepancy is displayed.  An average system can hold around 8,000-12,000 different error and warning messages, many of which specifically support the commissioning process. These can immediately provide accurate indications in case of unexpected plant conditions.
  • Remote access via VPN router possible, so that the experts are always just around the corner.

Modular

  • Ideal for series machine building
  • Ideal for retrofit and for systems to be progressively updated and modernized.
  • Future-proof – extensions are often already prepared and simply need to be “unlocked”, i.e. by installing additional hardware.
  • Replacement of equivalent parts from various manufacturers (pumps, meters, gas flow regulators, power supplies) is provided for.
  • Standardized internal interfaces; device coupling achieved via a “driver”.
  • Operating software (HMI- human-machine interface) is automatically adapted to the machine configuration.  An average plant control software contains around 4,000 configuration objects, which are managed by the machine control system.
  • The typical 8,000-10,000 parameter values for configuration and machine settings are available. Settings that are not required are automatically deactivated after commissioning and are only accessible via a special authorization. This allows both plant engineer and operator to maintain an overview of the process.  A PLC programmer can easily active the add-ons with no deep insight into the application software necessary.
  • Pumps can be adapted to different configuration levels (single or multi-stage); variable number of turbopumps or other vacuum pumping systems (e.g. oil diffusion pumps) possible.
  • Sources are configurable as magnetron or evaporator, perfect for hybrid systems.
  • All common bus systems and communication protocols (RS 232, RS485, Modbus, Profibus, ProfiNET) available. Main communication achieved via EtherCAT, the fastest available ethernet-based industrial bus.

Product flow monitoring

  • Not only are the products monitored and the production progress documented, but the consumption of resources and the maintenance status are continually monitored as well.
  • Unlockable option: intelligent target management with storage for non-consumed targets.
  • All data are available via several interfaces; connection to your ERP system is possible.
  • Unlockable option: At the conclusion of a production step, a very detailed report can be outputted automatically via the internal QA system. The content of each report can be configured via the recipe and is individual to each product. Should something be forgotten, the report can be adjusted and regenerated.  Data is stored in the tamper-proof PDF A-3a format for long-term archival.

Maintenance and operating hours counter

  • The basic operating hours counters are included in the standard package and are freely configurable.
  • When a configured meter is tripped, the system operator is prompted to perform the required maintenance.
  • Unlockable option: A full electronic machine logbook, and many more configurable maintenance counters.

Data storage

  • MS SQL Server, local installation, or network server can be used. A local server is recommended for performance reasons (standard installation). The free SQL Server Express (from version 2016) is recommended.
  • Continuous archival of up to 1000 process values simultaneously.
  • An internal SFDC system graphically displays plant workload.
  • Machine connection values (mains connection, control voltages, air pressure) are also recorded.
  • Intelligent hard disk management. When capacity decreases, the oldest data is deleted automatically.  Disk space to be kept free or age of data to be stored is freely configurable in the HMI.
  • Graphical analysis of the archives, also related to run batches.
  • Real-time chart view, configurable. No limit to the number of curves (except due to processor performance and memory).

For your series machine

  • Manufacturer branding possible, using your own (animated) logo (please note: not available for retrofit).
  • If required, individual function modules can be unlocked worldwide via a unique key. Submitting the individual machine code generates a single-use activation key.  This process is also possible without an internet connection.
  • Your customer only buys what they really need.
  • A programmer is usually not required for commissioning, reducing the costs for each individual set-up.
  • Three different software packages available: for the classic batch plant, for the multi-chamber plant with round-cycle operation, and for the inline multi-chamber plant.  Packages are optimized to your specific situation.
  • The machine is no longer defined by its software but by the configuration. This can be archived and serves as the basis for the next set-up: upload it, make a few adjustments, and the machine is ready to be tested. In the event of data loss, all machine parameters can be quickly restored.
  • The software will fit, no matter what the hardware design.

For your unique special machine or a retrofit

  • Because the software package already includes a full range of options, the degree of customization necessary to your specific solution is significantly reduced.

Image hosted by Beckhoff (c)

Automation hardware

  • Made in Germany.  The control hardware produced by Beckhoff, Verl (www.beckhoff.de) is one of the most innovative machine automation systems available on the market.
  • Moreover, Beckhoff is known for its long product lifecycles (up to 20 years), confirming the sustainability of your investment.  The electronic components are manufactured in Germany, guaranteeing high quality.
  • Runtime TwinCAT 3.1: Tasks are divided between several processor cores according to their tasks and priorities. This ensures optimal PLC performance.

Let’s take time to talk about your project

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