ConVac

ConVac: An Intelligent Vacuum Process Control Environment The efficiency of modern vacuum production is determined not only by the reliability of the hardware but also by the excellence of the control algorithms. The ConVac software suite is a digital ecosystem designed specifically to ensure stable process cycles and protect equipment during continuous operation. ConVac manages critical plant components: from automatic coordination of pumping systems to signal verification at the controller level. We have combined an intuitive interface with uncompromising industrial safety protocols. This allows the company to focus on the quality of its products, entrusting the monitoring of complex physical processes to proven automation. ?️ Hierarchical Security System ConVac implements strict access control, protecting equipment from unauthorized changes and human error:

• Manager: Highest access level. Allows for in-depth configuration of system functions and fine-tuning of all equipment components.

• Technologist: Specialized tools for developing and implementing new deposition recipes. Enables the creation of unique processing algorithms without the risk of interfering with basic operating functions.

• Operator: Optimized interface for daily operation. Restricts access to the process structure, ensuring strict adherence to established regulations. ⚙️ End-to-end monitoring and diagnostics ConVac provides complete transparency of each node’s operation. A specialized “Equipment” module allows you to monitor the interaction of the control system with actuators in real time:

• Direct PLC control: Monitoring command signals and instant responses from the controller ensures the accuracy of each operation.

• Centralized parameter database: All operating constants and equipment settings are consolidated into a single digital table. The system visually confirms successful data recording to the controller’s memory, eliminating data transfer failures. ? Automation and Intelligent Pumping Algorithms The control system fully coordinates vacuum line operation, analyzing data from seven highly sensitive sensors:

• Seamless Cycle: Automatic control of all pumping stages (from fores to high-vacuum pumps) with switching based on set pressure thresholds.

• Thermal Protection: Intelligent blocking of diffusion pump heaters until the required vacuum is reached and monitoring of the working fluid temperature.

• Logical Protection: The system prevents the opening of valves or shutoff valves if this conflicts with safe operating conditions or the current system state. ? Technological Flexibility and Repeatability The “Processes” module is designed to ensure consistent product quality:

• Recipe Management: The system supports the creation of a process library with unique names and identifiers. The use of shared files for different technological processes ensures the same parameters when scaling production. ? Ergonomics and Visualization An interactive mnemonic diagram (pumping diagram) displays the unit’s status dynamically. Animated indicators for pumps, evaporators, and ion sources allow the operator to instantly read the system’s status. Any abnormal situations are recorded in the event log, providing quick feedback and minimizing downtime. Visualization and In-Depth Analytics: Everything Under Control ConVac software transforms dry numbers into clear management tools. Thanks to a dynamic graph system, the operator instantly assesses the status of all unit components without having to read tables. Visual Real-Time Monitoring:

• Leak Test: The program generates a real-time leak graph, allowing you to instantly assess the system’s tightness and the chamber’s readiness for operation.

• Thermal Profile: Complete temperature control—from the status of diffusion pumps to the power of heaters and the temperature inside the chamber. You can see heating dynamics and process stability on a single screen.

• End-to-end vacuum monitoring: Interactive graphs from all sensors (in the chamber, high-vacuum pump, and fore) provide a complete picture of pressure distribution in the system. Data security and export: The system automatically maintains a detailed log of each process. Specialized log analysis software is included for managing these records.

• Transparency: View the history of any cycle in detail.

• Mobility: Export data in convenient formats for reporting or further research.

• Reliability: Every operator action and change in system parameters is recorded, ensuring complete production traceability. Spectral Monitoring The Spectral Monitoring module in ConVac is an intelligent control center for the optical characteristics of manufactured parts. The system allows you to monitor coating parameters directly during the deposition process, ensuring guaranteed high results without interruptions or rework. Why it’s effective:

• Full visualization: The interface is optimized for dual-monitor operation. You can simultaneously view calculated graphs, actual readings, and the instantaneous system signal.

• Flexible on-the-fly editing: No need to interrupt the process to make changes. Adjust refractive indices, geometric factors, and substrate parameters directly during processing—the system automatically recalculates the characteristics of the entire coating.

• Compatibility with global standards: ConVac easily imports process files from third-party software (TFCalc, MultiSpectrum, etc.), eliminating the need for manual data transfer.

• Smart witness control: The automated “odd/even” function allows for simultaneous monitoring of two witnesses, which is critical for complex multilayer structures.

• Precise signal tuning: Control exposure, averaging, and noise smoothing to achieve a perfectly clean spectrum, even when working with weak signals. ________________________________________ ConVac transforms complex vacuum equipment into a responsive and predictable instrument, where every step of the process is protected by intelligent control algorithms.