2.45 ghz microplasma technology at the fh aachen · holger heuermann fh aachen university of...
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Holger Heuermann FH Aachen University of Applied Sciences Institute of Microwave and Plasma Technology
2.45 GHz Microplasma Technology at the FH Aachen
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 2
Contents:
- Comparison: Laser / MW-Plasma
- Introduction Microplasma
- Technology to Generate Microplasmas
- Other Applications - Lamps - Jets and more
- 2.45GHz Spark Plugs
Overview
08.2006:
First microplasma spark plug
from the FH Aachen driven
with a magnetron with 600W
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- First laser from 1960
- First hardware was very expensive
- 1980: Breakthrough with cheap semiconductor lasers
- Meanwhile in a lot of applications: e.g. DVD, laser printers,
pointer, cutting, welding, eye and shin treatment, spectroscopy
- In Europe: Maybe 5 lasers per household
Status Laser
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- Arc discharge (or Corona discharge)
- Very long history and the first hardware was cheap
- Meanwhile very much applications: e.g. lamps, spark plugs,
plasma TV, welding, melting, jets for activation, coating and other industry processes
- In Europe: Maybe 30 plasma sources per household
Status Atmospheric Plasma
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- Microplasma: Microwave driven plasma
- FH Aachen: large plasmas at 2.45 GHz driven with cheap
semiconductor technology
- In contrast to an arc plasma: Microplasmas does not need a ground electrode
- The plasma temperature is higher than the electrode temperature
- At higher pressure, plasma volume reduces as energy density increases
Introduction Microplasma
2010:
First microplasma jet from the
FH Aachen driven with a
transistor-circuit at 100W
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Technology to Generate Microplasmas: Theory of High Voltage Generation
Simplified
electrical circuit
of the three stage
impedance transformer
Realization of the
impedance
transformation using
distributed elements
in coaxial technique
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Technology to Generate Microplasmas Theory of High Voltage Generation
Input impedance Z0 = 50 Ω
Output impedance Zout ≈ 0.5 MΩ
This concept is based on a three stage transformation network. The
first and third transformation are realized by a gamma-transformer and
the second stage by an autotransformer.
The full mathematical derivation is
presented in other papers. The
results to calculate the elements are
given in the following equations:
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 8
Technology to Generate Microplasmas Theory of High Voltage Generation
All mechanical
components of
our first
microplasma
spark plug
Impedance
transformer
(in simple
form)
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Technology to Generate Microplasmas Theory of High Voltage Generation
Reflection coefficient of the impedance transformator for ignition
Matching for ignition
Matching = 6 dB
(25% of the energy
is reflected)
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 10
Technology to Generate Microplasmas Theory of High Voltage Generation
Voltage = 10,000V
Calculated ignition voltage
Output voltage of the realized impedance transformator for ignition
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 11
Technology to Generate Microplasmas Theory of High Voltage Generation and Operation
Bi-static matching
Optimization for both states:
- Ignition (matching and high voltage)
- Operation of a microwave plasma (matching)
Frequency shift between the two stages:
- 40 MHz in the 2.45 GHz ISM-Band
40 MHz jump is only possible with semiconductors
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Technology to Generate Microplasmas Microwave Generator and Control Loop
Block diagram
VCO
Low pass filter
Coupler 1 Coupler 2 Plasma
Detector 1 Detector 2
Difference
(~ S11)
Variable
DämpfungPA
Amplifier
external
Amplitude-
discriminator
MVG-IC
Inner circuit to control the bi-static matching in a control loop
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Technology to Generate Microplasmas Microwave Generator and Control Loop
RBW 1 MHz
VBW 1 MHz
SWT 5 ms
*
*
1 AP
CLRWR
A
Ref -10 dBm Att 0 dB*
Start 2.2 GHz Stop 2.7 GHz50 MHz/
SGL
PRN
-110
-100
-90
-80
-70
-60
-50
-40
-30
-20
-10
1
Marker 1 [T1 ]
-48.18 dBm
2.458000000 GHz
Date: 25.OCT.2010 09:29:22
SMD-realization to control our generators including automatical locked loop for bi-static matching (replaced by MVG-IC)
2.3 2.4 2.5 2.62.2 2.7
-8
-6
-4
-2
0
-10
2
freq, GHz
dB
(S(1
,1))
Readout
m2
2.462G-2.991
m3
2.453G-5.653
m4
m2freq=dB(S(1,1))=-2.973
2.440GHz
m3freq=dB(S(1,1))=-3.664
2.460GHz
m4freq=dB(S(1,1))=-5.959Min
2.450GHz
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 14
Technology to Generate Microplasmas Microwave Generator and Control Loop
New circuit for 15W-application
Highly integrated generator electronic with LDMOS transistor for an
energy saver lamp, http://3ppbulb.com
MVG-IC
Pre-amplifier
Main-amplifier
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Technology to Generate Microplasmas Microwave Generator and Control Loop
Laboratory generator for ignition
Portable development environment to generator the microwave power
(up to 100W) and to monitor the matching during operation
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 17
Just presented on the Light and Building
Lamps for general lighting
First electrode-less low pressure discharge lamp called 3ppBulb
Mercury-
free!!
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Just presented on the Light + Building: Beamer Lamp Future: low power
Actual research work at FH Aachen: 1.: 10W-lamps based on this beamer lamp for general lighting: 2016: lamps with best spectrum 2.: head lamps for car: Project with Osram, Hella, supported by NXP
Novel 120W single-sided beamer
lamp driven by an 2.45 GHz signal
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Just presented on the Light + Building: Beamer Lamp Innerer Aufbau der ersten HF-Beamerlampe
Lg
Lt Ckoppel
50 - Zuleitung
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 20
Just presented on the Light + Building: Beamer Lamp Erster Aufbau HF-Beamerlampe (Diplomarbeit)
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 21
Just presented on the Light + Building: Beamer Lamp Ein Entwicklung der HF-Beamer-Lampe
9,9*1
19,1*1
45,3*2 48,9*257,2*2
0
10
20
30
40
50
60
70
80
2009 2010
lam
p e
ffic
acy
lm/W
50 W UHP
120 W PVIP
• Verbesserungen innerhalb des nur einjährigen Projektes
• Potential für 80 lm/W vorhanden
From Philips
From KIT
*1 Measured at Philips Research Aachen
*2 Measured at LTI Karlsruhe
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Just presented on the Light + Building: Beamer Lamp Innerer Aufbau der ersten HF-Beamerlampe
Aktivitäten:
• Vertrieb dieser Beamer-HF-Lampen
• F+E-Projekt mit 2,5 Mitarbeitern über 3 Jahre:
Thema UHP-Lampen bis 35W
Eigenschaften Referenzlampe: Philips
TOP
120 W / 132 W 1.0
Mikroplasma-Lampe:
OSRAM PVIP
120 W / 132 W 1.0
modifiziert
Lichtstrom [lm] 7825 8521
Lampenleistung [W] 132 149
Lampeneffizienz [lm/W] 60,2 57,2
Leuchtdichte [Gcd/m2] 2,59 2,79
Farbwiedergabeindex Ra [%] 62,5 66,8
Anlaufzeit bei Kaltzündung
[s] 55 16
Wieder-Zündung nach
Betrieb [s] ca. 120 ca. 0 – 40
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Future: Low Power High Pressure Lamps Arc attachments of microwave driven HID-lamps
• Diffuse MW-mode appears only in MW operation
• Low global tip temperature of the electrode
• Low electron emission of the electrode
Displacement current
• Spot-mode appears in MW and AC operation
• High local tip temperature of the electrode
• high electron emission of the electrode
Conduction current
MW @ 15W
MW @ 25W
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Future: Low Power High Pressure Lamps „Electrode“ configurations for microwave operation
Capacitive coupling of the plasma arc:
Non-metal electrode/(-less)
High lifetime
Higher variety of the salts
Metal electrodes (tungsten)
Non-metal „electrodes“ (e.g. ceramic)
Electrode-less
Vessel (quartz or ceramic)
Plasma arc
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 25
Other Applications: Plasma Jets
FH Aachen research work microwave scalpel
Status > Patient on metall plane > Arc and current at 400W
Our project: > Jet similar to short range
laser > No current flow
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Other Applications: Plasma Jets
Products of Heuermann HF-Technik GmbH:
Plasma jet with cannula for high power applications
Generator with 200W
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 27
Other Applications: Plasma Jets
Products of Heuermann HF-Technik GmbH:
Mini plasma jet with
10W for health
applications (in medical
qualification) and
activation
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 28
- Low emission heating (drives burner!)
- Clean air (hospitals, clean rooms)
- Ultrasonic up to the um-range for a lot of applications
- Welding, melting, ….
Other Applications: Many
The expensive part is
the power amplifier!
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 29
1. Generation Runs in a standard engine
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Advantages of our spark plugs:
- Cheap and small electronic
- High voltage only in the spark plug
- Best plasma generation conditions by signal with a rise time of only 0.1 ns
- No electrode-material in the plasma – low wear
- Free in time of ignition
- Free in the number of ignitions
- Free in duration of ignition
1. Generation of 2.45GHz Spark Plugs
09.2006:
RF spark plug driven with 20W
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Highest voltage only at the electrode
1. Generation of 2.45GHz Spark Plugs
ca. 5,000,000 V/m
ca. 500 V/m
1. Generation of 2.45GHz Spark Plugs
Test motor at the
Aachen University
of Applied
Sciences
This engine run
with our spark
plug!
1. Generation of 2.45GHz Spark Plugs Operation under pressure
1bar 5bar 10bar
15bar 20bar 30bar (Filter)
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2. Generation - Design Design of 2. Generation 2.45GHz Spark Plug
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Novel inner construction
2. Generation of 2.45GHz Spark Plugs New design for higher pressure applications
Peek
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Explosion view of the novel inner construction
2. Generation of 2.45GHz Spark Plugs Easy to manufacture
Peek
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Cross section of the full spark plug
2. Generation of 2.45GHz Spark Plugs New design
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 39
Full finite element-model for simulation
2. Generation of 2.45GHz Spark Plugs Full finite element design: meshing
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 40
E Field
2. Generation of 2.45GHz Spark Plugs Electromagnetic results for the ignition
ca. 5,000,000 V/m
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 41
Matching S11
2. Generation of 2.45GHz Spark Plugs Results ignition
- 18 dB
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E Field
2. Generation of 2.45GHz Spark Plugs Results operation
ca. 1,000,000 V/m
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Matching S11
2. Generation of 2.45GHz Spark Plugs Results operation
- 5 dB
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2. Generation of 2.45GHz Spark Plugs Multi physic design: strength simulation
Numerical investigation of the spark plug ceramics with regard to strength at high-pressure conditions
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 45
Temperature simulation
2. Generation of 2.45GHz Spark Plugs Results ignition
294 °C
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 46
Temperature simulation
2. Generation of 2.45GHz Spark Plugs Results ignition
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 47
Temperature simulation
2. Generation of 2.45GHz Spark Plugs Results operation
1830 °C
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Temperature simulation
2. Generation of 2.45GHz Spark Plugs Results operation
1830 °C
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 49
2. Generation – Hardware and first Tests 1. Tests of the New 2.45GHz Spark Plugs
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 50
2. Generation of 2.45GHz Spark Plugs First hardware of the second generation
Peak capacitor
Microwave spark plug out of 7 components
Measure-
ment
adaptor
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 51
Ground electrodes melted
2. Generation of 2.45GHz Spark Plugs First tests: 1. problem
Replaced by external electrodes
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 52
Series-C melted
2. Generation of 2.45GHz Spark Plugs First tests: 2. problem
Replacement is on-going: cost actual 50% performance in operation mode (reflected power is 50% of incident power)
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 53
2. Generation of 2.45GHz Spark Plugs First tests: under atmosphere
Sparks between center electrode and ground electrodes at ca. 50W-puls with <100mJ (target: 100W-puls with 400mJ)
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 54
2. Generation of 2.45GHz Spark Plugs First flow tube measurements at the IAV
IAV-flow tube for first charge motion test
© FH AACHEN UNIVERSITY OF APPLIED SCIENCES 14. November 2016 | 55
2. Generation of 2.45GHz Spark Plugs First flow tube measurements at the IAV
Flow tube results for two views (pressure 1 bar)
Position 1
T = 1 ms / v = 0 m/s
T = 1 ms / v = 0 m/s
T = 1 ms / v = 25 m/s
T = 1 ms / v = 25 m/s
T = 5 ms / v = 25 m/s
T = 5 ms / v = 25 m/s
Position 2
Summary
- Introduction Microplasma
- Theory of High Voltage Generation
- Microwave Generator and Control Loop - Other Applications: Lamps, Jets und
much more
- 1. Spark Plug Generation with 2.45GHz Microplasma
- Design of 2. Spark Plug Generation with 2.45GHz Microplasma
- 1. Tests of 2. Spark Plug Generation