SYSTEM AND METHOD FOR PLASMA IGNITION

• US 20190096633A1
• Filed: 09/25/2018
• Published: 03/28/2019
• Est. Priority Date: 09/26/2017
• Status: Active Grant

• Current Assignee: Advanced Energy Industries Incorporated
• Original Assignee: Advanced Energy Industries Incorporated
• Inventors: Pankratz, Josh, Linn, Craig
• Granted Patent: US 10,475,622 B2
• Time in Patent Office: Days
• CPC Class Codes: H01J 2237/0203 Protection arrangements
• CPC Class Codes: H01J 37/32027 DC powered
• CPC Class Codes: H01J 37/32045 Circuits specially adapted for controlling the glow discharge
• CPC Class Codes: H01J 37/32064 Circuits specially adapted for controlling the arc discharge for plasma torches H01H1/36
• CPC Class Codes: H01J 37/32697 Electrostatic control
• CPC Class Codes: H01J 37/32816 Pressure
• CPC Class Codes: H01J 37/32935 Monitoring and controlling tubes by information coming from the object and/or discharge
• CPC Class Codes: H01J 37/32944 Arc detection

Abstract

This disclosure is generally directed to controlling energy distribution to a load, especially when anomalous events are detected. Benefits of the present disclosure include minimizing the length of a discharge event, mitigating the effects of an electrical discharge, and to improvements in inducing the ignition of a plasma. Methods and systems consistent with the present disclosure improve the control of operating conditions within a chamber and improve the ability for more rapidly initiating plasma ignition in a chamber.

Claims

1. A method for igniting plasma in a direct current (DC) plasma system, the method comprising:

providing an applied voltage to a plasma chamber of a direct current (DC) powered plasma system at a first voltage level, the first voltage level different from an operating direct current (DC) voltage of the plasma chamber;

changing the applied voltage provided to the plasma chamber to a second voltage level, wherein the second voltage is different from the operating voltage of the plasma chamber and the operating voltage is between the first voltage level and the second voltage level; and

returning the applied voltage to the plasma chamber to the first voltage level, wherein the voltage applied to the plasma chamber is changed between the first voltage and the second voltage until a plasma is ignited in the plasma chamber.

2. The method of claim 1, wherein the first voltage level corresponds to a negative voltage level and the second voltage level corresponds to a voltage level that is more negative than the negative voltage level.

3. The method of claim 1, wherein:

the plasma chamber is electrically connected to an upper rail and a lower rail that connect, respectively to a first and a second output of a power supply, the upper rail at the first voltage level;

the second voltage level is provided by closing a first switch biasing a first diode to conduct, the conduction of the first diode forming an electrical conductive path between the lower rail and the upper rail; and

the first voltage level is provided by opening the first switch to remove the conducting bias on the first diode, wherein the voltage applied to the plasma chamber is changed between the first voltage and the second voltage until a plasma is ignited in the plasma chamber by closing and opening the switch.

4. The method of claim 1, wherein the providing of the first voltage level and the changing of the applied voltage level is controlled by a controller at an identified frequency.

5. The method of claim 4, further comprising receiving one or more control signals from the controller that switches the applied voltage level between the first voltage level and the second voltage level.

6. The method of claim 1, wherein the second voltage level is the same magnitude of the first voltage level and an opposite polarity relative to a reference voltage.

7. The method of claim 1, further comprising:

charging a capacitor when a first switch and a second switch electrically coupled to a voltage reversal circuit are open, the charging of the capacitor based on a first diode and a second diode conducting when the first diode and the second diode are forward biased, wherein;

the first diode is electrically connected to an upper rail of the DC powered plasma system and to a first side of the capacitor, and

the second diode is electrically connected to a lower rail of the DC powered plasma system and to a second side of the capacitor,

closing the first switch and the second switch to reverse the applied voltage to the plasma chamber based on electrically connecting the second side of the capacitor to the upper rail of the DC powered plasma system and based on electrically connecting the first side of the capacitor to the lower rail of the DC powered plasma system, and

opening the first and the second switch to return the applied voltage to the first voltage level.

8. The method of claim 7, further comprising:

identifying an arcing condition associated with the plasma chamber; and

closing the first switch and the second switch to reverse the applied voltage to the plasma chamber based on electrically connecting the second side of the capacitor to the upper rail of the DC powered plasma system and based on electrically connecting the first side of the capacitor to the lower rail of the DC powered plasma system.

9. An apparatus for initiating plasma ignition in a direct current (DC) plasma system, the apparatus comprising:

a controller; and

the controller controls an applied voltage to a plasma chamber of the DC plasma system at a first voltage level,

the controller changes the applied voltage provided to the plasma chamber to a second voltage by affecting an upper supply rail connection to the DC plasma system,

the controller changes the voltage applied to the plasma chamber between the first voltage level and the second voltage level by controlled connection of the upper supply rail to the DC plasma system, and

the changing of the applied voltage level between the first voltage level and the second voltage level and back to the first voltage level is performed until plasma is ignited at the plasma chamber.

10. The apparatus of claim 9, wherein the first voltage level corresponds to a negative voltage level.

11. The apparatus of claim 9, further comprising:

an upper rail and a lower rail that respectively electrically connect to a first and a second voltage input of the plasma chamber;

a first switch; and

a first diode, wherein;

the second voltage level is provided by closing the first switch based on biasing the first diode to conduct, the conduction of the first diode forming an electrical conductive shunt path between the upper rail and the lower rail; and

the first voltage level is provided at the upper rail when the first switch is open.

12. The apparatus of claim 9, wherein the controller includes at least one of a processor that executes instructions out of a memory, a field programmable gate array (FPGA), an application specific integrated circuit (ASIC), digital logic, or analog components.

13. The apparatus of claim 9, further comprising:

a capacitor;

an upper rail of the DC powered plasma system;

a lower rail of the DC powered plasma system;

a first switch and a first diode coupled between the upper rail and the lower rail; and

a second switch and a second diode coupled between the upper rail and the lower rail, wherein;

the capacitor is charged when the first switch and the second switch electrically coupled to a voltage reversal circuit are open,

the first diode is electrically connected to the upper rail of the DC powered plasma system and to a first side of the capacitor,

the second diode is electrically connected to the lower rail of the DC powered plasma system and to a second side of the capacitor,

the first switch and the second switch are closed to reverse the applied voltage to the plasma chamber based on electrically connecting the second side of the capacitor to the upper rail of the DC powered plasma system and based on electrically connecting the first side of the capacitor to the lower rail of the DC powered plasma system, and

the first and the second switch are opened to return the applied voltage to the first voltage level.

14. The apparatus of claim 13, wherein:

an arcing condition associated with the plasma chamber is identified,

the first switch and the second switch are closed to reverse the applied voltage to the plasma chamber based on electrically connecting the second side of the capacitor to the upper rail of the DC powered plasma system and based on electrically connecting the first side of the capacitor to the lower rail of the DC powered plasma system.

15. The apparatus of claim 14, wherein the plasma chamber is restarted by changing the applied voltage level between the first voltage level and the second voltage level and back to the first voltage level is performed at an identified frequency until plasma is ignited at the plasma chamber.

16. The apparatus of claim 9, further comprising an voltage source that is controllably switched by one or more switches to provide an electrical voltage associated with the voltage source to one or more terminals of a plasma chamber.

17. An apparatus for initiating plasma ignition in a direct current (DC) plasma system, the apparatus comprising:

an upper rail and a lower rail that are disposed to form an electrical link between a DC plasma chamber and a first and a second output, respectively of a power supply;

a plurality of switches that electrically couples a voltage changing circuit to at least one of the upper rail or the lower rail of the power supply when at least one of the plurality of switches are closed; and

a control component coupled to the plurality of switches that controls switching between at least a first switch configuration and a second switch configuration, wherein the control component controls;

the closure of at least a first switch of the plurality of switches to electrically couple the voltage changing circuit to at least one of the upper rail or the lower rail of the power supply to provide a first voltage to the DC plasma chamber, the closure of the first switch corresponding to the first switch configuration,

the first switch and a second switch of the plurality of switches to open or close according to the second switch configuration, the second switch configuration providing a second voltage to the DC plasma chamber,

switching between the first switch configuration and the second switch configuration until the ignition of the plasma occurs based on switching between the first voltage and the second voltage provided to the DC plasma chamber.

18. The apparatus of claim 17, wherein the voltage changing circuit includes an energy source.

19. The apparatus of claim 18, further comprising:

a capacitor;

a first diode serially coupled with the first switch between the upper and lower rail; and

a second diode serially coupled with the second switch between the upper and the lower rail, wherein;

the capacitor is positioned to provide a charge path through the first diode and the second diode when the first switch and the second switch are open,

the first switch and the second switch are closed to reverse the applied voltage to the plasma chamber based on electrically connecting the capacitor to the upper rail and the lower rail of the DC powered plasma system.