Gantry type plating machine

Gantry type plating machine

Gantry type plating machine overview:

This series gantry type plating machine is suitable for multi variety production. It is readily to change plating types and to adjust electroplating time. Main machine adopts imported motor with brake. Therefore, has features of smooth running, reliable brakes, less shaking, coupled with PLC program control. Then the automation degree is high. Screens displayed and controlled by touch screen. It is willfully to transform any process and procedures. Which can meet different electroplate cladding material matches.

Gantry type plating machine main parameters:

Output cycle: 2 minutes or more/hanging adjustable;
Maximum plating workpiece: Can be designed according to customer demands;
Working conditions: continuous production for 24 hours;
Maximum lifting weight: could be designed according to users’ end product.
Suitable for galvanized, nickel, tin, and other plating.

Gantry type plating machine

Gantry type plating machine

Linear gantry electroplating machinery is characterized using a gantry crane to hoist and carry plating parts (with hanging rod or pole with a barrel roller). With variety plate bathes with in a straight parallel line or more lines, while cranes make a straight line along the track, making the use of one or two pairs crane lifting hook for hoisting, then to make the automatic production line complete the machining tasks according to the program. The gantry crane has advantages of good rigidity, significant hoists weight, stable running, which is suitable for various sizes of plating tank lifting workpieces. For auto line of large length of the electroplating tank, can use this type of body structure. The working rails installed on double sides of plating bath, that has advantages of slowing corrosion when track running, and convenient of electrical sensor fault checking; Using larger coating bath automatic line controlled by high precision computer, which has advanced functions of parameters automatic memory and storage on production process, that is available for quality inspection traceability; and can be equipped with a vibration swing; air agitation; PLC automatic control, precise operation; as well as can be equipped with high precision filter, to ensure high-quality coating and plating; also could be accompanied by high-quality rectifier to ensure the stability of plating.

Barrel plating machine

Barrel plating equipment

When plating workpieces volume is small and with larger quantities, it is reasonable and economical to use barrel plating equipment.

Compare to rack electroplating, Barrel plating equipment has the following advantages:

① Barrel plating equipment without loading and unloading jigs processes, which saving time, and its production efficiency is higher than the rack 4 to 6 times;
② Sometimes barrel plating machinery can also improve the coating quality, because of the constant rolling of the workpiece, it is equivalent of a strong agitation, can make surface bubbles early leave, to prevent adhesion of impurities, then make the coating bright;
③ Because of do not use rack, avoided the print appearance of plating hung racks.

Barrel plating equipment

Barrel plating equipment

But the shape and size of barrel plating equipment workpieces are subject to certain restrictions, the appropriate plating layer thickness is also less than rack electroplating, majority the thickness is less than 10μm, while the coating film thickness is not easy to control.

Parts suitable for barrel plating machine: bolts, nuts, washers, etc., while easy to fit together the parts (such as spring, sheets, etc.,) as well as easily deformed, easy to collision damage, required to maintain edges parts, then can not use barrel plating machine. There are many of plating types suitable for barrel plating machine, such as Zn, Cd, Ag, Sn, Cu, Ni, etc..

In order to overcome some of the limitations of barrel plating production line, expansion the barrel drum diameter and length in barrel plating equipment recently, and simplify and automate the loading operation, improve barrel drum solution circulation and so on, so that the barrel plating machine yield can be improved, while suitable barrel plating production line parts range expanded, and operation is greatly simplified.

Mechanical type-Manual plating

Manual plating equipment

Manual plating equipment:

Manual plating line is to rely on manual operation, which entry bath and out of bath relying on people controlling, this kind of machine suitable high quality parts electroplating treatment, but when face quantity production, it will appear low efficiency problem, and because of it’s feature with controlling by people, if there is any quality problem, it is trouble to trace problem source.
Automatic plating machine is run automatically by PLC, with advantages of unified process, suitable for high-volume production and high efficiency. But for some special requirements of precision parts, automatic line is not as good as manual plating equipment so convenient and practical.
In a word, automatic plating machine is suitable for mass production mature processes products, while manual electro plating machine is suitable for electroplating more sophisticated requirements and automatic plating line not easy to treatment.

Advantage of manual plating equipment is better adaptability for various products, which is flexible to arrange production, but the efficiency is low. The auto electro plating machine with obvious high efficiency advantage and relatively stable quality, less quality fluctuation caused by human factor, but the automatic line has feature of poor adaptation for products, some specializing plating production lines only suitable special designed products, when product shape and coating requirements changes, it will reduce the efficiency, and can not take automatic advantages.

Manual plating equipment arrangement:

Manual electroplating line arrangement is basically based on the production process. In order to prevent fatigue and operating interference in processes, usually divided into pre-plating treatment, electro plating treatment, and after plating three sections. The ideal layout is set up in a separate pre-processing workshop, where there is organic oil degreasing, chemical degreasing and etching processes. And pre-treatment of electrolytic degreasing and activation processes moved to electro plating section.

Electroplating process electroplating workshop is based processing areas, some companies will after plating and electroplating in the same area, after cleaning the upcoming electroplating, plating production also complete the drying area. In a small business or workshop class plating processing units, which are more common layout methods. Large electroplating enterprises there after plating a special area will be processed and dried after plating placed in a special area, and additionally has a packaging area. Such management of stable quality and efficiency are very advantageous.

Manual plating equipment

Manual plating equipment

Circular vertical electroplate production line

Overview of Circular vertical electroplate production line:

Circular vertical electroplate production line is suitable for medium and large hardware, metal, and ABS plastic and circuit board plating. Our plating machine uses hydraulic and mechanical transmission. Has the features of reliable operation and low noise. Advanced design of control circuit, and adopts imported PLC and transducer and photoelectric proximity switches. Travel switch multiple protection to ensure reliable operation. And the running speed, time can be adjusted according to requirements.

Main parameters of Circular vertical electroplate production line:

Output cycle: 30 second/hanging adjustable; Maximum plating workpiece: can be designed according to user; Working conditions: 24 hours of continuous production; Maximum lifting weight: could be designed according to users’ end product. Suitable for galvanized, nickel, tin, and other electroplating.

Circular vertical electroplate production line

Circular vertical electroplate production line

Circular vertical electroplate production line typical process tank arrangement of full automatic ring electroplating machines present as U-shaped, by a number of fixed bathes with basically same width but different length, and mechanical devices that push hanging piece forward and fixed points go up and down, and automatic control devices and other devices.

Hanging tool along with plating workpiece regularly conduct the steps of fall, delay, rise, forward and other actions, it can automatically combine many procedures, including degreasing, pickling, cleaning, electroplating and other dozens. Automatic ring plating production line with high degree of automation, high efficiency, reduce labor intensity, less the operator, beautiful appearance; leverage vertical lift, plating tank capacity utilization is high; mechanical movements are simple, low-maintenance cost of equipment; the time of exposing on the air is short, workpiece running smoothly, each arm about 2-100s; equipment operation speed is adjustable and has a cushioning device, so that the plating holding steady; run cycle short; which is suitable for high quality coating, high-volume, single shape, mature technology electroplating.

Circular vertical electroplate production line features:

Compare to gantry type plating machine hanging, circulation vertical electroplating production line has following features: In the production process, each process baths are all in load condition, so that the efficiency is high, which is suitable for mass electro plating production, and mature technology products, but circular vertical electro plating machinery mechanical structure is more complex, more investment, as well as changing difficulties in technological. Automatic circular plating machine line of each rack as a beat, move each distance, will fixed lifting, and the plating workpiece will be forward sequential. Therefore, the plating bath placement arrangement arranged in a U shape according to technical production process.

Auto Rack plating machine

1, Overview of auto rack plating machine:

Auto rack plating machine is in accordance with certain technical requirements, various plating tank-related traffic, racks, electrical systems, power equipment, ventilation system, filtration system, temperature control heating systems, air mixing system, level control systems, cathodic mobile devices form a complete multi-functional automatic control system. This production line is suitable for rolling, hanging plating dual.

2, Working process:

Plating production line using straight cantilever crane, while the crane equipped with lifting hook. Crane and hook each driven by motor separately, and motors speed controlled by inverter. There are proximity switches and sensors in suitable position on crane, and the sensors will be installed according to positioning rail, thus crane translation and hook lifting will be all positioned by sensors. For simplicity in explanation of Crane operation for plating line, now will simplify 30 station 30 to 5: loading station, pre-processing station,  plating bath station, after-processing station, unloading station. Following picture shows the working process.

Crane working process flow

Crane working process flow

Loading and unloading station are beginning and end of crane running. On loading position, hung plating workpiece manually, then return loading station to hang electroplating products, i.e. cycle the plating work. Lift the hanging workpiece and not stop until sensor close to the upper limit. Go to the next step: move crane to right until sensor approach the 2nd, then stop, at this moment, the hook just above on the pre-processing station;
Down hook and do not stop until sensor close to the lower limit, then put plating workpiece into plating bath, according to specific process requirements to deal with plating products on timing period;
When the timing period reached, lift the hook to rise electroplating product and not stop until sensor arrive at the upper limitation, after that, continue to the next step;
Continue to the move crane right until sensor close to the 3rd sensor then stop, at that time, the electroplating product is  just above the plating bath station;
Still drop hook and do not stop until sensor close to lower limit, then put the plating piece in to plating bath, according to specific requirements to deal with plating parts on timing period;
After plating process finished, rise the hook and not stop until sensor close to upper limit, continue to the next step;
Continue to move crane on right direction, until sensor close to the 4th sensor, then stop, at this moment, the part is just above the after-processing bath station;
Then down hook and don’t stop until sensor close to the lower limit, then put the parts into after-processing bath to proceed bath solution recycling, and wash cleaning with water;
After the hook rising in place, continue to move the crane on right side to approach unloading station to unload the electroplated parts, and then return to the loading station to repeat the previous step one by one.

3, Mechanical design:

This time we take straight line cantilever structure type as our sample. Mechanical structure mainly includes rack structure, cranes and variety kinds of plating baths.

3.1 Rack:

Considering larger acid and alkali corrosive for environment on plating production, we use high quality stainless steel profiles for integral part of the rack, in order to improve equipment corrosion resistance, and also achieve the required device strength and rigidity. In the mean time, for easy installation, the rack each part adopts screw join, then maintenance is simple, and the appearance is compact.

3.2 Crane:

Except manual loading and unloading workpiece the entire production process is full automatic operation. The crane driving relies on primary and secondary rail along with the side of the rack. While lift arm slide along with the rail on crane rack, using method of rolling or sliding to replace directly elevate or drag, then to reduce the bearing.

3.3 Cathode moving:

When in plating there are bubbles generated on the cathode, if these gas stick on to the cathode surface, then will prevent metal irons continue deposition, resulting in coating surface mottling, micropore, thereby affecting products quality. In order to eliminate this phenomenon, we adopt cathode moving devices. These devices is horizontal movement type, which movement number: 15-20 times/min, moving stroke 60ram, driven by single phase DC power: 370w. And equipped with position sensors in cathode one side, so that the crane movement compatible with cathode moving, to prevent accidental operation, then affect normal processes operation.

4, Electrical design section:

As per features of complex running, circular motion, auxiliary equipment, various types of positioning detection, so many signal picking up for electroplating production line, and based on different technological demands, the tasks need to be achieved are different. This will require the ability to modify technical processes and operating parameters at any time, so the whole control system should have strong adaptability and adjustability, also require the system safe, reliable, accurate and stable performance. Therefore we choose PLC, IPC, inverter, touch screen as mainly control system.

Electroplating touch screen parameters

Electroplating touch screen parameters

4.1 PLC:

We adopt Siemens PLC or Mitsubishi PLC which based on customers’ requirements. Use sensor to control solution liquid level. On condition of communication with IPC, to control crane movement, cathode moving, spray system, air agitation system.

4.2 IPC:

PLC and IPC via serial communications to conduct real-time monitor of production process, and the preparation and operation all operated under WINDOWS. The system has function of power-off protection, which can timely protect on-site data and station, to ensure that the system can continue to operate safely.
When start computer, will appear control software welcome interface, then click the button to enter into management menu. In this menu to select technology, complile technical, storage technology, delete process, power management, cathode movement on/off and exit menu. After call in the technical management menu, then can modify the technical parameters.
In power management function modules: power control mode divided into remote mode and local mode, the plating current and voltage can be adjusted by these two modes.

4.3 Touch Screen:

After IPC setting parameters and reading in PLC data, but can not take effect immediately. For solving this problem, we use touch screen, to display various parameters and operating functions. Conditions take it force: press initialization button on touch screen, and then successful complete initialization. Parameters will be effective immediately after setting, then been replaced until IPC parameters conditions meet the demands. Operator can flexibly use machine in accordance with this characteristic. In standby state, if this is not alarm. The initial menu of touch screen functional blocks shown in as following figure:

1) Automatic and manual modes. Crane movement will auto running according to parameters set based on process automatically;
Manual mode, by means of control box to control crane moving, and emergency brake stop button can be used to stop any movement.
These two modes can be switched with each other, which provides the necessary means for facilitate maintenance, operations, and the safe operation of the machine.
2) Initialize the module: it is premise for crane normal operation, only in initialization state read PLC parameters can take effect.
3) Barrel and Rack plating: two ways can be switched depending on demands of products.
4) Start module: initialization is completed, you can press this button to start running the program, crane will run accordance with the technological process.
5) Process parameter module : this module is pressed to switch to process parameter setting screen, ease for user check IPC parameters, and modify process time.
6) Crane parameter module: in this module, crane accelerate and decelerate time, rinse bath station, spray time, enter bath time with electricity and cathode movement stop and moving time can be set.
In addition, if alarm occurs. Touch screen display alarm figure, and display alarm cause. After troubleshooting pressing the release button to display initialization interface. Recover normal state.

4.4 Inverter:

In order to locate small car accurately, it is necessary to control crane speed. When the inverter has a positive output, the motor forward, crane move left, hook rise; When the inverter has a reverse output, motor reversal, crane right move, hook dropping.
In order to prevent plating workpieces shaking and can’t reach destination when crane working, we required, when crane translation, first fast speed, when approaching the station turn into a slow speed, in order to reduce braking torque, and improve positioning accuracy, as well as rails wearing.

5, Key auxiliary machine:

5.1 Spray equipment:

In order to thoroughly wash and clean the workpiece in bath, there equipped with spray device in each plating rinse bath. After crane arriving at rinse bath according to technical process and finishing the washing, the workpiece will be lifted, the magnetic valve controlled by PLC will be opened immediately, and shut down after periodically washing the products.

5.2 Plating power supply:

From principle knowledge, we know electroplating power supply must be DC power or pulsed power supply. While various types of plating bath, the power requirements are not same, so in electroplating production the electric current, voltage should be controlled within a certain error range. Therefore, use high-frequency switching power supply with features of constant voltage, constant current , constant current density control, IGBT module and unique driving protection method. Via PLC to conduct local and remote control and their conversion, to bring convenience for actual production.

5.3 Temperature control system:

Since high temperature demands of electrolytic degreasing and plating bath,  which directly affects the quality of the plating products, therefore we use temperature control systems. This system is composed by temperature controller, temperature sensor, heating tube and electrical relay.

Temperature control system working principle:

When bath solution temperature measured by sensor below the set temperature, temperature controller output signal to drive relays, then heating tube continue to heat;
When the measured temperature is higher than the set temperature, temperature controller stop to output signal, then heating pipe stop heating.