Metal Finishing Guide Book

2013

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finishing equipment & plant engineering ENERGY AND RESOURCE REDUCTION FOR AUTOMATED FINISHING SYSTEMS BY TIMOTHY J. KURCZ, DIRECTOR OF SALES, JESSUP ENGINEERING, INC., ROCHESTER HILLS, MICH. OEM and independent job shops can benefit tremendously from investment in new automatic finishing equipment by operating faster, more efficient machines that deliver repeatable quality with reduced labor. Knowledgeable buyers increasingly demand integrated computer controls to manage water and chemistry replenishment, rectifiers, ventilation and air makeup systems, and wastewater treatment to reduce energy and resource consumption and associated ongoing costs. Before management features can be designed, a new machine should be carefully sized to meet current and future production requirements. The very foundation of energy management begins with proper sizing of the rack, barrel, or basket — collectively known as the work package. Total work package surface area is critical for rectifier sizing; chemistry and rinse water replenishment. For racks and baskets, the work package is defined as the width, height, length direction of travel (DOT), and load weight, plus liquid if very large or cupping parts are processed. Barrel capacity is defined as the width, diameter, and load weight: A long-established rule of thumb suggests 33% fill for plating and 80% fill for coating (volumes) are typical for barrels. With the work package established, overall dimensions are used to determine tank size and hoist capacity. The objective is to limit tank surface area to the greatest extent possible, thus reducing evaporative losses and floor space required. Maximum load weight, combined with rack or barrel weight, dictates hoist capacity, including lift, transfer, and up-rotation motor sizes. One more step is needed before machine footprint can be established: It is critical to secure chemistry supplier input when developing a process sequence. Figure 1. High-efficiency full machine enclosure. (Photo credit: Photography by Colleen Sadlik, CreationsMadeSimply.com.) 697

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