Metal Finishing Guide Book

2013

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They provide technical process details, including baths and temps, immersion time, rectification, number of rinses, dry time, and water supply requirements. During the machine layout phase, it may be prudent to add space for additional process tanks, rinses, or dryer cells to accommodate future expansion. Alternately, the work package might be expanded to enable increased future capacity should floor space limit DOT additions. Money is usually better spent increasing the work package of a single machine, compared with the cost and space required for a second future machine. For that reason, multiple processes should be considered at this time. Potential machine builders should willingly provide preliminary layouts, cycle analyses, and resource consumption estimates to assist decision making. Once agreement is reached between the plating shop, chemistry supplier, and machine builder, application of available resource reduction technology can be applied. Implementation can make a significant difference in long-term profitability. Concepts and features presented are easily implemented in new machines (Figure 1), and can be retrofitted into existing automatic finishing systems with careful engineering. ENERGY & LABOR REDUCTION Simple, rugged, reliable hardware and easy-to-use controls make best use of resources when run round-the-clock. Individual rectification improves process efficiency and part quality when integrated with in-process weighing or other workload measurement systems. For shops running short schedules, end-of-shift or weekend auto-shutdown enables energy reduction. Auto-start-up ensures that an automated finishing system is ready for operation without the need for set-up personnel. Recipe-driven individual cell rectification enables precise, repeatable plating thickness for every load regardless of part count for rack plating, or by weight for barrel plating operations. This feature can calculate surface area on a discreet part number basis. Operator-entered load data assures precise amp-square-foot (ASF) delivery for rack plating systems. Barrel weight is verified by load cells, assuring precise rectification settings. Hoist improvements reduce energy consumption and enable faster motions, reducing wear and improving operator safety for finishing systems. Highefficiency, VFD-controlled motor/drive combinations provide the smoothest possible motion profiles and reduce electrical energy consumption. Corrosionproof belt lifts reduce drag and dramatically extend maintenance intervals. Full-length, non-contact absolute linear encoders allow faster, smoother, more precise hoist positioning and virtually eliminate rack or barrel shake. These features reduce energy consumption, downtime, and maintenance cost for machine operators. WATER & CHEMISTRY REDUCTION Given today's pressure to conserve earthly resources, it's prudent to make efficient use of water and chemicals. Advances in fluid devices and management can dramatically reduce consumption of both. Naturally, computer controls are at the core of production-based rinse water replenishment and chemistry addition functions. Production-based, load-by-load rinse replenishment can optimize water consumption on a recipe-driven basis. This feature enables experimentation with minimum rinse water volume necessary to ensure quality processing. TheĀ  ultimate goal is to reduce water usage, which also reduces wastewater 698

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