Metal Finishing Guide Book

2013

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level. Further, should your finishing system reside within its own room or a defined air makeup zone, additional savings can be achieved if VFD controls are added to throttle the makeup system, which is, in turn, slaved to the ventilation system. More complicated to design and install, a full machine enclosure can offer several benefits. They reduce total volume of ventilation air required, and reduce or eliminate disruptive external transient air flows, which can adversely affect push-pull ventilation systems. Furthermore, operator safety is often improved because the transparent ventilation barrier is located between the catwalk and automation. * It is important to note that industrial ventilation and scrubbing technology is an Figure 4. Up-barrel rotation reduces drag-out. (Photo credit: Photography by Colleen Sadlik, evolving science. Federal, state, CreationsMadeSimply.com.) and local regulations regarding emissions — and the methods and cost of air treatment — are beyond the scope of this article and should be addressed with a competent ventilation system supplier. CONTROL, MONITORING, RECORDING, REPORTING PC/HMI operation of finishing systems should be considered standard for all finishing systems. Error-proof NADCAP & ISO processing is possible if the machine is equipped with appropriate sensor technology. Data such as tank temperatures, immersion times, rectification, pH, conductivity, rotation/oscillation speed and/or duration, chemistry additions, drain dwells, dryer temps, and water usage, are collected, stored, and exported to the customer database for analysis and report generation. From an operational standpoint, engineered process cycles offer the most efficient production performance, though mixed processes and variable plate time cycles are available at the cost of some productivity. Most operators prefer fixed production rates so load/unload operations and external logistics remain unaffected. Regardless of operational strategy, machine operation must be simple and intuitive. A user-friendly, multi-lingual, touch screen, human machine interface (HMI) is a necessity in today's finishing environment. A PC with MS Windows-based software offers easy PLC interface and requires no special programming skill. Recipe upload is typically accomplished with bar code scanner technology. Most important: Individual rectifier, chemical, tank level, tank temperature, ventilation, and wastewater management functions can be easily managed through a security-coded interface. Additional features may include monitoring and control of hoist equipment, process tanks, and accessory equipment. Performance monitoring may include shift reports for total time and number 701

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