At present, with the continuous development of technology, modern electroplating equipment has become an indispensable part of the development of contemporary electroplating enterprises.
If electroplating enterprises want to produce and process electroplated products on a large scale and in large quantities in a short period of time, they cannot do without modern electroplating equipment.
In order to ensure the normal operation of electroplating equipment, it is necessary to repair and maintain the electroplating equipment in a timely and effective manner.
1 Analysis of electroplating automatic production line
- Hanging plating automatic production line
The hanging plating automatic production line is roughly divided into two types, namely linear production automatic line and mechanical automatic production line.
- Roller plating automatic production line
Roller plating automatic production line is roughly divided into two types, namely linear gantry production automatic line and circular mechanical production automatic line.
Among them, the bell-shaped roller with inclined automatic loading and unloading is suitable for circular mechanical production automatic line.
In addition, the circular mechanical production automatic line is also used to produce standard parts of FAW and Second FAW in China.
- Electroplating power supply
In the electroplating production process, electroplating power supply is one of the most important auxiliary equipment.
At present, thyristor rectifiers and silicon rectifiers are still the main auxiliary equipment used in China.
The voltage of thyristor rectifiers and silicon rectifiers is mostly 12V, and the current is 100-20000A, both of which are low-voltage and high-current devices. Only when the load is relatively large, the thyristor rectifier will have a better waveform.
At present, my country is vigorously promoting the electroplating power supply with stable current and voltage, and most electroplating power supplies require the installation of A/D conversion to achieve PC control.
- Electroplating solution filtration equipment
A major factor in the quality of electroplating products is the filter.
In the past, filters from Japan and the Netherlands were mainly used, while currently, cartridge pressure filters are mainly used.
The centrifugal pump filter produced by Japan Sanjin Manufacturing has a very large filter bag and a large filtering capacity; the magnetic pump filter is also a representative work produced by Japan, with a relatively small filtering capacity. At present, more cartridge pressure filters are used, with a maximum filtering capacity of 20t/h. Not long ago, Japan developed a new type of filter, which is mainly used for chrome plating, chemical nickel plating and chrome plating. Both in terms of product materials and product quality, it has been greatly improved.
- Cooling and heating equipment
Traditional electroplating heating methods are mainly based on electric heating and steam.
Diesel burners manufactured in Sweden, Italy and Germany, hot water tanks are heated by diesel burners, and the temperature is controlled by thermostats. Through hot water pumps, hot water can be transported from water pipes to tanks that need to be heated. Different tank liquids will achieve heat exchange through different pipes, including polytetrafluoroethylene pipes, stainless steel pipes, Qin pipes, etc. The exchanged water flows back to the hot water tank again, and is heated again, thus continuously circulating.
The coating drying box and electroplating tank are the first equipment to be heated by fuel equipment, which helps to save electricity.
At present, many electroplating companies in my country are using natural gas hot water boilers for hot water circulation heating. Natural gas hot water boilers are equipped with microcomputer controllers and imported burners. They use hot water in the heating pipes and hot water circulation pumps to automatically circulate the boiler to achieve the purpose of heating, which helps to improve the quality of electroplating products.
In addition, the cooling equipment currently used by most electroplating companies is the cooling unit.
The main components of the cooling unit are compressors, evaporators, condensers, and expansion valves, which can directly cool the liquid medicine for circulation or cool the liquid medicine through water circulation, thereby achieving the cooling effect of the unit.
2 Repair and maintenance of electroplating equipment
- Rack
After one month of production, the mounting screws in the rack should be retightened.
To ensure that the rack remains clean for a long time, the sliding doors, pedestrian walkway railings, stainless steel column surfaces, etc. in the rack should be cleaned every 4 months.
- Crane
For the reducer, it should be checked every 700-800 hours to check whether it produces abnormal noise, and the tightness of the reducer seat should be checked and adjusted.
To avoid damage to the shaft, bearing, and housing, it is strictly forbidden to use a hammer to knock when installing the pulley, coupling, and gear.
For the brake mechanism, it should be checked and debugged every 7000-8000 hours. For the power cord in the junction box, its contact condition should be checked every 7000-8000 hours. Once the joint is found to be loose, it should be tightened in time.
For the insulation layer of the wire, once there is aging or melting, the power cord should be updated in time to effectively improve the insulation of the power cord. For bearings and bearing seats, the lubrication and tightness should be checked every 7000-8000 hours.
For the lifting guide wheel, its clamping clearance should be checked and adjusted every 600-700 hours, and whether to replace the guide wheel should be considered every 10000 hours according to the actual situation.
For the transverse guide wheel, its installation clearance should be checked and adjusted every 700-800 hours. For the secondary transverse main and driven wheels, its positioning and fastening status should be checked every 700-800 hours. Once there is looseness or displacement, it should be tightened and corrected in time.
For the sling clamp, its tightness should be checked every 10000 hours, the bolts should be tightened, and whether to replace the sling should be considered every 20000 hours according to the actual situation.
For the sensor and the sensor plate, their relative position should be checked and corrected every 7000-8000 hours. For the two gear racks, their meshing synchronization should be checked and adjusted every 2000 hours.
3. Swing mechanism
For the reducer, its operating status should be checked every 600-700 hours, and the tightness of the reducer seat should be checked and adjusted every 1000 hours.
For the brake mechanism, its braking performance should be checked and debugged every 7000-8000 hours. For the power cord in the junction box, its contact condition should be checked every 7000-8000 hours. Once the joint is found to be loose, it should be tightened in time.
For the insulation layer of the wire, once there is aging or melting, the power cord should be updated in time to effectively improve the insulation of the power cord. For the roller bearing, grease it once every 5000 hours and replace the bearing with more severe wear.
For the vibration motor mounting bolts, the wear of the vibration rubber should be checked once every 1000 hours, and the vibration rubber with more severe wear should be replaced.
4. Circulation filtration system
For the pump motor power cord, the contact condition of its connector should be checked once every 1000 hours. If there is any looseness, it should be tightened in time. To ensure the safe insulation and good contact of the route, the aged wires should be replaced.
For the filter element of the filter, to ensure the flow of the filter, it should be replaced once every 10 days. To prevent the float in the flow meter from colliding rapidly and causing the glass tube to break, the ball valve in front of the flow meter should be opened and closed slowly. At the same time, the reading in the filter pressure gauge should be checked once a day.
Generally speaking, the pressure gauge will not be damaged unless the diaphragm in the pressure gauge seat is aged, cracked, perforated, etc., resulting in the direct inflow of medicine into the pressure gauge, which corrodes and damages the Bourdon copper tube in the pressure gauge.
In this case, the pressure gauge and diaphragm need to be replaced. If the filter pressure gauge reading is too low, the following aspects should be checked, namely, whether the power connector of the pump motor is missing phase or poor contact; whether the pressure gauge fails; whether the pump outlet pipe is blocked; whether there is air inflow between the pressure gauge and the diaphragm in the pressure gauge seat. If so, the pressure gauge should be removed, water should be added to the diaphragm cavity until it is full, and then the pressure gauge should be installed.
If the filter pressure gauge reading is too high, the following aspects should be checked, namely, whether the filter element has serious fouling; whether the crystals block the spray holes of the water spray hose in the tank; whether the pressure gauge fails; whether the pump outlet pipe is blocked, etc.
5. Other parts
Other parts include exhaust system, heater, hanger and dagger handle, cooling coil, trough, anode, low-pressure blower, etc. For these parts, they should also be repaired and maintained.
3 Maintenance before long-term shutdown
If the electroplating equipment is to be shut down for a long time, the following maintenance measures should be taken, namely: to ensure that the machine is in a dry environment, the accumulated water on the ground should be cleaned;
To prevent aging, wrap all motors with plastic wrap; inject grease into all bearings; inject grease into all rubber wheel bearings in the crane; wrap all spray parts in the crane with plastic wrap; clear the medicine in all pipes; clean all heaters and cooling coils.
- Check the electroplating equipment before restarting after long-term shutdown
After long-term shutdown, before restarting again, all the cling film wrapped in the equipment parts during shutdown should be removed;
For all the wiring heads in the motor junction box, check its contact. If the wires are aging, they should be replaced;
For the reducer, check its lubrication condition. During the motor test run, check whether the reducer will produce noise; check the lubrication condition of all bearings and rubber wheel bearings.
According to the actual situation, consider whether to inject grease; for the oil-spraying parts in the frame, they should be checked. Once the paint of some parts falls off or ages, they should be sprayed.
For all the fasteners in the frame, their fastening should be checked. In order to keep the machine in a clean state, all stainless steel parts and sliding doors should be cleaned; for the trough, check whether it has water leakage, if there is water leakage, it should be repaired; all pipelines should be checked, if there is water leakage, the leaking pipes should be repaired and replaced.
For the brake motor, its braking performance should be fully checked, and the reliability and sensitivity of the instruments in the pipeline should be checked.