Automatic galvanizing line drum-hanger

Work done

Based on the initial data (annual program, type of parts, coating requirements, etc.), the specialists of IVES LLC determined the technology of electroplating, selected the equipment. Based on the annual program for the volume of coating of parts and the type of parts, it was determined that this line should be automatic with the processing of parts both on suspensions and in bulk in galvanic drums.

After agreeing on the terms of reference and specification of the equipment, a set of design documentation was developed. An automatic galvanic galvanizing line of drum-suspension type was manufactured and installed.

Scope of work

1. preparation of technical specifications based on the requirements of the Customer;
2. selection of coating technology, determination of the type of line;
3. development of design documentation for the line (galvanic baths, gantry operators, metal structures, control system, etc.)
4. a set of galvanic baths was made;
5. two portal operators were manufactured;
6. metal structures for the installation of baths and auto operators, a navigation bridge were manufactured;
7. a power supply and control system for the galvanic line was manufactured;
8. an exhaust ventilation system was manufactured;
9. filter units, dosing pumps, rectifiers and other necessary equipment are installed;

Project description

The universal automatic galvanic line is a production complex that allows you to perform technological processes of applying a protective and decorative zinc coating to steel products in bulk in a drum or individually on suspensions with various types of surface passivation.

The operation of the equipment and the operations of the technological process are carried out in an automatic mode controlled by software.

The design capacity of the automatic galvanic line is not less than 30000 m²/year with a 2-shift mode of operation.

The universal automatic galvanic line of drum-suspension galvanizing was implemented within the framework of the project to organize modern and highly efficient galvanic production at the Customer's premises, in order to expand the range of products and increase the efficiency of the enterprise.

During the creation and commissioning of the automatic production line, the specialists of the IVES company performed a set of works and measures, including:

• assistance to the customer in determining the requirements for the production line, drawing up technical specifications, taking into account the nomenclature, overall dimensions and weight of products, types of coating, processing methods and productivity;
• development and implementation of optimal design, technological and engineering solutions aimed at minimizing the consumption of raw materials, materials, heat and energy resources;
• design work on the creation of the main and auxiliary capacitive equipment using the specialized TANK DESIGNER program, which ensures the optimal design of galvanic baths, in accordance with the DVS 2205 standard and compliance with the requirements of GOST 12.2.003-91 "System of Labor Safety Standards. Production equipment.
• production and complex equipment of technological equipment using structural materials and components from the world's leading manufacturers;
• software development and organization of an automated production line control system;
• selection of the required compositions of working solutions and electrolytes of process baths, modes of the production process aimed at ensuring the required quality of galvanic coating of products and minimizing defects;
• installation and commissioning, sea trials of the line equipment were carried out and training of production personnel was carried out;

The automatic galvanic line is made in a single-row version and represents a set of equipment including:

Process bath set

intended for the content of working solutions and electrolytes, in which surface preparation and treatment operations are performed, application of functional zinc coating by electrochemical method.

Technological baths are a rectangular body of various designs, the material of which is selected depending on the chemical composition of the solution used and the temperature regime of processing parts.

Depending on the functional purpose, the bathtubs are equipped with:

• • a drain pipe with chemically resistant shut-off valves;

• water supply device with shut-off valves; water supply control devices – rotameters;
• an overflow pocket with a branch pipe for wastewater disposal;
• a system for mixing the composition with compressed air;
• Scanning heating elements with IP66 protection, bimetallic overheating protection and a maximum error of ± 3°C;
• temperature and level sensors NT, NS by Mazurczak, which provide registration of the technological parameters of the bath;
• thermal insulation of the side surfaces;
• on-board exhaust ventilation system suctions that ensure the collection and removal of polluted air;
• catching supports made of polypropylene.
• all process and hot baths are equipped with lids covering the bath mirror;
• Electrochemical degreasing and galvanizing baths are equipped with current-carrying rods made of rolled strip copper with holders and high-efficiency DC power sources;
• the electrochemical degreasing bath is equipped with a device for removing foam and oils from the surface of the electrolyte - an oil separator with a skimmer model FRIESS Oil Skimmer Type 1U with a capacity of up to 500 l/h;
• The galvanizing baths are equipped with powerful filter systems manufactured by Siebec with a capacity of up to 5 m³/h, which ensure effective purification of the electrolyte from mechanical contaminants and reaction products;
• The galvanizing baths are also equipped with electrolyte cooling and automatic dosing systems for functional additives using specialized equipment from Emec, controlled by software in automatic mode.

In order to ensure rational water consumption and ensure the required parameters of the content of pollutants in the wash water, the flushing baths are made in a two-stage version.

Transport system

It is implemented in the form of two gantry-type autooperators moving along the tracks - rails fixed along the galvanic line and designed for lifting, moving to positions and lowering technological satellites (suspension, drum) into baths, or on loading and unloading racks.

The work of auto operators is synchronized with each other and divided into "areas of responsibility", which allows you to optimize the production process, minimize downtime and idle runs.

Car operators have their own control system, which ensures the operation of the transport system in three modes:

• in automatic;
• in manual;
• in the commissioning room.

In automatic mode, auto operators are controlled by commands coming from the control panel via the local information network.

Installation and movement of processed products is carried out on technological carriers of two types:

• suspension of its own design depending on the model of the product;
• Electroplating drum of the corresponding model.

Parts drying

on suspensions takes place in an automatic drying bath, which is equipped with a lid, temperature and pressure sensors, heating and convection systems.

Drying of bulk coated parts is carried out automatically in a centrifuge manufactured by LMFinishing to minimize the manual labor of workers.

Local exhaust ventilation

It is designed to collect, remove and purify polluted air from the mirror of process and hot baths. Exhaust ventilation includes prefabricated air ducts and on-board bath suctions. Air is removed from the surface of the solution using an exhaust fan, which is made in a corrosion-resistant design and is designed to move gas-vapor-air explosive mixtures.

Air purification is carried out on the RIF-FK-25 ion exchange filter, which ensures effective removal of exhaust air contaminants to the maximum permissible emissions and compliance with the requirements for the air of the working area.

Automated Control System (ACS)

under the control of specialized programs developed by IVES LLC, ensures the optimal functioning of all units of the line for the implementation of the launched technological processes.

An automated control system is a three-level system (lower, middle and upper levels). It is possible to transmit at the request of a computer of a higher level the current parameters of the line components, internal protocols and other necessary information for the subsequent analysis of the line operation and quality control of the manufacture of a batch or series of products.

Remote access to the system via the Internet is provided.

The lower level of the automated control system includes sensors for temperature and liquid level in baths and tanks and actuators (solenoid valves, electric motors for pumps and filters).

The average level of automated control system includes:

• programmable logic controller (PLC);
• operator panel;
• power switching and protective devices (contactors, circuit breakers, etc.).

Medium-level equipment performs such basic functions as:

• data exchange with the equipment of the upper level of the automated control system via the local information network;
• Continuous monitoring of sensor outputs
• control of actuators in automatic and manual modes by commands coming from the equipment of the upper level of the automated control system, and signals of sensors;
• continuous diagnostics of protective and switching equipment included in the automated control system, other control equipment;
• blocking the operation of the system as a whole or its components in a controlled emergency situation;
• Issuance of emergency light and sound signals when the monitored parameters go beyond the permissible limits or when protective devices are triggered.

The upper level of the automated control system includes a control panel made on the basis of a panel computer with a touch screen. In addition to the computer, the remote control includes the necessary controls and indications.

The equipment of the upper level performs the following main functions:

• control of auto operators and line rectifiers via the local information network in accordance with the technological processes implemented on the line;
• giving commands to the shield to control the line units;
• visualization of the technological process on the computer screen of the control panel;
• Providing the operator with data on the state of the system, including:

a) on the condition of sensors and actuators;

b) the degree of filling of baths and containers;

c) reports on abnormal and emergency situations on the line;

• input and correction of parameters of technological processes implemented on the line and storage of the entered data for subsequent use;
• maintenance and storage in non-volatile memory of internal protocols necessary for line operation analysis and product quality control (protocols of technical processes, operating modes, warning messages and emergency situations);
• selection of the ACS operating mode;
• communication with a computer of a higher level and transmission of the current parameters of the line components, protocols and other necessary information at its request.

Result

The customer received a modern automatic galvanic galvanizing line of drum-suspension type, which meets all requirements for performance, type of coating, ease of operation and maintenance.

The commissioning of an automatic galvanic line manufactured by Ives made it possible to:

– to organize modern galvanic production that provides an optimal ratio of quality and cost of products;

– minimize manual labor of personnel and eliminate the "human factor" in the production process, which will ensure consistently high quality of products, minimize the number of defects and related costs;

– to expand the range of products manufactured by the enterprise, to reduce production costs associated with the manufacture and purchase of these products on the side,

– to ensure the efficiency and flexibility of the enterprise.

The share of products of IVESS LLC's own production in the galvanic line is more than 75%.