Mechanized galvanic line for galvanizing studs

The mechanized galvanic line is designed for the application of decorative and protective zinc coatings with subsequent passivation on large-sized profiled steel products, such as rod, cylinder, stud, etc. on suspensions.
The maximum permissible overall dimensions of the coated products: length up to 6000 mm, diameter up to 60 mm, complexity class - no more than 2. Required coating thickness: up to 25 μm.
The design capacity of the galvanic line is not less than 8700 m2/year in 2-shift operation, the estimated hourly capacity is 2.2 m2/h.

Work done

A mechanized galvanic galvanizing line for large-sized products was implemented as part of a project to organize a modern galvanic coating complex, in accordance with the requirements and restrictions specified by the Customer:

• Limited project funding (budget limit);
• Tight deadlines for project implementation (time limit for order execution);
• Maximum energy efficiency of production equipment;
• Limited production areas of the Customer.

Scope of work

During the implementation of the project for the commissioning of a mechanized production line, the specialists of the IVES company performed a set of works and applied technical solutions that made it possible to impeccably fulfill the established requirements of the Customer:
• Assistance was provided in determining the requirements for the production line, the terms of reference were drawn up, taking into account the nomenclature, overall dimensions and weight of products, type of coating, processing method and productivity;
• The technology was developed and the technological process of electroplating was introduced: the compositions of working solutions and electrolytes of process baths were selected with an indication of the manufacturers of reagents, modes of the process, the required energy consumption, recommendations were provided on the number of line personnel with an indication of qualifications;
• The design and manufacture of a full range of technological equipment for the line was completed. Design work on the creation of capacitive equipment was carried out using the specialized TANK DESIGNER program in accordance with the DVS 2205 standard, which ensured its high quality and energy efficiency;
• Installation and commissioning works, sea trials of the line equipment were carried out, coating modes were worked out, training of production personnel was carried out;
• A number of design and technological and design solutions aimed at saving the production space of the workshop were developed and implemented. In particular, the operations of pre-preparation of the surface of the products to be coated are removed from the production line and are carried out at the existing facilities of the Customer;
• The transport system of the galvanic line is integrated into the general shop, which made it possible to significantly reduce the cost of production equipment, without losing the productivity of the line and ensuring the required quality of coverage;
• A list of required equipment, devices and reagents for equipping the laboratory of chemical analysis of electroplating production was prepared and recommended;
• Warranty service and post-warranty support are provided.
  

  Project description

  The mechanized galvanic galvanizing line for large-sized products is made in a single-row version.
  Processing and transportation of products is carried out on traverses of a unique design developed by IVES specialists, taking into account the overall dimensions, weight, complexity of the product design and the required current loads.
  The transport system is controlled manually by the line operator.
  Monitoring and control of the equipment operation, conducting the technological process: process temperature modes, operation duration, current loads, operation of the exhaust ventilation system and water flow are carried out in automatic mode by the line control system centrally from the command post.
  The complex of technological equipment of the line includes:

  1. Process bath set

     Technological baths, auxiliary tank equipment and tooling are manufactured on modern processing equipment of European and American production, using structural materials and components of the world's leading manufacturers.
     Depending on the functional purpose, the bathtubs are equipped with:
     Pipelines for the supply of industrial water and the removal of waste solutions and compounds with shut-off valves, water supply control devices - rotameters;
     Compressed air mixing system;
     Scandymet heating elements with IP66 protection, bimetallic overheating protection and a maximum error of ± 3°C;
     Temperature and level sensors NT, NS Mazurczak, which provide registration of the technological parameters of the bath;
     Thermal insulation of side surfaces;
     On-board exhaust ventilation system suctions that ensure the collection and removal of polluted air;
     Catching supports made of chemically resistant structural material.
     All process and hot baths are equipped with lids that cover the bathtub mirror.
     The galvanizing bath is equipped with current-carrying rods made of rolled strip copper with holders and high-efficiency converter-type DC sources, as well as a powerful filtration unit manufactured by Siebec, which provides effective cleaning of the electrolyte from mechanical contaminants and reaction products.
     Also, the galvanizing bath is equipped with an electrolyte cooling system.
     In order to ensure rational water consumption and ensure the required parameters of the content of pollutants in the wash water, the washing bath after galvanizing is made in a two-stage version.

  2. Drying

     To remove moisture from finished products, a drying zone is provided, combined with a loading/unloading area. Drying of products is carried out naturally or forcibly, by blowing compressed air manually;

  3. Local exhaust ventilation

     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 an ion exchange filter, which ensures effective removal of contaminants of the exhaust air to the maximum permissible emissions and compliance with the requirements for the air of the working area.

  Result

  The implementation of this project and the commissioning of a mechanized galvanic line for zinc coating of large-sized products manufactured by IVESS made it possible to:

  • To organize modern galvanic production in conditions of limited production areas of the workshop and a limited budget of the Customer;
  • To ensure the optimal quality/cost ratio of products;
  • To increase the load of the Customer's existing production facilities and reduce the general production costs of the enterprise;
  • To expand the range of products and diversify the revenue side;
  • Ensure the efficiency and flexibility of the enterprise.