Automated Electroplating Production Line for Hardware Manufacturing
Equipment Description:
I. Typical process flow
1. Pre-treatment stage: Degreasing: ultrasonic cleaning with alkaline solution to remove surface oil stains;
Pickling: hydrochloric acid or sulfuric acid solution to remove the oxide layer, time 30-120 seconds.
2. Electroplating stage: Electroplating tank immersion plating: the robot grabs the workpiece and immerses it in the plating solution (such as zinc plating, nickel plating), the current density is 1-5A/dm², and the coating thickness is 5-30μm.
3. Post-treatment stage: three-stage countercurrent water washing → passivation (trivalent chromium/chromium-free formula) → centrifugal drying (800-1200r/min) → hot air drying (60-80℃).
II. Technical features
High automation: support one-key switching of process programs, changeover time ≤15 minutes, suitable for small batch production of multiple varieties.
Energy saving and environmental protection: The closed design reduces VOCs emission, and the wastewater reuse system (RO reverse osmosis) achieves low-concentration emissions (COD ≤ 50mg/L).
Flexible expansion: Customizable tank size (length 500-2500mm, width 500-1800mm), process modules (such as anodizing, imitation gold plating).
III. Application scenarios
| Industry |
Applicable process |
Typical workpieces |
Technical Specifications |
| Hardware manufacturing |
Galvanized/nickel-plated |
Screws, springs |
Coating thickness 10-25μm, salt spray resistance ≥480h |
| Electronic components |
Tin-plated/silver-plated |
Connectors, contacts |
Surface resistance ≤0.05Ω, RoHS compliant |
| Decorative electroplating |
Imitation gold/antique copper |
Bathroom accessories, jewelry |
Color uniformity error ≤±5%5 |
Main structures and components:
I. Core structure
1. Robotic arm unit
Single-arm mechanical device : A 6-axis robotic arm driven by a servo motor, with a positioning accuracy of ≤±0.5mm, supports precise grabbing and transfer of hangers or rollers.
Drive system : Equipped with a reducer and guide rails, the operating speed is 1-3m/min, the load capacity is 50-200kg, and it is suitable for small workpieces (below Φ50mm).
2. Electroplating treatment tank group
Tanker design : Made of PP/PVC or stainless steel, it includes electroplating tanks, pickling tanks, washing tanks, etc. The fully enclosed structure reduces chemical volatilization.
Liquid system : Built-in magnetic pump and 5μm precision filter to achieve plating solution circulation filtration, with a utilization rate of ≥95%.
3. Transmission system
Track and hanger : Modular track design, with detachable hangers or rollers (PP/titanium alloy), supports multi-station continuous operation.
Sensor positioning : Photoelectric sensors and RFID devices track the position of workpieces in real time to ensure process synchronization.
4. Control system
PLC control unit: integrated Siemens/Mitsubishi PLC and touch screen human-machine interface, preset multiple sets of process parameters (current, temperature, time), support automatic mode switching.
Power management: rectifier provides stable DC power supply, current density control accuracy ≤±0.1A/dm².
II. Auxiliary components
1. Tank body frame
Frame material: stainless steel square tube or angle iron frame, corrosion-resistant and high support strength.
2. Environmental protection treatment module
Waste gas collection: acid mist extraction system + alkali liquid spray tower, purification efficiency ≥90%.
Wastewater reuse: RO reverse osmosis device treats cleaning wastewater to achieve low-concentration discharge (COD≤50mg/L).
3. Heating/cooling device
Temperature control system: titanium metal heating tube or indirect cooling pipeline to maintain the bath temperature fluctuation range of ±1℃.
III. Technical parameter examples
| Components |
Specifications |
Performance indicators |
| Robotic arm |
6-axis servo drive |
Positioning accuracy ≤±0.5mm15 |
| Plating tank capacity |
500-2000L (PP material) |
Temperature resistance ≤80℃45 |
| Power system |
DC rectifier (0-1000A adjustable) |
Current density 1-5A/dm² |
| Wastewater reuse rate |
RO reverse osmosis system |
Recycling rate ≥80%56 |
Features:
1.High cost performance: Based on the customer's product positioning and development strategy, and with economic affordability as the foundation, we achieve the best cost performance.
2.The advanced and meticulous design concept of the equipment, along with the highly automated industrial equipment, showcases the image of a modern and advanced enterprise.
3. It has high adaptability, meeting the current production requirements and reserving room for development, taking into account the needs of increased production and improved quality in the future.
4.Quality compliance strictly adheres to the ISO900 quality management system, with every minute detail of the entire equipment installation being strictly controlled.
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