Quantum leap in surface coating
Product presentation of the next generation, a system with the fundamental cornerstones not seen before, united in one electroplating plant:
- Waste water free
- Exhaust air-free with partial exhaust to avoid the formation of hydrogen
- Not subject to approval only partial approval
- Energy-efficient through the use of heat pumps
- Environmentally friendly
- Modular design, space-saving
- Intelligently networked systems
- Highly flexible production
- Resource productivity
- Situational self-control
- Limited self-correction for detected errors
Brief technical description of this innovative technology:
The future of coating production - the self-organizing factory - our vision industry 4.0
The "GalvanoMat® PCB of the future" requires intelligent networking of the individual sub-areas that communicate smartly in coherent data. The sub-areas comprise the integration of:
Absence of sewage
The process concept of the GalvanoMat® PCB leads to a minimization of the emissions of air and exhaust air as well as of rinsing and waste water. Depending on the type of surface treatment, the material flows are conducted as closed as possible. If this is not technically possible, the emissions are minimised to such an extent that wastewater treatment is no longer required.
Thus a wastewater discharge can be avoided until the public sewer network.
Waste Air Free
The goal was a cost-optimized, waste air-reduced coating system that avoids further investments with regard to waste air. The waste air from the process is processed and returned to the plant. Any residues from the exhaust air cleaning are fed into the process bath, whereby the absence of waste water is partly already achieved. Harmful air constituents are degraded without the addition of chemicals and without water spraying (classic wet scrubbing). This means that the waste air is cleaned dry and no additional waste water is produced. Thermodynamic synergies of generated waste heat, evaporation and condensation are used for this purpose. Flow-optimised extraction systems and the use of closed process tanks (as far as possible) with tank covers can keep the exhaust air volumes small and reduce the effort required for exhaust air cleaning enormously.
Energy-efficient though the use of Heat Pumps
High-temperature heat pumps are used for cooling and heating the active tanks. They cover all areas of excess heat or required cooling and thus positively influence the energy balance.
The process analysis is performed automatically and all important process data is recorded and controlled automatically. The system is thus controlled fully automatically and the required process chemicals are added. As a result of the process analysis, the chemical residues in the waste water are reduced.
Modular Power Sources / Rectifiers
The GalvanoMat® PCB is equipped with state-of-the-art, newly developed and digitally finely adjustable power sources. The identical characteristic values of each rectifier and the parallel or series connection will provide increased flexibility for system expansion, production and process changeover. Redundancy minimizes the risk of failure.
Water cooling must be emphasized in order to effectively return the waste heat from the rectifiers to the process. This results in an energy balance that synergistically returns waste heat to the process throughout the entire plant.
The rectifiers are easy to diagnose and to maintain remotely due to the connection to the system analytics module.
Control and IO System
By using the Siemens ET200 AL IO system, the components can be kept modular (function blocks) and expanded as required. Service times are kept to a minimum as connected components can be replaced in the shortest possible time.
In combination with the fully graphical system visualization and system analysis, you have a direct overview of all important data and characteristic values for each function block and can quickly make adjustments.
By networking all components in the system analytics, the "Preventive Maintenance" module stores all values in a database and checks them with the standard values and target values. These statistical values are used to carry out self-adaptive evaluations with each additional data record, and the percentage probability of an event (regular maintenance, preventive inspection) is displayed accordingly.
Hoist Driving Programm
The self-optimizing driving program and the supplied editor enable the chemist or process engineer to define the process parameters. Self-optimization calculates the optimum running-in times for each product carrier located in the plant. This makes the creation of a time-path diagram obsolete.
In addition, a program module is provided with the mixing program with free time selection - "MfZ", which always guarantees maximum capacity even in the mixing mode of the plant. This makes it possible to assign each control room operator his own driving program, including his own dwell times in the active baths.
As an example:
Flightbar 1: 300 Min. Cu
Flightbar 2: 60 Min. Cu + 12 Min. Sn
Flightbar 3: 12 Min. Sn
Drying Technology "Dränierung" (Patent pending)
The novel dewatering process (called drainage) used in electroplating dehumidifies the production goods in an energy- and cost-efficient manner. This dries the material to be electroplated at room temperature. This makes this process extremely environmentally friendly compared to conventional drying processes.
With different dynamic pressure parameters on the front and back of the drainage container, dry air flows through the material to be electroplated. Thus, the thread, through and blind holes are dehumidified quickly and qualitatively with a high aspect ratio.
Planned "Acoustic Surface Waves" (University of Coburg)
The integration of the Institute for Sensor and Actotechnology (German ISAT) of the University of Coburg is planned for the development of an electrochemical deposition of coating metal on the surface supported by the introduction of surface noise.
Surface acoustic waves are ultrasonic waves propagating on the surface of solids. This principle is used to accelerate electrochemical processes.