Abstract : Controlling the electroplating process is the quantitative material required for uniform plating on all parts of the workpiece. The key is accurate and stable electroplating current, stable and stable plating, and consistent product before and after production. Automated control of the timing output current, the output current remains highly stable and consistent, can produce high quality, uniform coating thickness of the abrasive products. Shenzhen Chenjie Technology has specially developed a series of products with high stability, high accuracy electroplating power supply, automatic sand plating machine and high precision ammeter to provide a good precondition for the production of fine superhard material abrasive tools.
Key words: superhard material plating; manual plating power supply; self-regulating electroplating power supply; safety time meter; automatic electroplating water production line
At present, most of the manufacturers of liquid electroplating process for producing superhard material abrasive tools still rely on manual operation, manual adjustment of plating current, manual control of plating time, whether or not the electroplating requirements are met by manual visual inspection, not only the production speed is slow, but also the product quality. Stability, consistency, and uniformity of thickness of the nickel plating layer are also difficult to ensure. Some manufacturers have proved that the error of the hand-plated qualified products is between 10% and 20%, at least between 10% and 15%. This has a major impact on the service life and effectiveness of superhard material tools.
The complete process flow for producing superhard material abrasive tools by liquid electroplating includes: pre-plating treatment, electroplating process, and post-plating treatment. The pre-plating treatment includes: mechanical treatment, degreasing, etching and descaling and activation treatment, and non-plating part of the insulation treatment; post-plating treatment includes: dehydrogenation treatment of the plating layer, protective coating treatment of the workpiece, quality inspection, etc.; : Electro-current impact before electroplating, electroplating, sanding, sanding, thickening, etc., in which the manual processing and the secondary strengthening of some intermediate processes can be added according to the shape and requirements of the workpiece.
At present, a small number of manufacturers use automated, semi-automated, or electromechanical control equipment to produce superhard materials , and the degree of automation and methods are quite different.
Shenzhen Chenjie Technology has been focusing on this industry for several years. In order to improve the stability and consistency of the quality of electroplated abrasive products, the uniformity of thickness of nickel plating layer is effectively guaranteed; the use of automated production to fully utilize time to increase production capacity, independent research and development production Specially used in diamond electroplating products: electroplating measuring instruments (ampere meter), self-control series electroplating power supply, hand-operated series electroplating power supply (including ampere meter), programmable series power supply, automatic sand plating machine, automatic control System, automatic control line (production line), parameter transmission and monitoring system.
The application basis, application and application effects of these products are described in detail below. Each diamond plating product company can choose the application according to its own conditions, which will double the product quality and production efficiency.
1·Electroplating measurement
The theoretical thickness and actual thickness of nickel plated with 1A current per square decimeter area are shown in Table 1:
During electroplating, when the electroplating current and plating time are manually controlled, the accuracy of the two factors is difficult to ensure. If the measurement result is changed to a measurement result, or the measurement value is automatically controlled, the accuracy is greatly improved. The meter--Antime meter has solved this problem; it has been proved in the production practice of the track cutting wheel for the Beijing-Shanghai high-speed rail. The meter can be used alone to make electroplating control parameters without changing the existing equipment, and can receive significant effects.
The measurement accuracy of the ampere meter is divided into several grades: 5%, 2%, 1%, 1 ‰. The metering accuracy of the centralized ampere meter on the electroplating power supply is 1 ‰, and the measurement accuracy of the ampere meter of the separate split is 1% to 5%. Thereby, the thickness of the plating plating can be controlled to the μm level to achieve the requirement of accurately controlling the thickness.
The plating solution needs to be supplemented with some components after plating for a certain period of time. In the past, all companies added or adjusted based on their own experience or after discovering product quality problems at the final quality inspection. Now, after using the Anshiometer, each manufacturer can add or adjust the composition of the plating solution according to the measurement results of Anshi.
2. Self-control, hand-operated series electroplating power supply
Power supply series include: self-control series electroplating power supply, hand-operated series electroplating power supply (including metering), programmable series power supply. The pulse series will be launched soon.
At present, the electroplating power supply used by domestic manufacturers is a commercially available or separately customized DC constant current power supply of various specifications and requirements. The quality levels of these power products are uneven, some power supply output fluctuates greatly, and the ripple is also large; some even have no requirements. Therefore, it is difficult for each superhard material abrasive manufacturer to ensure the stability of the plating current and the consistency of the production before and after.
Shenzhen Chenjie Technology has developed a DC constant current power supply for these problems faced by ultra-hard materials electroplating products enterprises. The output stability of this power supply can be guaranteed at mA level, generally around 2mA; and it is suitable for acid and alkaline environments to achieve long life. The output control accuracy can be selected to be 10mA or mA depending on the needs of the product being produced. In order to reduce the number of products used in the field and facilitate operation, we integrate the independent intellectual property's safety time meter into the own-brand DC constant current power supply, and add timing display.
The hand-operated series power supply is suitable for the current manual plating, the local hand-operated work; the self-control series power supply is only suitable for the automation system equipment, and receives the signal work outside the machine.
The series products have been in use since 2008, and the practice has proved that the service life is long, the output is stable, the control precision is high, and the plating thickness can be easily controlled at the μm level; the plating current and the plating safety time are strictly controlled within the allowable accuracy range, according to Faraday's law and evidence, the quality or thickness of the material plated on the workpiece is completely controlled. For the 300-800# corundum, the package degree is between 50% and 70%, which allows the user to feel the control package degree changed by 2%. change.
3 programmable series plating power supply
Manual operation has problems that are strictly enforced according to process requirements. In order to better solve this problem, Shenzhen Chenjie Technology independently developed a programmable power supply. It can store current parameters up to 300 segments. Before the product is plated, set the current level and the required time or number of hours in each step. After startup, the power supply automatically outputs the plating current according to the set parameters without manual. Adjust the current; or program the next set of plating current parameters during the plating process.
Programmable series power supply (including ampere meter): KCD-D10XSXX(F)G LCD display, mA level or 10mA level, ampere or ampere (999.9AH, 99.99AH, 999.9AM, 99.99Am), plating time display . This series of products has the functions of local manual operation and local programming output current curve. It is mainly used for the application of super-hard material plating workpiece without rotating, and only by changing the constant current current (automation of electroplating current). Therefore, it is especially suitable for the production of buried plating. The products have been equipped with an integrated chronometer with a measurement accuracy of <±1%. The setting parameters are current and ampere-hour.
4 automatic sand plating machine
Regardless of the shape of the workpiece, most of the grinding tools are rotary bodies. To uniformly distribute the super-hard material on the 360-degree circumference, the workpiece must be accurately positioned to rotate the sand and adhere to the sand at a constant speed, which is a prerequisite for ensuring uniform distribution of the super-hard material . At the same time, it is also necessary to ensure that the current intensity is consistent at each positioning point and at a constant speed; the concentration of the plating solution is as uniform as possible before and after; the concentration of the superhard material is as uniform as possible.
The quality of the electroplated material on the plated workpiece is completely within the envisaged range as described above, but will it be evenly distributed on the plated workpiece as envisaged? The answer is not necessarily. This needs to be judged according to the shape of the workpiece to be plated and the specific conditions of the plating process configuration.
Therefore, in order to evenly distribute the super-hard material on the workpiece, only the power supply and electroplating are not enough. It is necessary to introduce automatic and accurate positioning of the workpiece, automatic constant-speed rotating mechanism, electroplating liquid stirring mechanism, electroplating liquid concentration control system, electroplating liquid temperature control part. In terms of various aspects, it is automatically adjusted to adapt to the ever-changing electroplating process.
Shenzhen Chenjie Technology's automatic control system and automatic sand plating machine were put into use in 2007, and began to be put into production in batches in 2008. The product quality is stable, long life, less maintenance and complete. The plating thickness control of the electroplated diamond grinding tools, the uniformity of the plating distribution, and the consistency of the electroplating products are significantly improved; the requirements and proficiency of the operators are significantly reduced, and the manipulation is easy. Practice has proved that the expected results have been achieved. Some users of abrasive tools also specify the use of this series of products, and a certain factory replaces imported products.
To produce superhard material abrasive tools in an automated or semi-automated manner, it is necessary to do some basic work, or to summarize the production experience data and combine it with the theory while using it. Only in this way can the range of products produced be more The more you expand.
The equipment is independently developed by Shenzhen Chenjie Technology Co., Ltd. It is fully automated for the electroplating process. It is specially designed for electroplating (rolling) diamond grinding tools—grinding wheels, grinding heads and grinding discs. It is suitable for fine sand barrel plating. It is customized according to the diameter requirements of the workpiece. It is customized according to the grinding tool production process. software.
The thickness of the plating plating of the equipment is controlled accurately, the consistency of the electroplating products is good, the stability is high, the long life and high stability are utilized; the time is utilized to maximize the production capacity; the quality of the personnel is low, and the training can be carried out after a little training.
5 automatic control system, production line
The automatic sand plating machine completes the entire plating process in a single barrel. The assumption of the above automatic control system is that the plating process can be carried out by the same plating solution. In fact, the current density required by the workpiece is different in each process. Different plating solutions can withstand different current density ranges, and the plating parameters need to be changed accordingly, so that the parameters can be selected and the quality can be produced. High product. Therefore, our company expands the single-barrel automatic control device into an automatic assembly line. After the workpiece enters the assembly line, no personnel operation is required, and all the automatic control and operation of the assembly line equipment is completed.
The automatic control system is specially tailored for the automatic sand plating machine or the production line. It is responsible for controlling all relevant operations of the entire plating process, instead of manual operation control. The production of the products is different, the configuration of the automatic control system is different; according to the requirements of each user, the control functions and parameters that are included in the self-control range are different, such as current, time or ampere, workpiece rotation, plating stirring or simulated hand sanding, plating Liquid heating, plating solution replenishment, etc.
The automatic flow production line is a flow production line set up by a number of different functions of the automatic sanding electroplating machine according to the production cycle of the fixed product. The central automatic control system controls the workpiece removal mechanism, automatically grabs the workpiece, automatically distributes the work bucket, and automatically places the workpiece. Automatic power-on plating and automatic execution of the function of each different plating bath. It is especially suitable for applications where the product is single, large, and can be used with an automatic sanding machine. The process flow is shown in Figure 1.
6. Process parameter transmission and monitoring system
The automatic electroplating process parameter automatic transmission and communication monitoring system is a local area network set up for automatic sand plating machine, special scheduling and control production. It is especially suitable for manufacturers who use automatic sand plating machines in batches.
When the actual use of automatic sand plating or automatic flow production line equipment is large, all these automatic control system equipments are connected into a network, and each process parameter is automatically transmitted to the corresponding equipment to be produced, and the process parameters are prepared in advance, and the operator only needs Production can be initiated by confirming that the placed workpiece is consistent with the corresponding process parameters. At the same time, it is also possible to monitor the process of each device running, the execution of parameters, etc. on the host computer, and then read and record the parameters for production. The relevant production technicians can pre-distribute which single-barrel equipment to produce a plurality of different products, and input the process parameters and instructions to be delivered to the corresponding equipment in advance, so as to quickly enter the production of the next batch of products. The process parameter transfer and monitoring system can fully meet this requirement.
7 recommendations
When implementing different types of superhard material abrasive manufacturing enterprises, they can choose any of the above five methods according to their actual conditions:
If your company has a large amount of power, and the power quality is good, you can use the ammeter to change the control parameters slightly, and set the current size and the number of hours to control the plating time. If the plating time is the same, The amount of nickel on the plating must be the same;
If the quality of the electroplating power supply is not too good, or you have to change it, you may want to switch to a high-stability power supply. The unit also integrates an ammeter, but you need to set the current size and the number of hours to control the plating time. Otherwise, you can't see it. Superiority
If the demand for the product is large, the automatic sand plating machine can be used directly when the automatic sand plating is used;
If the output of the abrasive products is large and single, it can be produced by automatic assembly line;
Perhaps these are not entirely suitable, just control the plating current, "programmable power supply" is the best choice.
Of course, unless the current output is automatically controlled, the process parameters are preferably changed from the original set current and time to the set current magnitude and the number of ampere-hours to control the plating time. Otherwise, the manual control time is difficult to ensure the thickness of the coating.
8 Conclusion
In summary, the above equipment can meet the different requirements of the current implementation of the electroplating process. However, whether the superhard material electroplated products meet the requirements of the user, not only the requirements of wear resistance, service life, but also the requirements of size, tolerance and shape. Therefore, a qualified superhard material electroplating abrasive tool needs: machine addition, pre-plating post-plating treatment, plating liquid preparation and processing, electroplating equipment and fixture, control and execution of electroplating process, comprehensive cooperation of all influencing factors. Stable production of high quality, quality products. The above solution is only part of it and a solution to one of the important factors.
One of the industries that Shenzhen Chenjie Technology is currently focusing on is the super-hard material plating industry. The company will wholeheartedly provide a complete set of solutions for the industry, and propose solutions according to the different requirements of each user. After several years of operation, the above solutions can be achieved:
(1) The consistency of the execution of process parameters is greatly improved;
(2) Improve the stability of product quality and quality, and significantly improve product quality;
(3) Significantly reduce the requirements for the quality of personnel, and it is not necessary for many years of masters to produce high quality and high quality products;
(4) Make full use of production time, increase production capacity and improve production efficiency;
(5) Overall reduction of costs and improvement of efficiency.
Shenzhen Chenjie Technology Co., Ltd. Cao Zhenhui
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