Automation Of Electroplating Technique Using P.L.C
0 likes91 views
This document discusses automating the electroplating process using a programmable logic controller (PLC). Electroplating is described as coating metal objects with a thin layer of a different metal through electrolysis. The paper outlines the typical electroplating process and then discusses automating the horizontal conveyor, vertical conveyor, and gripper circuits that move parts through the electroplating system using a PLC. Program code examples are provided for each circuit component controlled by the PLC. The automated system is presented as having strong adaptability and the ability to easily switch between manual and automated control.
![International Journal of Innovative Research in Computer Science & Technology (IJIRCST)
ISSN: 2347-5552, Volume-5, Issue-2, March 2017
DOI: 10.21276/ijircst.2017.5.2.9
Copyright © 2017. Innovative Research Publications. All Rights Reserve 257
Abstract—Electroplating technique is widely utilized
in various industries for the purpose of coating metal
objects with a thin layer of a different metal’s. The
layer of metal deposited has some desired property,
which the metal of the object lacks. For example,
chromium plating is done on many objects such as car
parts, bath taps, kitchen gas burners, wheel rims and
many others for the fact that chromium is very
corrosion resistant, and thus prolongs the life of the
parts. It is also used in making inexpensive jewelry.
Electroplating increases life of metal and prevents
corrosion. This paper deals with the detailed process of
electroplating technique using PLC.
Index Terms—PLC, DC power supply, cation,
electro-deposition.
I. INTRODUCTION
Electroplating:-It is a process in which a layer of a
metal is deposited on metallic or non-metallic electrode by
electrolysis in an electrolytic cell. Electroplating is
primarilyused to change the surface properties of an object,
but may also be used to build up thickness on undersized
parts or to form objects by electroforming.
An example of a chemical change is when
nickel plating improves corrosion resistance. An example
of a physical change is a change in the outward appearance.
An example of a mechanical change is a change in tensile
strength or surface hardness which is a required attribute in
tooling industry.[10] Electroplating of acid gold on
underlying copper/nickel-plated circuits reduces contact
Resistance as well as surface hardness. Copper-plated areas
of mild steel act as a mask if case hardening of such areas
are not desired. Tin-plated steel is chromium-plated to
prevent dulling of the surface due to oxidation of tin.
Manuscript received March 14, 2017
Urvashi Trivedi, Electrical Department,UKA Tarsadia University/
C.G.P.I.T/ Maliba Campus, bardoli, India.
Patel Tanvi,Electrical Department,UKA Tarsadia University/ C.G.P.I.T/
Maliba Campus, bardoli, India.
Ragde Arti,Electrical Department,UKA Tarsadia University/ C.G.P.I.T/
Maliba Campus, bardoli, India.
Shah Hitesh ,Electrical Department,UKA Tarsadia University/
C.G.P.I.T/ Maliba Campus, bardoli, India.
Limbachiya Vandana ,Electrical Department,UKA Tarsadia University/
C.G.P.I.T/ Maliba Campus, bardoli, India.
Hinal Surati ,Electrical Department,UKA Tarsadia University/
C.G.P.I.T/ Maliba Campus, bardoli, India.
Fig.1: Electroplating of metal [5][11]
The process used in electroplating is
called electro-deposition. It is analogous to a galvanic
cell acting in reverse. The part to be plated is the cathode of
the circuit. In one technique, the anode is made of the metal
to be plated on the part.
Both components are immersed in a solution called
an electrolyte containing one or more dissolved metal
salts as well as other ions that permit the flow of electricity.
A power supply supplies a direct current to the anode,
oxidizing the metal [2] [11] atoms that it comprises and
allowing them to dissolve in the solution. At the cathode,
the dissolved metal ions in the electrolyte solution are
reduced at the interface between the solution and the
cathode, such that they "plate out" onto the cathode. The
rate at which the anode is dissolved is equal to the rate at
which the cathode is plated, is a current through the circuit.
In this manner, the ions in the electrolyte bath are
continuously replenished by the anode.
II. PURPOSE OF ELECTROPLATING
Some of the purposes for which articles are electroplated
are:
(1) Appearance
(2) Protection
(3) Special surface properties
(4) Engineering or mechanical properties.
The very thin layer of gold applied to some articles of
inexpensive jewellery has little or no protective value; it is
there principally to attract a potential buyer.
Trivedi Urvashi, Patel Tanvi,Ragde Arti,Shah Ritesh ,Hinal Surati, Limbachiya Vandana
Automation of Electroplating Technique
Using P.L.C.](https://image.slidesharecdn.com/automationofelectroplatingtechniqueusingp-230806142413-974984b8/85/Automation-Of-Electroplating-Technique-Using-P-L-C-1-320.jpg)
![Automation of Electroplating Technique Using P. L. C.
Copyright © 2017. Innovative Research Publications. All Rights Reserve 258
III. COMPARISON OF DIFFERENT TYPES OF
ELECTROPLATING [9][8]
Chrome
or
chromiu
m plating
Stainless
steel
Carbon
Steel
Aluminu
m Steel Non-stick
Not an
alloy; only
Chromium
.
Alloy
containing
at least
10.5%
Chromium.
An alloy
of
iron and
carbon
Is an
element
but not an
alloy
An alloy
of
iron and
carbon
Coated metal
Less
durable
than
Stainless
steel.
More
durable
than
chrome.
Can rust
Lighter
and not
very strong
compared
to
steel
Can rust
Can be easily
damaged
Shinier
than
stainless
steel, but
more
difficult to
Keep
clean.
Not as
shiny as
chrome, but
easier to
keep
Clean.
Hard
and
wear-
resistant
Doesn’t
give
out sparks
Used in
making
heavy
equipmen
t
and in the
constructi
on
industry
Easier to
clean
Less
expensive
than
stainless
steel.
More
expensive
than
chrome.
Brittle
Cheaper
Less
reactive
Cheaper
due to
simple
refining
process
Strong
and
malleable
Concerns
about health
Table 1 Comparison of different types of electroplating
IV.ELECTROPLATING TECHNIQUE WITH
PLC[12]
Fig.2: Block diagram of electroplating [5]
V. PROPOSED BLOCK DIAGRAM [1],[2],[3]
Fig.3: Proposed Block diagram of electroplating
VI.IMPLEMENTED BLOCK DIAGRAM IN PLC
[12][9]
INPUT: H1, H2, V1, V2, RP, RE
OUTPUT: HC, VC, GS
Fig.4: Implemented Block diagram of electroplating in
PLC
VII. HORIZONTAL CONVEYER [9]
Ton:- H1*V1*GS*RP
Toff:-GS*V1*H2
HC = (Ton+HC) * Toff
HC = (H1*V1*GS*RP+HC)*(H2*V1*GS)](https://image.slidesharecdn.com/automationofelectroplatingtechniqueusingp-230806142413-974984b8/85/Automation-Of-Electroplating-Technique-Using-P-L-C-2-320.jpg)
![International Journal of Innovative Research in Computer Science & Technology (IJIRCST)
ISSN: 2347-5552, Volume-5, Issue-2, March 2017
DOI: 10.21276/ijircst.2017.5.2.9
Copyright © 2017. Innovative Research Publications. All Rights Reserve 259
Fig.5: Program of Horizontal Conveyer Circuit
VIII.VERTICAL CONVEYER CIRCUIT [5]
Ton:- H2*V1*GS*RP+ H1*V1*GS*RE
Toff:-GS*V2*H2+H1*V2*GS
VC = (Ton+VC) * Toff
VC = (H2*V1*GS*RP
+ H1*V1 *GS*RE+VC)*(GS*V2*H2+H1*V2*GS)
Fig .6: Program Of Vertical Conveyer Circuit
IX .PROGRAM OF GRIPPER CIRCUIT
Ton:- H2*V2*RP
Toff:-V2*H1
GRIPPER = (Ton+GRIPPER)*Toff
GRIPPER = (H2*V2*RP+GRIPPER)*(H1*V2)
Fig.7 Program Of Gripper circuit
V. CONCLUSION
This paper introduces the use of programmable controller
to control a driving the working process of the
electroplating method, simplified the connection of the
control system. Implementation of electroplating
production line system based on PLC control, the system
has a strong ability to adapt, can be easily automated,
manual control and switch between each other[12].
REFERENCES
[1] Baudrand (1994), Electro less nickel plating, surface
engineering (Vol. 5). ASM Hand Book, Material Park, Ohio;
American Society for Materials.
[2] Van Nostrand Reinhold , Electroplating Engineering
Handbook 4th Edition 1984, L.J Durney (Eds)
[3] M.P. Groover,1986 Automation, Production Systems, and
Computer-Integrated Manufacturing 3rd
Ed, Prentice-Hall
International
[4] G.Coulouris and J Dillimore,1992 Distributed Systems -
Concepts and Design, Addison-Wesley.
[5] S. L. Wang, R. Tang, J. Zhou, H. Zhou, 2011 "Research on
Automatic Electroplating Product Line’s Scheduling System
in Small Batch and Multi Types of Electroplating",
Advanced Materials Research, Vols. 317-319, pp. 621-626.
[6] Ken Osborne, 1996 Metal Protection Ltd, Auckland, with
editing by John Packer
[7] B. Boudot and G. Nury, February 7, 1984 "Additive
Composition Bath and Process for Acid Copper
Electroplating," U.S. Patent 4,430,173.
[8] W. H. Safranek, 1996.The Properties of Electrodeposited
Metals and Alloys, 2nd Ed., American Electroplaters and
Surface Finishers Society, Orlando, FL.
[9] R. Bernards, G. Fisher, W. Sonnenberg, and E. J. Cerwonka,
September 24, 1991 "Additive for Acid-Copper
Electroplating Baths to Increase Throwing Power," U.S.
Patent 5,051,154.
[10] J. O. Dukovic,(1993) "Feature-Scale Simulation of Resist
Patterned Electroplating,"IBM J. Res. Develop. 37, 125-141.
[11] https://en.wikipedia.org/wiki/Electroplating.
[12] Guiyan Li,Design and study of electroplating driving control
system based on PLC ,Weifang University of Science and
Technology, Shouguang, Weifang, Shandong, 262700,
China.](https://image.slidesharecdn.com/automationofelectroplatingtechniqueusingp-230806142413-974984b8/85/Automation-Of-Electroplating-Technique-Using-P-L-C-3-320.jpg)
Automation Of Electroplating Technique Using P.L.C
- 1. International Journal of Innovative Research in Computer Science & Technology (IJIRCST) ISSN: 2347-5552, Volume-5, Issue-2, March 2017 DOI: 10.21276/ijircst.2017.5.2.9 Copyright © 2017. Innovative Research Publications. All Rights Reserve 257 Abstract—Electroplating technique is widely utilized in various industries for the purpose of coating metal objects with a thin layer of a different metal’s. The layer of metal deposited has some desired property, which the metal of the object lacks. For example, chromium plating is done on many objects such as car parts, bath taps, kitchen gas burners, wheel rims and many others for the fact that chromium is very corrosion resistant, and thus prolongs the life of the parts. It is also used in making inexpensive jewelry. Electroplating increases life of metal and prevents corrosion. This paper deals with the detailed process of electroplating technique using PLC. Index Terms—PLC, DC power supply, cation, electro-deposition. I. INTRODUCTION Electroplating:-It is a process in which a layer of a metal is deposited on metallic or non-metallic electrode by electrolysis in an electrolytic cell. Electroplating is primarilyused to change the surface properties of an object, but may also be used to build up thickness on undersized parts or to form objects by electroforming. An example of a chemical change is when nickel plating improves corrosion resistance. An example of a physical change is a change in the outward appearance. An example of a mechanical change is a change in tensile strength or surface hardness which is a required attribute in tooling industry.[10] Electroplating of acid gold on underlying copper/nickel-plated circuits reduces contact Resistance as well as surface hardness. Copper-plated areas of mild steel act as a mask if case hardening of such areas are not desired. Tin-plated steel is chromium-plated to prevent dulling of the surface due to oxidation of tin. Manuscript received March 14, 2017 Urvashi Trivedi, Electrical Department,UKA Tarsadia University/ C.G.P.I.T/ Maliba Campus, bardoli, India. Patel Tanvi,Electrical Department,UKA Tarsadia University/ C.G.P.I.T/ Maliba Campus, bardoli, India. Ragde Arti,Electrical Department,UKA Tarsadia University/ C.G.P.I.T/ Maliba Campus, bardoli, India. Shah Hitesh ,Electrical Department,UKA Tarsadia University/ C.G.P.I.T/ Maliba Campus, bardoli, India. Limbachiya Vandana ,Electrical Department,UKA Tarsadia University/ C.G.P.I.T/ Maliba Campus, bardoli, India. Hinal Surati ,Electrical Department,UKA Tarsadia University/ C.G.P.I.T/ Maliba Campus, bardoli, India. Fig.1: Electroplating of metal [5][11] The process used in electroplating is called electro-deposition. It is analogous to a galvanic cell acting in reverse. The part to be plated is the cathode of the circuit. In one technique, the anode is made of the metal to be plated on the part. Both components are immersed in a solution called an electrolyte containing one or more dissolved metal salts as well as other ions that permit the flow of electricity. A power supply supplies a direct current to the anode, oxidizing the metal [2] [11] atoms that it comprises and allowing them to dissolve in the solution. At the cathode, the dissolved metal ions in the electrolyte solution are reduced at the interface between the solution and the cathode, such that they "plate out" onto the cathode. The rate at which the anode is dissolved is equal to the rate at which the cathode is plated, is a current through the circuit. In this manner, the ions in the electrolyte bath are continuously replenished by the anode. II. PURPOSE OF ELECTROPLATING Some of the purposes for which articles are electroplated are: (1) Appearance (2) Protection (3) Special surface properties (4) Engineering or mechanical properties. The very thin layer of gold applied to some articles of inexpensive jewellery has little or no protective value; it is there principally to attract a potential buyer. Trivedi Urvashi, Patel Tanvi,Ragde Arti,Shah Ritesh ,Hinal Surati, Limbachiya Vandana Automation of Electroplating Technique Using P.L.C.
- 2. Automation of Electroplating Technique Using P. L. C. Copyright © 2017. Innovative Research Publications. All Rights Reserve 258 III. COMPARISON OF DIFFERENT TYPES OF ELECTROPLATING [9][8] Chrome or chromiu m plating Stainless steel Carbon Steel Aluminu m Steel Non-stick Not an alloy; only Chromium . Alloy containing at least 10.5% Chromium. An alloy of iron and carbon Is an element but not an alloy An alloy of iron and carbon Coated metal Less durable than Stainless steel. More durable than chrome. Can rust Lighter and not very strong compared to steel Can rust Can be easily damaged Shinier than stainless steel, but more difficult to Keep clean. Not as shiny as chrome, but easier to keep Clean. Hard and wear- resistant Doesn’t give out sparks Used in making heavy equipmen t and in the constructi on industry Easier to clean Less expensive than stainless steel. More expensive than chrome. Brittle Cheaper Less reactive Cheaper due to simple refining process Strong and malleable Concerns about health Table 1 Comparison of different types of electroplating IV.ELECTROPLATING TECHNIQUE WITH PLC[12] Fig.2: Block diagram of electroplating [5] V. PROPOSED BLOCK DIAGRAM [1],[2],[3] Fig.3: Proposed Block diagram of electroplating VI.IMPLEMENTED BLOCK DIAGRAM IN PLC [12][9] INPUT: H1, H2, V1, V2, RP, RE OUTPUT: HC, VC, GS Fig.4: Implemented Block diagram of electroplating in PLC VII. HORIZONTAL CONVEYER [9] Ton:- H1*V1*GS*RP Toff:-GS*V1*H2 HC = (Ton+HC) * Toff HC = (H1*V1*GS*RP+HC)*(H2*V1*GS)
- 3. International Journal of Innovative Research in Computer Science & Technology (IJIRCST) ISSN: 2347-5552, Volume-5, Issue-2, March 2017 DOI: 10.21276/ijircst.2017.5.2.9 Copyright © 2017. Innovative Research Publications. All Rights Reserve 259 Fig.5: Program of Horizontal Conveyer Circuit VIII.VERTICAL CONVEYER CIRCUIT [5] Ton:- H2*V1*GS*RP+ H1*V1*GS*RE Toff:-GS*V2*H2+H1*V2*GS VC = (Ton+VC) * Toff VC = (H2*V1*GS*RP + H1*V1 *GS*RE+VC)*(GS*V2*H2+H1*V2*GS) Fig .6: Program Of Vertical Conveyer Circuit IX .PROGRAM OF GRIPPER CIRCUIT Ton:- H2*V2*RP Toff:-V2*H1 GRIPPER = (Ton+GRIPPER)*Toff GRIPPER = (H2*V2*RP+GRIPPER)*(H1*V2) Fig.7 Program Of Gripper circuit V. CONCLUSION This paper introduces the use of programmable controller to control a driving the working process of the electroplating method, simplified the connection of the control system. Implementation of electroplating production line system based on PLC control, the system has a strong ability to adapt, can be easily automated, manual control and switch between each other[12]. REFERENCES [1] Baudrand (1994), Electro less nickel plating, surface engineering (Vol. 5). ASM Hand Book, Material Park, Ohio; American Society for Materials. [2] Van Nostrand Reinhold , Electroplating Engineering Handbook 4th Edition 1984, L.J Durney (Eds) [3] M.P. Groover,1986 Automation, Production Systems, and Computer-Integrated Manufacturing 3rd Ed, Prentice-Hall International [4] G.Coulouris and J Dillimore,1992 Distributed Systems - Concepts and Design, Addison-Wesley. [5] S. L. Wang, R. Tang, J. Zhou, H. Zhou, 2011 "Research on Automatic Electroplating Product Line’s Scheduling System in Small Batch and Multi Types of Electroplating", Advanced Materials Research, Vols. 317-319, pp. 621-626. [6] Ken Osborne, 1996 Metal Protection Ltd, Auckland, with editing by John Packer [7] B. Boudot and G. Nury, February 7, 1984 "Additive Composition Bath and Process for Acid Copper Electroplating," U.S. Patent 4,430,173. [8] W. H. Safranek, 1996.The Properties of Electrodeposited Metals and Alloys, 2nd Ed., American Electroplaters and Surface Finishers Society, Orlando, FL. [9] R. Bernards, G. Fisher, W. Sonnenberg, and E. J. Cerwonka, September 24, 1991 "Additive for Acid-Copper Electroplating Baths to Increase Throwing Power," U.S. Patent 5,051,154. [10] J. O. Dukovic,(1993) "Feature-Scale Simulation of Resist Patterned Electroplating,"IBM J. Res. Develop. 37, 125-141. [11] https://en.wikipedia.org/wiki/Electroplating. [12] Guiyan Li,Design and study of electroplating driving control system based on PLC ,Weifang University of Science and Technology, Shouguang, Weifang, Shandong, 262700, China.
- 4. Automation of Electroplating Technique Using P. L. C. Copyright © 2017. Innovative Research Publications. All Rights Reserve 260 Urvashi Trivedi,B.Tech in Electrical Engineering, With area of interest in controllers and power system modeling. Patel Tanvi,B.Tech in Electrical Engineering, With area of interest in controllers ,machine design and power system modeling. Ragde Arti, B.Tech in Electrical Engineering, With area of interest in machine design and power Electronics. Shah Hitesh, B.Tech in Electrical Engineering, With area of interest in PLC-SCADA and renewables Limbachiya Vandana, B.Tech in Electrical Engineering, With area of interest in PLC ,machine design and power system optimization. Hinal Surati , Assistant professor , Electrical Department, UKA Tarsadia University/ C.G.P.I.T.B.E Electrical and electronics engineering ,M.E Power electronics and electrical Drives, with area of specialization in controlling, optimization and design of machines.research work:Hybrid power generation.