垂直连续电镀设备(VCP)取代龙门电镀线的必然趋势

GuangDeDongweiPlatingEquipmentTechnologyCo.,Ltd.广德东威电镀设备技术有限公司JianboLiu刘建波TrendofReplacementfromGantryPlatingEquipmenttoVerticalContinuousPlatingEquipment垂直连续电镀设备（VCP）取代龙门电镀线的必然趋势Advantage-自主研发，技术领先ComparisonBasedon:SafetyPK,EconomyPK,ProductsQualityPK,etc.对比基于：安全性对比，经济性对比，电镀产品质量对比等Capacitypermonth：47,500m2月产能47,500m2；PanelplatingCuthickness：0.4mil面铜厚度：10um；Workinghoursanddays:22hoursperdayand26dayspermonth每天生产22小时，每月生产26天;Calculation：计算Hoist—12platingunits，width=4.2m，3setstransporter龙门线–12缸，宽度4.2米，3台天车VCP—12Cu,V=2.18m/minVCP12个铜槽，传动速度2.18米/分钟VCPvsHoistTypePlating-VCP与龙门电镀对比BigfirerisksexistinthehoisttypeplatingequipmentsandmanyfirehazardsareshownontheTVs龙门线存在较大的火灾风险，而龙门线起火事故在电视中屡见报道VCPequipmentscontainsspecialfire-proofdesignandminimizehumanfactorsforfirehazards.Currentlynoanyfirehazardhappens。VCP设备具有专门的防火设计，能够最大程度地减少火灾风险。迄今为止，东威公司生产的VCP设备没有发生过一起火灾；VCPvsHoistTypePlating–FireHazardsRisks火灾风险VCPequipmentVCP电镀线Fullsealedworkingenvironmentandnobadsmells外觀整潔、全封閉式設計，工作環境良好，可实现四季恒溫控制HoisttypeequipmentNoisy,openwithbadsmellsandplatesareeasytodropwhenaddingcopper傳統龍門電鍍，環境嘈雜，敞口式設計，（不利于消防喷淋设施）化學品極易揮發，易發生墜落意外VCPvsHoistTypePlating–OperatorSafety员工安全Equipmenttype设备类型Consumption耗材CopperConsumption铜球消耗Capacity/m^2产量Totalconsumption总消耗量Hoisttype龙门线Copper磷铜球25Kg/100m247,50011.875TVCP21.3Kg/100m247,50010.1174TReasonforcoppersaving:uniformityimprovement省铜理由：均匀性提高VCPVSHoistTypePlating–Economy节约磷铜球Hoisttypeplating龙门线VCPNumberofpeople人工数Cost/month/person人员月工资Totalcost/month每月成本Numberofpeople人工数Cost/month/person人员月工资Totalcost/month每月成本Loading/unloading上下料3350010500035000Dry产品吹干235007000035000On-lineinspection巡检135003500135003500Maintain维护1350035000.535001750Totalcost/8hours总成本24500RMB5250RMBVCP-RobotarmAutoloading&unloading自动上下料HTP-loading&unloadingbyhands人工上下料VCPvsHoistTypePlating–LaborCost节约人工Laborsavingmonthly:~20,000RMB每月节约人工费：2万元傳統龍門式電鍍線槽名槽體積(L)理論溢流量(L/MIN)更槽頻率月耗用水量(L)剝掛架水洗1600410天/次143680水洗220010每週一次392000高位水洗2200鍍銅後水洗122007.5298400鍍銅後水洗22200酸洗22008800鍍銅1~126500*12水洗烘乾線酸洗400每週一次1600酸後水洗2007.5258200磨刷4001600沖污水洗200800清水洗2007.5258200月總耗用水量:L/Month1363280VCP電鍍線槽名槽體積(L)理論溢流量(L/MIN)更槽頻率月耗用水量(L)剝掛水洗2402每週一次69600清潔40001600清潔後水洗1505172200鍍銅1~122200*12鍍銅後水洗115010每週一次346600鍍銅後水洗2150鍍銅後水洗3150預浸4000水洗烘乾線酸洗0每週一次0酸後水洗000磨刷00沖污水洗00月總耗用水量:L/Month590000VCPvsHoistTypePlating–WaterSaving节水Watersavingmonthly:760ton每月节约用水：760吨Hoisttypeplating龙门线VCPName名称KWH千瓦时Set组/个Power/monthKWH功率/千瓦时/月KWH千瓦时Set组/个Power/monthKWH功率/千瓦时/月Filterpump过滤泵3.71841558.42.23041184Rectifier整流机2242995222426956.8Transportermotor天车马达5.9311044.81.51936Exhaustsystem抽气系统301187207.514680AirBlower吹干7.529360000Vibrationmotor振动马达0.05762371.2000Shakemotor摇摆马达222496000Power/monthKWH总耗电量115,502.473,756.8VCPvsHoistTypePlating–PowerSaving节电Powersavingmonthly:40,000KWH每月节约用水：4万度傳統龍門式電鍍線項目周工時周人數月累計工時工時折算成工資添加銅球45801656.80水洗槽保養4116331.36VCP電鍍線項目周工時周人數月累計工時工時折算成工資添加銅球4000.00水洗槽保養218165.68傳統龍門式電鍍線項目程度備註工作強度大工安易發生占地面積大40mL*10mW*5mH故障率/維修成本振動馬達老壞，天車故障銅排更換44只/三年6111.11硝酸1200L/10天4320地面要求專業coating地面150000VCP電鍍線項目程度備註工作強度小工安不易發生占地面積小40mL*3mW*3.6mH故障率/維修成本基本沒有銅排更換0%0硝酸400L/月480地面要求地面不用coating，做簡單的防腐處理即可，在產線的底部會按裝防漏盤（裝機時廠商負責）。VCPvsHoistTypePlating–ConsumptionSaving運行維護及其它成本节约VCPVSHoisttypeVCP与龙门线对比VCPvsHoistTypePlating–AppearancePK外观对比VCPProject项目Standard标准RMBCOV93%RangeR值3umThrowingpower贯孔能力95%BoardScraped摔飛靶報廢，吊掛報廢0%Copperscraped殘銅報廢0%0Hoisttypeplating龙门线Project项目Standard标准RMBCOV85%RangeR值5.5umThrowingpower贯孔能力90%BoardScraped摔飛靶報廢，吊掛報廢16.5pcs/day4290Copperscraped殘銅報廢12.8pcs/day2662.4Copperboardthickness:10um面铜10umVCPvsHoistTypePlating–Quality/UniformityPK均匀性对比Conclusion：1.VCPrunningcostdownaround25%；2.About22months,savingmoneycanbuytheequipmentreplacecostHoisttypecost/month龙门线成本/月VCPcost/monthVCP成本/月VCPSavingVCP节约Water（20RMB/T)水费（20元/吨）1363,28027,266RMB590,00011,800RMB15,466RMBPower（0.8RMB/KWH）电费(0.8元/千瓦时）115,50292,402RMB73,75759,005RMB33,397RMBCopper（62,000RMB/T）磷铜球（62000元/吨）11.875736,250RMB10.1175627,285RMB108,965RMBManpower(3500RMB/month/person）人工费（3500元/月）24,500RMB/Team49,000RMB5,250RMB/Team10,500RMB38,500RMBMaintaining维护保养费1,988RMB166RMB1,822RMBOthercost(scrap、HNO3andcoppercathodechange）其他成本（报废，硝酸，铜排更换等）10,431RMB480RMB9,951RMBTotalcost总成本917,337RMB709,236RMB208,101RMBVCPvsHoistTypePlating–Conclusions结论Moneysavingmonthly:20,000RMB每月节约费用：20万HoistTypeVSVCPSafety安全性FireRisk/火灾风险Yes/有风险Nohappen/无风险PlatesDropRisk工件掉落风险Yes/有风险Nohappen/无风险InjuredRisk/员工受伤风险Yes/有风险Nohappen/无风险WorkingEnvironment工作环境Smellbad&Noise&Hightemperature气味难闻，噪声大，高温Clean&Morecomfort(closed/lownoiseandA/Ccontrol)环境干净舒适，低噪音，空调控温RunningCost运营成本WaterCost/用水成本100%44.9%Running-suppliesCost材料消耗成本100%85.2%ServiceCost/维修成本100%20%Uniformity镀层均匀性CuThickness：0.4mil/铜层厚度：0.4milCOVValue/COV值≤12≤5RValue/R值5um3umTPValue/TP值90%95%结论：1.VCP運行成本下降25%左右；2.22个月左右，节约之总金额足以支付VCP购买之费用。VCPVSHoistTypePlating–Conclusions结论VCPforNi_Auplating镀镍金VCP产线名称传统龙门线金手指线东威VCP图片说明生产人力：6安全系数：差车间环境：差操作：不方便故障率：高均匀性：10u”生产人力：6安全系数：一般车间环境：一般操作:一般故障率：中最大作业尺寸高度：350均匀性：极差5u”生产人力：2安全系数：优车间环境：优操作:简单故障率：低最大尺寸高度：根据客户定义；均匀性：极差4u”总结东威镀镍金VCP根据行业需求而去改善，改善传统镀镍金龙门线缺点以及优化金手指