垂直連續(xù)電鍍設(shè)備(VCP)取代龍門電鍍線的必然趨勢

1、GuangDe GuangDe DongweiDongwei Plating Equipment Technology Co., Ltd. Plating Equipment Technology Co., Ltd.廣德東威電鍍設(shè)備技術(shù)有限公司廣德東威電鍍設(shè)備技術(shù)有限公司JianboJianbo Liu Liu 劉建波劉建波Advantage-Advantage-自主研發(fā)，技術(shù)領(lǐng)先自主研發(fā)，技術(shù)領(lǐng)先Comparison Based on: Safety PK, Economy PK, Products Quality PK, etc. 對比基于：安全性對比，經(jīng)濟性對比，電鍍產(chǎn)品質(zhì)量對比等 Ca

2、pacity per month：47,500 m2 月產(chǎn)能47,500 m2；Panel plating Cu thickness：0.4 mil 面銅厚度：10um；Working hours and days: 22 hours per day and 26 days per month 每天生產(chǎn)22 小時，每月生產(chǎn)26天;Calculation：計算 Hoist12 plating units，width=4.2 m，3 sets transporter 龍門線 12缸，寬度4.2米，3臺天車 VCP 12Cu, V=2.18 m/min VCP12個銅槽，傳動速度2.18米/分鐘VC

3、P vs Hoist Type Plating - VCPVCP vs Hoist Type Plating - VCP與龍門電鍍對比與龍門電鍍對比Big fire risks exist in the hoist type plating equipments and many fire hazards are shown on the TVs 龍門線存在較大的火災(zāi)風(fēng)險，而龍門線起火事故在電視中屢見報道VCP equipments contains special fire-proof design and minimize human factors for fire hazards. C

4、urrently no any fire hazard happens。 VCP設(shè)備具有專門的防火設(shè)計，能夠最大程度地減少火災(zāi)風(fēng)險。迄今為止，東威公司生產(chǎn)的VCP設(shè)備沒有發(fā)生過一起火災(zāi)；VCP VCP vsvs Hoist Type Plating Fire Hazards Risks Hoist Type Plating Fire Hazards Risks火災(zāi)風(fēng)險火災(zāi)風(fēng)險VCP equipment VCP電鍍線Full sealed working environment and no bad smells 外觀整潔、全封閉式設(shè)計，工作環(huán)境良好，可實現(xiàn)四季恒溫控制Hoist type eq

5、uipmentNoisy, open with bad smells and plates are easy to drop when adding copper傳統(tǒng)龍門電鍍，環(huán)境嘈雜，敞口式設(shè)計，（不利于消防噴淋設(shè)施）化學(xué)品極易揮發(fā)，易發(fā)生墜落意外VCP VCP vsvs Hoist Type Plating Operator Safety Hoist Type Plating Operator Safety 員工安全員工安全Equipment type設(shè)備類型設(shè)備類型Consumption耗材耗材Copper Consumption 銅球消耗銅球消耗Capacity/m2產(chǎn)量產(chǎn)量Total

6、 consumption總消耗量總消耗量Hoist type龍門線Copper磷銅球25 Kg/100 m247,50011.875 TVCP21.3 Kg/100 m247,50010.1174 TReason for copper saving: uniformity improvement省銅理由：均勻性提高VCP VS Hoist Type Plating Economy VCP VS Hoist Type Plating Economy 節(jié)約磷銅球節(jié)約磷銅球Hoist type plating 龍門線龍門線VCPNumber of people人工數(shù)人工數(shù)Cost/month/per

7、son人員月工資人員月工資Total cost/month每月每月成本成本Number of people人工數(shù)人工數(shù)Cost/month/person人員月工資人員月工資Total cost/month每月成本每月成本Loading/unloading上下料上下料3350010500035000Dry 產(chǎn)品吹干產(chǎn)品吹干235007000035000On-line inspection巡檢巡檢1 350035001 35003500Maintain 維護維護1 350035000.5 35001750Total cost/8hours總成本總成本24500 RMB5250 RMBVCP-Rob

8、ot arm VCP-Robot arm Auto loading & Auto loading & unloadingunloading自動上下料自動上下料HTPHTP-loading & -loading & unloading by unloading by handshands人工上下料人工上下料VCP VCP vsvs Hoist Type Plating Labor Cost Hoist Type Plating Labor Cost 節(jié)約人工節(jié)約人工Labor saving monthly: 20,000RMB每月節(jié)約人工費：2萬元傳統(tǒng)龍門式電鍍線

9、傳統(tǒng)龍門式電鍍線槽名槽名槽體積槽體積(L)理論溢流量理論溢流量(L/MIN)更槽頻率更槽頻率月耗用水量月耗用水量(L)剝掛架水洗剝掛架水洗1600410天天/次次143680水洗水洗220010每週一次每週一次392000高位水洗高位水洗2200鍍銅後水洗鍍銅後水洗122007.5298400鍍銅後水洗鍍銅後水洗22200酸洗酸洗22008800鍍銅鍍銅1126500*12水洗烘乾線水洗烘乾線 酸洗酸洗400每週一次每週一次1600酸後水洗酸後水洗2007.5258200磨刷磨刷4001600沖污水洗沖污水洗200800清水洗清水洗2007.5258200月總耗用月總耗用水量水量:L/Mont

10、h1363280VCP電鍍線電鍍線槽名槽名槽體積槽體積(L)理論溢流量理論溢流量(L/MIN)更槽頻率更槽頻率月耗用水量月耗用水量(L)剝掛水洗剝掛水洗2402每週一次每週一次69600清潔清潔40001600清潔後水洗清潔後水洗1505172200鍍銅鍍銅1122200*12鍍銅後水洗鍍銅後水洗115010每週一次每週一次346600鍍銅後水洗鍍銅後水洗2150鍍銅後水洗鍍銅後水洗3150預(yù)浸預(yù)浸4000水洗烘乾線水洗烘乾線 酸洗酸洗0每週一次每週一次0酸後水洗酸後水洗000磨刷磨刷00沖污水洗沖污水洗00月總耗用水量月總耗用水量:L/Month590000VCP VCP vsvs Hois

11、t Type Plating Water Saving Hoist Type Plating Water Saving節(jié)水節(jié)水Water saving monthly: 760ton每月節(jié)約用水：760噸Hoist type plating龍門線龍門線VCP Name名稱KWH千瓦時Set 組/個Power/monthKWH功率/千瓦時/月KWH千瓦時Set組/個Power/monthKWH功率/千瓦時/月Filter pump過濾泵3.71841558.42.23041184Rectifier 整流機2242995222426956.8Transporter motor天車馬達5.93110

12、44.81.51936Exhaust system抽氣系統(tǒng)301187207.514680Air Blower 吹干7.529360000Vibration motor振動馬達0.05762371.2000Shake motor搖擺馬達222496000Power/monthKWH總耗電量115,502.473,756.8VCP VCP vsvs Hoist Type Plating Power Saving Hoist Type Plating Power Saving節(jié)電節(jié)電Power saving monthly: 40,000KWH每月節(jié)約用水：4萬度傳統(tǒng)龍門式電鍍線傳統(tǒng)龍門式電鍍線項

13、目周工時周人數(shù)月累計工時工時折算成工資添加銅球45801656.80 水洗槽保養(yǎng)4116331.36 VCP電鍍線電鍍線項目周工時周人數(shù)月累計工時工時折算成工資添加銅球4000.00 水洗槽保養(yǎng)218165.68 傳統(tǒng)龍門式電鍍線傳統(tǒng)龍門式電鍍線項目程度備註工作強度大工安易發(fā)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(yè)coating地面150000VCP電鍍線電鍍線項目程度備註工作強度小工安不易發(fā)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

14、/月480地面要求地面不用coating，做簡單的防腐處理即可，在產(chǎn)線的底部會按裝防漏盤（裝機時廠商負(fù)責(zé)）。VCP VCP vsvs Hoist Type Plating Consumption Saving Hoist Type Plating Consumption Saving運行維護及其它成本節(jié)約VCP VS Hoist typeVCP與龍門線對比 VCP VCP vsvs Hoist Type Plating Appearance PK Hoist Type Plating Appearance PK 外觀對比外觀對比VCP Project 項目Standard 標(biāo)準(zhǔn)RMBCOV93

15、%Range R值3umThrowing power 貫孔能力95%Board Scraped摔飛靶報廢，吊掛報廢0%Copper scraped殘銅報廢 0%0Hoist type plating龍門線龍門線Project 項目Standard 標(biāo)準(zhǔn)RMBCOV85%Range R值5.5umThrowing power 貫孔能力90%Board Scraped摔飛靶報廢，吊掛報廢16.5pcs/day4290Copper scraped殘銅報廢 12.8pcs/day2662.4Copper board thickness:10um 面銅10umVCP VCP vsvs Hoist Typ

16、e Plating Quality/Uniformity PK Hoist Type Plating Quality/Uniformity PK均勻性對比均勻性對比Conclusion ：1. VCP running cost down around 25%；2. About 22 months, saving money can buy the equipment replace cost Hoist type cost/month龍門線成本龍門線成本/月月VCP cost/monthVCP成本成本/月月VCP SavingVCP節(jié)約節(jié)約Water （20RMB/T)水費（20元/噸）136

17、3,280 27,266RMB590,00011,800RMB15,466RMBPower （0.8RMB/KWH）電費(0.8元/千瓦時）115,50292,402RMB73,75759,005RMB33,397RMBCopper（62,000RMB/T）磷銅球（62000元/噸）11.875736,250RMB10.1175627,285RMB108,965RMBManpower(3500RMB/month/person）人工費（3500元/月）24,500RMB/Team49,000RMB5,250RMB/Team10,500RMB38,500RMBMaintaining 維護保養(yǎng)費1,

18、988RMB166RMB1,822RMBOther cost(scrap、HNO3 and copper cathode change）其他成本（報廢，硝酸，銅排更換等）10,431RMB480RMB9,951RMBTotal cost 總成本917,337 RMB709,236 RMB208,101RMBVCP VCP vsvs Hoist Type Plating Conclusions Hoist Type Plating Conclusions結(jié)論結(jié)論Money saving monthly: 20,000RMB每月節(jié)約費用：20萬Hoist TypeHoist Type VS VCP

19、VS VCPSafetySafety安全性安全性Fire Risk/火災(zāi)風(fēng)險Yes / 有風(fēng)險 No happen/無風(fēng)險Plates Drop Risk工件掉落風(fēng)險Yes /有風(fēng)險 No happen/無風(fēng)險Injured Risk/員工受傷風(fēng)險Yes /有風(fēng)險 No happen/無風(fēng)險Working Environment工作環(huán)境Smell bad & Noise & High temperature 氣味難聞，噪聲大，高溫Clean & More comfort( closed / low noise and A/C control )環(huán)境干凈舒適，低噪音，空調(diào)

20、控溫RunningRunning Cost Cost運營成本運營成本W(wǎng)ater Cost/用水成本 100% 44.9%Running-supplies Cost材料消耗成本100% 85.2%Service Cost/維修成本100%20%UniformityUniformity鍍層均勻性鍍層均勻性Cu ThicknessCu Thickness：0.4mil/0.4mil/銅銅層厚度：層厚度：0.4mil 0.4mil COV Value/COV值 125R Value/R值 5um3umTP Value/TP值 90%95%結(jié)論：結(jié)論：1. 1. VCP運行成本下降運行成本下降25%左右

21、；左右； 2. 22個月左右，個月左右，節(jié)約之總金額足以支付節(jié)約之總金額足以支付VCP購買之費用。購買之費用。 VCP VS Hoist Type Plating Conclusions VCP VS Hoist Type Plating Conclusions 結(jié)論結(jié)論VCP for VCP for Ni_AuNi_Au plating plating 鍍鎳金鍍鎳金VCPVCP產(chǎn)線名稱產(chǎn)線名稱傳統(tǒng)龍門線傳統(tǒng)龍門線金手指線金手指線東威東威VCP圖片說明生產(chǎn)人力： 6安全系數(shù)：差車間環(huán)境： 差操作：不方便 故障率： 高均勻性： 10u”生產(chǎn)人力：6安全系數(shù)：一般車間環(huán)境：一般操作: 一般故障率： 中最大作業(yè)尺寸高度：350均勻性： 極差5u”生產(chǎn)人力：2安全系數(shù)：優(yōu)車間環(huán)境：優(yōu)操作: 簡單故障率： 低最大尺寸高度：根據(jù)客戶定義；均勻性：極差4u”總結(jié)東威鍍鎳金VCP根據(jù)行業(yè)需求而去改善，改善傳統(tǒng)鍍鎳金龍門線缺點以及優(yōu)化金手指線產(chǎn)能需求（金手指線超過350mm產(chǎn)品需要鍍兩次，vcp只需要鍍一次）。Up to present, KSDW has sold out more than 300pcs VCP lines and the cost saving is roughly more than 600 million RMB 迄今為止，東威公司已經(jīng)制造銷