垂直連續(xù)電鍍設(shè)備(VCP)取代龍門電鍍線的必然趨勢

GuangDeDongweiPlatingEquipmentTechnologyCo.,Ltd.廣德東威電鍍設(shè)備技術(shù)有限公司JianboLiu劉建波TrendofReplacementfromGantryPlatingEquipmenttoVerticalContinuousPlatingEquipment

垂直連續(xù)電鍍設(shè)備（VCP）取代

龍門電鍍線的必然趨勢Advantage-自主研發(fā)，技術(shù)領(lǐng)先ComparisonBasedon:SafetyPK,EconomyPK,ProductsQualityPK,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

Capacitypermonth：47,500

m2

月產(chǎn)能47,500m2；PanelplatingCuthickness：0.4mil面銅厚度：10um；Workinghoursanddays:22hoursperdayand26dayspermonth每天生產(chǎn)22小時，每月生產(chǎn)26天;Calculation：計算Hoist—12platingunits，width=4.2m，3setstransporter

龍門線–12缸，寬度4.2米，3臺天車VCP—12Cu,V=2.18m/minVCP12個銅槽，傳動速度2.18米/分鐘VCPvsHoistTypePlating-VCP與龍門電鍍對比BigfirerisksexistinthehoisttypeplatingequipmentsandmanyfirehazardsareshownontheTVs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VCPequipmentscontainsspecialfire-proofdesignandminimizehumanfactorsforfirehazards.Currentlynoanyfirehazardhappens。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)；VCPvsHoistTypePlating–FireHazardsRisks火災(zāi)風(fēng)險VCPequipmentVCP電鍍線Fullsealedworkingenvironmentandnobadsmells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HoisttypeequipmentNoisy,openwithbadsmellsandplatesareeasytodropwhenaddingcopper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VCPvsHoistTypePlating–OperatorSafety員工安全Equipmenttype設(shè)備類型Consumption耗材CopperConsumption銅球消耗Capacity/m^2產(chǎn)量Totalconsumption總消耗量Hoisttype龍門線Copper磷銅球25Kg/100m247,50011.875TVCP21.3Kg/100m247,50010.1174TReasonforcoppersaving:uniformityimprovement省銅理由：均勻性提高VCPVSHoistTypePlating–Economy節(jié)約磷銅球Hoisttypeplating龍門線VCPNumberofpeople人工數(shù)Cost/month/person人員月工資Totalcost/month每月成本Numberofpeople人工數(shù)Cost/month/person人員月工資Totalcost/month每月成本Loading/unloading上下料3350010500035000Dry

產(chǎn)品吹干235007000035000On-lineinspection巡檢135003500135003500Maintain

維護1350035000.535001750Totalcost/8hours總成本24500RMB5250RMBVCP-RobotarmAutoloading&unloading自動上下料HTP-loading&unloadingbyhands人工上下料VCPvsHoistTypePlating–LaborCost節(jié)約人工Laborsavingmonthly:~20,000RMB每月節(jié)約人工費：2萬元傳統(tǒng)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2200

8800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400

1600沖污水洗200

800清水洗2007.5258200月總耗用水量:L/Month

1363280VCP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(yù)浸4000水洗烘乾線酸洗0

每週一次0酸後水洗000磨刷0

0沖污水洗0

0月總耗用水量:L/Month590000VCPvsHoistTypePlating–WaterSaving節(jié)水Watersavingmonthly:760ton每月節(jié)約用水：760噸Hoisttypeplating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Filterpump過濾泵3.71841558.42.23041184Rectifier

整流機2242995222426956.8Transportermotor天車馬達5.9311044.81.51936Exhaustsystem抽氣系統(tǒng)301187207.514680AirBlower

吹干7.529360000Vibrationmotor振動馬達0.05762371.2000Shakemotor搖擺馬達222496000Power/monthKWH總耗電量115,502.473,756.8VCPvsHoistTypePlating–PowerSaving節(jié)電Powersavingmonthly:40,000KWH每月節(jié)約用水：4萬度傳統(tǒng)龍門式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45801656.80水洗槽保養(yǎng)4116331.36VCP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/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（裝機時廠商負責(zé)）。

VCPvsHoistTypePlating–ConsumptionSaving運行維護及其它成本節(jié)約VCPVS

HoisttypeVCP與龍門線對比

VCPvsHoistTypePlating–AppearancePK外觀對比VCP

Project

項目Standard

標(biāo)準(zhǔn)RMBCOV93%

Range

R值3um

Throwingpower貫孔能力95%

BoardScraped摔飛靶報廢，吊掛報廢0%

Copperscraped殘銅報廢

0%0Hoisttypeplating龍門線Project

項目Standard

標(biāo)準(zhǔn)RMBCOV85%

Range

R值5.5um

Throwingpower貫孔能力90%

BoardScraped摔飛靶報廢，吊掛報廢16.5pcs/day4290Copperscraped殘銅報廢

12.8pcs/day2662.4Copperboardthickness:10um面銅10umVCPvsHoistTypePlating–Quality/UniformityPK均勻性對比Conclusion：VCP

runningcostdownaround25%；About22months,savingmoneycanbuytheequipmentreplacecost

Hoisttypecost/month龍門線成本/月VCP

cost/monthVCP成本/月VCPSavingVCP節(jié)約Water

（20RMB/T)水費（20元/噸）1363,280

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1,988RMB166RMB1,822RMBOthercost(scrap、HNO3andcoppercathodechange）其他成本（報廢，硝酸，銅排更換等）10,431RMB480RMB9,951RMBTotalcost總成本917,337RMB709,236RMB208,101RMBVCPvsHoistTypePlating–Conclusions結(jié)論Moneysavingmonthly:20,000RMB每月節(jié)約費用：20萬

HoistType

VSVCPSafety安全性FireRisk/火災(zāi)風(fēng)險Yes/有風(fēng)險Nohappen/無風(fēng)險PlatesDropRisk工件掉落風(fēng)險Yes/有風(fēng)險Nohappen/無風(fēng)險InjuredRisk/員工受傷風(fēng)險Yes/有風(fēng)險Nohappen/無風(fēng)險WorkingEnvironment工作環(huán)境Smellbad&Noise&Hightemperature氣味難聞，噪聲大，高溫

Clean&Morecomfort(closed/lownoiseandA/Ccontrol)環(huán)境干凈舒適，低噪音，空調(diào)控溫RunningCost運營成本W(wǎng)aterCost/用水成本100%44.9%Running-suppliesCost材料消耗成本

100%85.2%ServiceCost/維修成本

100%20%

Uniformity鍍層均勻性CuThickness：0.4mil/銅層厚度：0.4milCOVValue/COV值≤12

≤5

RValue/R值5um

3um

TPValue/TP值90%

95%

結(jié)論：1.VCP運行成本下降25%左右；2.22個月左右，節(jié)約之總金額足以支付VCP購買之費用。

VCPVSHoistTypePlating–Conclusions結(jié)論VCPforNi_Auplating鍍鎳金VCP產(chǎn)線名稱傳統(tǒng)龍門線金手指線東威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）。Uptopresent,KSDWhassoldoutmorethan300pcsVCPlinesandthecostsavingisroughlymorethan600millionRMB迄今為止，東威公司已經(jīng)制造銷售了超過300條VC