GALVANIC CONTROLSYSTEM

GCS Plating Technology with controlledcurrent density (Patent No. EP032892A1), Steel Tire Cord Manufacturing

©2016 CPA - Vers. 2016_02

Applications

Steel Tire Cord Production Plants

Hose Wire Production Plants

Bead Wire Production Plants

Bailing Wire Production Plants

Welding Wire Production Plants

Brass Plating Plants

Copper Plating Plants

Zinc Plating Plants

Tin Plating Plants

Nickel Plating Plants

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adsorbedalignedwater dipoles

specifically adsorbed anion, loosely hydrated

Positive surplus chargesin rigid and diffusedouble layer

adsorbed organic molecule

external Helmholtzlayer

internal Helmholtzlayer

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Basics and electrical Design of the plating section:

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According to Ohm’U=RxI a linear dependency between current and voltage is expected. However, the mass transport in the diffusion layer is the determining step. A so called limit current i is observed.Gr

j Current DensityA AreadQ delta chargedt delta Time

dt

dQ

AA

Ij ×==

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Only the current density allows the prediction how much is plated on a certain point. And more important, if the plating was done within the optimal electric conditions, which are needed for high quality layers.

Resistor Network of only 1 Plating Cell

Simplified diagramm

Basics and electrical Design of the plating section

Group Current Supply

different current on each wire because ofdifferent resistancedifferent current means different coating

Separated Current Supply anodic side controlled

Single Cell Control – SYSTEM CPA

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Exactly controlled power supplies:

Control of current density controlled deposition conditions:

Voltage monitoring:

Documentation of process data for each wire

Detection and compensation of errors in individual plating cells:

Individual plating conditions for each wire possible

• 60 % load change within 500 ns (100 kHz power supply)

• nearly ripple-free

• better thickness distribution• avoidance of by-products no impurities no pores• higher corrosion resistance

• Conductivity• Ion concentration• detection of wire breaks• detection of contact problems

• maintenance during production possible

Power Supply

Galvanic bath with separated chambers

GCS 8008 Power Supply Modulesfor each Plating Cell

Cabinets with GCS - Power Supply Modules

Constant current output:

output direct voltage 1 - 15 Voutput direct current 2 - 50 Arelative inaccuracy 1 %max. overshoot 10 %transient load response 0,5 ms at 60 % load

jump Temperature ranges:

storage temperature -25 °C to +70 °Coperating ambient temperature 0 °C to +55 °C

The advantages

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Process Automation and Manufacturing Execution Systemwith ERP – Interface for Computer Integrated Manufacturing

! ! Output of all interferences, times, events in form of parameters for the production process an event protocol

! Collection of analogous (speeds, temperatures, ! Order account with target or actual values, fault-count values, quantities consumed…) and digital statistics etc.(messages, faults…) information and conditions ! Overviews and reports of outputs (machine and/or over standard PLC systems, industrial PC's with relating to orders), errors, interruptionsinterface cards, terminals, etc. ! Graphic error statistics

! Monitoring of production speed and disruptions, ! All overviews and reports can be issued after each input of disruptions and cause of malfunctions shift, on a daily, monthly, quarter-yearly or yearly

! Automatic transacted production feedback for basis or evaluation time perioded can be selected process status or manually performed by the freely.service personnel. Overview on the current status ! Extensive information listing and statistical of all production machines with indication of programsmachine designation, order, order dates ! ODBC interface(comparative), speed, operator, faults, alarm and ! SQL interfacemaintenance messages etc.

Start / Stop of orders, automatic setting of

Software - Features and Functions:

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! IMPERIO GCS Galvanic Control System

! IMPERIO MES Manufacturing Execution System

! Transparent and real-time overview on the production events

! Immediate reaction on quality issues

! Accurate, real-time data for planning, control and recalculation

! Improvement of quality and scheduling through on-line process supervision and real-time

order tracking

! Acceleration of data flow through online acquisition

! Real-time data provided for the entire control and monitoring of operations

IMPERIO PMS Process Management System

Fully Controlled Production by:

Management

Administration

Production

Process-management

Process-control

Process Data

LAN

V24/RS 422/ RS 485 Profibus ...

Strategic MGTand Planning

Administration Controlling

Purchase Department Sales Department Financ. planning, prod.planning, control and

data managementQuality Department

Production controlwire

Goods receiving station and material management

Production controlLayer aplication

Warehouseand delivery

PDC: Shop floordata collection

PDCQDC QDC

Machine control OPT OPTAutomatic

process control

Drawing machine Scales ScalesTest equipment Test equipmentLacqueringmachine

FT and Terminalemulation

Wire drawing Coating area

Data systemmanagement

LANLAN

QDC: Quality Data CollectionPDC: Production Data CollectionOPT: Operation Terminal

Software Components and Functions at the example of a magnet wire production

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Standard Design – long ways due to outside operating platform

CPA Design – saving of operating time due to central operating platform

Mechanical Design

Fume Hoods with exhaust pipes Separated plating cells for up to 60 wires

CPA - MELPICK - 3 Phase e Pickling System lectrolytic with separated basins

Standard Design – long ways due to outside operating platform

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Jet Rinsing with pre-rinsing bath and air wipe

Bath preparation and maintenance tanks

Exhauster with air scrubber

Compressed air supply system for air wipesand dryer

Subsystems

Synchronously to the wire speed drivencontact rolls guarantee minimum abrasion of contact rolls and wire.

Symmetric, redundant

contact systems for each plating cell

Different wire speeds by special constructionof the contacts and guidance rollers possible

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Subsystems for the protection of the environment:

Subsystems

Acid regeneration plant

Waste water treatment plant

Demineralization water station

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Pay-off and take-up systemfor continuous operation and common spool sizes

Interface to CPA-IMPERIO Automation and MES System for recipe control

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Brass plating is the key process in steel tyre cord production, which influences the quality of the end product General requirements to modern brass plating plants:and the production costs. All producers of steel tyre cord agree that a successful and efficient production is only ! Reduction of costs in wet drawing, stranding and roping possible with an optimized brass plating equipment. due to avoidance of wire fractures, elongation of life of

the wire-drawing dies and prevention of torsional Expense factors in brass plating of steel tyre cord: problems in roping

! Long life of contact-rolls with minimum friction between ! Prevention of rejects and high capacity through the wire and the rolls because of synchronized speed

controlled coating controlled by frequency converter ! High system efficiency through redundancy of all parts ! Easy and quick insertion of the wires without

which are necessary for an uninterrupted and fail-safe complicated loading through air nozzles and rinsing operation strips

! Reduction of operating and supervising personnel and ! Integrated regeneration, filter- and recycling system costs. solves all environmental problems and reduces costs

! Enormous savings on maintenance- and spare part ! Recognition of wire fractures and automatic power shut-costs compared to other systems because of avoiding of down of individual wires during loading sliding contacts ! Easy, quick adjustment and operation of the plant

! High quality of the final product and avoidance of costs without particular programming knowledge of the for customers complaints resident personnel

! Low energy consumption also in partly loaded operation ! Control, logging and statistics of all production compared to plants with the same basic technology parameters to create reproducible conditions and (diffusion) constant increase of knowledge on the influencing

! Reduction of costs on account of longer electrolyte life factors.! Enormous reduction of costs for anode material due to

complete dissolution of the anodes and thus increased Special requirerments to modern brass plating linesutilization.

To achieve such high-quality and cost efficiency ! Exact control of the current amount and current density factors it is necessary to meet the following basic with electrically decoupled plating cells by electrolyte requirements: resistant tracks and fast chopper power supplies.

! Automatic adjustment of current and wire speed in case ! clean wire after pickling of break-down of individual plating cells. ! guaranteed contact between wire and contact rolls ! Supervision of ion concentration and conductivity of

individual plating cells and recognition of short-circuits ! optimized anode geometryand shortage of anode material.! precise control of bath composition and bath

! Possibility of remote diagnosis and data query via temperaturetelephone modems and Internet ! predefined electrolyte flow in the plating cell and most

! Supervision of the operating staff's readiness for duty as importantwell as guided actions by operating instructions in case ! a precisely defined and well controlled CURRENT of trouble DENSITY at any time and at any place on the wire

! Automatic readjustment of the recipes on the basis of surfacelaboratory data or by online-analysis (optional)

! Process automation, supervision and visualization of the complete system including chemical equipment and waste water purification plant by process automation and data acquisition system

! Manufacturing Execution System for integration of the plant into Enterprise Ressource Planning Systems

Brass plating systems with only one current source for several plating modules (One-wire-systems) and parallel plated wires (Multiwire-systems) are not able to fulfill these requirements.

Steel Tyre Cord Manufacturing

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Process steps of brass plating Steelcord production - Process flow

Costs and quality of the steel tyre cord production are determined primarily by the brass plating process

Phase Diagramm

The phase diagramm shows the necessity of an exact layer application and composition of alloy in order to avoid ß-brass.

1. Pay-off 2. Pre-cleaning 3. Austenitization furnace 4. Patenting furnace 5. Quenching 6. Electrolytic pickling (sulfuric acid) 7. Cascade rinsing station 8. Alcaline bath (sodium hydroxide) 9. Cascade rinsing station10. Pickling (sulfuric acid) 11. Cascade rinsing station12. Galvanic coating (copper-

pyrophosphate) 13. Cascade rinsing station 14. Galvanic coating (copper sulfate) 15. Cascade rinsing station 16. Galvanic coating (zinc sulfate) 17. Cascade rinsing station 18. Drying air wipes19. Diffusion (Fluidized Bed) 20. Cooling Bath21. Phosphoric acid bath22. Cascade rinsing station23. Drying a24. Drawing grease emulsion bath25. Take-up

ir wipes

Air wipes are installed between all process steps.

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!! Possibility of remote diagnosis and data query via internet. ! Supervision of the operating staff's readiness for duty as well as guided actions by operating instructions in

case of trouble.! Reduction of operating and supervising personnel.! Easy correction of defects without down time for maintenance work due to modular and redundant design.! Distribution of current onto the remaining chambers of the same type in case of failure of a galvanic chamber.! Different wire diameters and different coat thicknesses possible simultaneously in one plant. ! Longer electrolyte life. ! Enormous reduction of costs for anode material due to almost complete decomposition of the anodes and

thus increased utilization. ! Considerably longer lifetime of the drawing dies. ! High reduction of wire breaks during subsequent forming, thus high reduction of rejects and decline in

auxiliary process time.! Higher constant quality of the final product and minimum reject

Easy, quick adjustment and operation of the plant without programming knowledge of the resident personnel.

ADVANTAGES OF THE CPA TECHNOLOGY

Traditional Technology CPA Technology

60,5 61,5 62,5 63,5 64,5 65,5 66,5

100%

60,5 61,5 62,5 63,5 64,5 65,5 66,5

100%

Results in:

!! brass abrasion during drawing is typical 5%! lower friction coefficient during twisting! break reduction by 50%! reduced downtime ! increase of machine operation by one operator

! deviation of coating composition typical ±1% ! significant reduction of reject rate! reduction of order execution time

die wear reduction during fine drawing

CHARACTERISTICS

Precise chemical composition Coating thickness No remaining scale under the brass layer

Clean production due to completely closedplant design

* Compared to Plants with only vertical anodes

ABACS - Automatic Bath Analysis andControl System

Supervision and control system for up to 10 lines with 60 wires and 150.000 Datapoints

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62.7 % 64.1 %

61.6 %

64.7 %

62.5 % 62.6 %

62.2 %

62.9 %

conventionalSystem CPA - System

Unique homogeneity of chemical composition and coatingthickness

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Analysis of cost reduction

anodes*

dies

rejects

staff

twisting

For the CPA technology

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technologies for excellence

Austria8055 GrazLagergasse 322Tel.: +43 / 316 / 4670-0Fax: +43 / 316 / 4670-7

Homepage: www.cpa.at Email: office@cpa.at

PR. ChinaCPA Science & Technology Co., Ltd. 888 Changjiang North RoadBacheng Town,Kunshan Euroamerican Industrial Park

Kunshan City, Jiangsu Province Tel.: +86/512/57689566 Fax: +86/512/57689500

Certified according to EN ISO 9001: 2008

CPA Building & Factory Technologies GmbHControl Division

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! MES - Manufacturing Execution System! BAS - Building Automation System! GCS - Galvanic Control System! CWS - Cable and Wire System! WSS - Water Supply System! WWS - Waste Water Systems! ABACS - Automatic Bath Analysis and

Control System! Comatic - Industrial-PLC! MicroMatic - Compact-PLC! Control Cabinet Construction

IMPERIO - Process Control Technology