72 ultrasonic systems for pilot electroplating line

Jedes Becken der Reinigung ist mit zwölf Tauchschwingern mit 25 kHz ausgestattet. (Bildquelle: Weber Ultrasonics AG) / Each cleaning tank is equipped with twelve submersible transducers with 25 kHz. (Image source: Weber Ultrasonics AG)

Die 72 Sonopower 3S Generatoren befinden sich in einem klimatisierten Raum und sind mit einer optionalen Profibus-Schnittstelle ausgestattet. Sie ermöglicht die Steuerung der Schwinger aus der Ferne. (Bildquelle: Weber Ultrasonics AG) / The 72 Sonopower 3S generators are located in an air-conditioned room and are equipped with an optional Profibus interface. This enables the transducers to be controlled remotely. (Image source: Weber Ultrasonics AG)

The Chinese company aimed to install a new electroplating line that would set benchmarks in the industry by employing the latest technology. Six cleaning stations are integrated into the system. Each one contains 12 ultrasonic units that ensure clean, grease-free parts, which are essential for achieving high-grade coating quality. When it came to the ultrasonic technology, the company opted for solutions from Weber Ultrasonics.

Chinese firm Changtai Kemei Kitchen & Bathroom Technology Ltd., the largest bathroom furnishings manufacturer in Asia, invested around 3.8 million euros in a new electroplating line at its factory in Zhangzhou. The line is used for finishing bathroom and kitchen fittings made from stainless steel and copper alloys.

Modern technology for first-class surface quality

The key criterion for an optimal plating result is achieving a clean and grease-free surface on the parts. As such, the new system has a cleaning line with six stations. Waxy polishing pastes are removed in four tanks, while the other two are dedicated to degreasing before the subsequent electroplating treatment.
In order to ensure an optimum and stable cleaning result as quickly as possible, the action of the medium is supported by ultrasound with a frequency of 25 kHz in all tanks. Changtai Kemei uses Sonopower 3S generators in the 2,600 watt power class and power-adjusted submersible transducers from Weber Ultrasonics AG for this purpose.

High process and operational reliability

Due to the large tank volume, each tank is equipped with twelve Sonosub submersible transducers. Their capsule is produced using a special laser welding technique that ensures extreme sealing strength and dimensional accuracy.

Digital frequency generation and control are performed by a Sonopower 3S generator for each transducer. Thanks to combined frequency and amplitude modulation, these single-frequency systems enable very homogeneous sound fields and thus prevent standing waves. This increases the ultrasonic effect so that the cleaning and degreasing processes can take place more quickly and efficiently. The Sonoscan also contributes to consistent ultrasound performance. It determines the operating frequency automatically before ultrasonic output and adjusts the system settings accordingly. During the process, the frequency can be continuously monitored and automatically adjusted. This means that the most efficient power output is always applied, even in the face of changing operating conditions such as temperature fluctuations. As the adjustments take place during running operation, uninterrupted operation is guaranteed ‒ a criterion that is just as important to Changtai Kemei as high quality and service life, as the system is in use in three-shift operation, seven days a week.

Controlled via Profibus

The 72 generators are located in an air-conditioned room and equipped with an optional Profibus interface. This makes it possible to select the parts-specific cleaning programs remotely, for example tailored to the different materials and parts dimensions. What's more, the power output can be continuously adjusted in the range from 10 to 100 percent.

The electroplating unit is a pilot project for a new industrial park in which up to 20 such electroplating lines are to be used. It is set to go into operation by 2022.