fully automated 12 stations anodising rack line

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Plasticraft Fully Automated 12 Stations Anodising Rack Line

Stock Code: TRIUM100Manufacturer: PlasticraftModel: Plasticraft Fully Automated 12 Stations AnodisingYear of Manufacture: 2006New or Used: Used (Second Hand)Work Envelope (WxDxH mm): 2000 x 900 - 1600 x 1750Process Stages: 12Other Info: Full motorised canopy transporter systemExternal Dimensions (WxDxH): 18,000 x 4,000 x 5,000

The Plasticraft plating line was originally ordered to meet the exacting demands of the Aerospace Industry for theAnodizing of aluminium and composite materials.

The fully automated system incorporates a motorised transporter system with full PLC control and multi programmefunctionality.

The system may also be used in a manual mode with the operator walking the transporter through the process via atravelling pendant control.

Although originally designed to work with sulphuric chromate solutions, with the addition of the spare stations manyother surface treatments and coatings could be applied within this plant, such as:

Pre-treatment with Phosphating, tartaric anodising, pickling, cleaning and the deposition of plate Nickle, Zinc,Cadnium etc.

The Marketplace for Surface Technology.New and Used Process Equipment & Machinery.

Riley Industries LtdA subsidiary of Barry Riley & Sons Ltd. Director: M P A Riley, Secretary: D Hemming

Registered in England no. 1965748

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Plasticraft Fully Automated 12 Stations Anodising Rack LinePlant Component OverviewTransporter

Fully motorised canopied transporter system to operate in either one of two modes.

Modes 1

Where all traverse and hoist movements automatically follow pre-set routes and process times.

Modes 2

Where all transporter movements are under the control of the operator.

Transporter FeaturesA high retaining arm sliding mechanisms has been fabricated from box section and plate fittedto each end with Polyurethane tyred wheels with bearing. Wheels are resistant to abrasion and to many commonchemicals, Polyurethane tyred wheels are capable of effectively carrying heavy loads and transmitting a good drivingforce.The main Transporter carriage and side masts are fabricated from pre-formed powder coated Mild Steel sheet,welded and bolted.The traverse drive is by means of a variable speed motor and gear box connected to standardR.S. wheel blocks under the control of a frequency inverter designed to give a smooth accelerating and deceleratingcurve.The hoist mechanism is by means of a Variable speed motor and gear box under the control of a frequencyinvertor designed to give a smooth accelerating and decelerating curve.The lifting beam is fitted with Polypropyleneguides which centralises the flight bar on raise and lower. Raise and lower are via flat tape belts.Safety over- runswitches are fitted on each end of the steelwork.Anti-lowering switches are incorporated on the transport to stop oneflight bar being lowered on top of another.To enable the transporter to be manually operated as required, a pendantcontrol mounted is mounted on the transporter. When the pushbuttons are released, the transporter will then simplycontinue traversing until it reaches the next proximity switch and then stop.A ‘Works Engineer’ manual mode which iskey or code lockable via the control panel. When in this mode, the transported may be stopped in any position ‘offstation’, i.e. for maintenance.Spreader unit assembly to open up work bars at high level over the Anodising Tankonly.Steelwork

Heavy Duty rectangular box section track will be supported from the floor mounted on hollow box columns withhollow section cross bracing. The structure will be bolted section and when painted and levelled will be fixed to thefloor.

Catenary System

The galvanised steel catenary track is supported at the rear of the line of the plant by cantilever supports, which arebolted to the structure along the full length of the plant.

The flatform multicore catenary power cable is suspended from the track system by means of Polypropylenehangers, each fitted with four bearing wheels for friction-free running.

Safety Guards

In order to comply with the requirements of the Health and Safety at Work Act, all motorised and automatic plantsare fitted with suitable guards.




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Plasticraft Fully Automated 12 Stations Anodising Rack LineClear PVC safety guards are fitted along both sides of the plant.

Guards will be interlocked so that the transporter will stop if interlock is broken.

A dual fail-safe ‘emergency stop’ pull cord system will be fitted along the full length of both sides of the plant on theoperating side. In addition, the transporter control box and load/unload stations have ‘emergency stop’ buttons.

Flight Bars

8 Off Single row flight bars constructed in solid Aluminium 21/2” x 1” section clad with Copper, complete with Coppercontacts and transporter pick-up horns. Mild Steel section support frame will be fabricated in box section.

Service Walkway

An operator’s walkway running the full length of the line will be supplied, having access steps and will bemanufactured in Mild Steel with a galvanised steel treadway.

Mobile Trollies

2 Off Mobile Trollies constructed in mild steel. Suitably braced and painted Trollies will be fitted with castors and willbe complete with work bar location brackets.

Mixing Facility For Chromic Acid Anodise Tank1 Off Mixing Tank size 850mm x 850mm x 990mm deep, on feet toraise tank to 1100mm working height.Constructed in PVC/ GRP.1 Off Plunger Unit complete with perforated baffleplate.1 Off Air Diaphragm Pump to transfer solution to the Chromic Acid Anodise Tank.1 Set Pipework and fittings forsolution transfer.For Chromic / Sulphuric Pickle Tank1 Off Mixing Tank size 650mm x 650mm x 990mm deep, onfeet to raise tank to 1100mm working height. Constructed in PVC/ GRP1 Off Plunger unit complete with perforatedbaffle plate.1 Off Air Diaphragm Pump to transfer solution to Chromic Sulphuric Pickle Tank.1 Set Pipework andfittings for solution transfer.1 Off Air Diaphragm Pump to transfer sulphuric acid from customer’s Carboy Unitcomplete with pipework to transfer to above mixing tank.Programme Control Equipment

1 Off Programmable Logic control to provide.

A powerful modular system with flexible communication facilities.Built in bi-directional MPI port and Ethernet forcommunications.I/O capacity expandable to cover 1600 points.Wide range of advanced special I/O modules, whichare co-processors to the main CPU; they can therefore hand complex tasks without adversely affecting the userprogram execution time.Program execution time from 0.375 milli seconds per instruction.Software features includesubroutines, interrupts, and scaling, full maths and communication commands.Analogue input and output moduleshave 121-but resolution conversion and include features such as scaling, mean value calculation, peak value holdand input disconnection flag.Temperature control modules accept inputs directly from the in tank probe. Conversionis carried out internally to a 4 digit BCD number thus not creating a load on the cycle time.

1 Off Data And Processing Acquisition Software To Include:




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Plasticraft Fully Automated 12 Stations Anodising Rack LineThis is a process control and data acquisition software package and its intended use is in the metal finishingindustry.It combines the latest front-end software with the most reliable programmable logic controllers available offthe shelf.The MMI (man machine interface) is made graphically thus reducing training and computer knowledge to aminimum.All facets of process control are catered for with near true graphical representation.The control parameters,such as pumps, heaters, transporter movements, are easily accessible through the icons on the screen.Data loggingis carried out continuously against numerous features. This can be interrogated to provide suitable valuablemanagement information.Data acquisition and reading is made easy by virtue of the fact that the system usesMicrosoft Access as its database. This allows any SQL (subjective query language) to interpret it, such as Excel orMicrosoft Access.Control UnitsThe process is fully controlled via PC HMI Work Station and the PLC.Control,monitoring and data logging is included.Control, monitoring and data logging of immersion times isincluded.Sequences/recipes are created through the on screen display and held on the PC for future callup.Automatic control of rectifier.The system uses Access 2000 database. This is a Microsoft product accessible bymost other database software packages.Colour graphics on screen displays current line activity.Alarm and signallingis included.Historical data logging.Rectifiers

1 Off – 50 Volt 1000amp air cooled rectifier having remote control panel with ammeter, voltmeter, potentiometers,on/off switch and man/auto select.‘Man’ provides manual control from the potentiometers. Auto provides automatic PLC control of voltage profiles forChromic Acid Anodise.

Water Break Tank

Wall mounted water break tank and pressurisation pump to provide filling and top up water for rinse and processtanks either direct or via DI water plant.

Drip Shields

3 Off polypropylene drip shields to close gaps between process tanks where no exhaust ducts are fitted.

Safety Shower

Safety shower with overhead spray drencher and body spray – made from non- corrodible materials such asstainless steel pipework and brass fittings – operated by ‘push lever’ control. The unit is free standing and comescomplete with safety shower sign.

Eye/Face Wash

Providing water to the eyes and face – operated by a simple “lean-in” action to lock open, allowing hands free toopen eye etc, and released by spring lever automatically closing over spray nozzles to protect from airbornecontamination and shutting off water – constructed of stainless steel frame, stainless steel pipework and allnon-corrodible valves and fittings. Complete fitted to shower.

Cooling system

Design criteria




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Plasticraft Fully Automated 12 Stations Anodising Rack LineApplication: 1 Off Chromic Acid Anodise Tank.Thermal Duty: 40 kWFluid Type: Water/Glycol solution 25%Cooling fluid supply temp: 8 °CCooling fluid supply temp: 13 °CrCooling fluid flowrate/pressure: 6.8m3 / hr @ 2.5 BarSite: Internal or ExternalAmbient air temp: 27 °C

ICE Standard ComponentsNominal 3 bar pressure water pumpWater pressure gaugeDual compressors and dualrefrigerant circuits (1 compressor per circuit)Refrigerant pressure gauges for each refrigerant circuitWater by-pass(protection against closed valve conditions)300 litre capacity integral water tankLow level water protectionMainsisolatorInternal/External sitingCabinet

The chiller cabinet is manufactured from galvanised steel sheet with a powder coated paint finish and is suitable forinternal and external siting.

Compressors (1 Off)

The Copeland Compliant Scroll compressors are hermetically sealed types mounted on rubber anti-vibration feet.The unique compliant scroll technology offers extreme reliability and renders the compressor almost indestructibly.Scroll compressors are also very user friendly as they are extremely quiet and do not require crankcase heaters forpre-heat prior to starting.

Condenser

The vertical condenser coils are manufactured with copper tubes and aluminium fins. The air-flow across the coil ishorizontal and is produced by three axial flow fans with vertical air discharge. The fan motor has its own internalmotor protection device. The coils are protected from damage and blockage from dirt/dust etc. by a stainless steelwire mesh air filter.

Evaporator

The evaporator is a dual finned coil type (one block per refrigerant circuit) mounted inside the horizontal 300-litrewater storage tank.

The coil comprises copper tubes and aluminium fins and is configured to ensure very low water velocities andpressure drops. This arrangement virtually eliminates the risk of impurities blocking the water circuit and allows theuse of much greater variations in water flows and temperature differences across the evaporator.

A small manual bypass is fitted to guarantee fault-free operation with fluctuating water flows and prevents the pumpfrom operating under closed valve conditions.

The accumulation tank incorporates a thermal buffer reducing compressor starts and temperature deviation duringlower load conditions.




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Plasticraft Fully Automated 12 Stations Anodising Rack LineWater Circuit

As partially described above, the water circuit comprises a 300 litre horizontal water storage tank and a centrifugalprocess pump which draws water from the tank and discharges it to the process.

The end suction centrifugal pump is directly connected to a totally enclosed fan cooled motor. All parts that are incontact with the process water are manufactured from stainless steel.

A water pressure gauge is fitted and indicates the pressure available from the discharge of the pump.

The water storage tank is fitted with a fill and vent tank, drain valve, low water level switch and an automatic air vent(close circuit version only) and is fully insulated to prevent ambient heat gains and condensation.

A sensor for the temperature control of the chiller is fitted to the tank outlet.

A sensor for the freeze protection is fitted in the tank.

Refrigeration System

The refrigeration system comprises two totally independent refrigerant circuits each with its own compressor,condenser and evaporator coil all described above. In addition to these components, each circuit has an expansionvalve, liquid line solenoid valve, liquid line drier, refrigerant charging schreader valve, high pressure and fan pressureswitches and high and low refrigerant pressure gauges. All circuit components are interconnected with high-graderefrigeration seamless copper tube. Brazed joints are used where possible to minimise the risk of refrigerant leakage.The system is factory pressure and helium leak tested, dehydrated and charged with refrigerant gas.

The expansion valve meters the flow of liquid refrigerant (R407c) to the evaporator depending on the system loadrequirements.

A capillary line is fitted across each expansion valve to ensure a minimum liquid flow to the evaporator to improveefficiency of the valve and evaporator.

The drier ensures a completely dry system on initial charging.

The fan pressure switch controls the condenser fan, switching it on/off depending on the load and ambient conditionsto ensure the high side system pressure is maintained within design limits. The high pressure switch will switch thecompressor off in the event of excessive pressures in the system.

The liquid line solenoid valve is fitted to prevent large volumes of liquid refrigerant migrating to the evaporator duringoff cycles and to facilitate pump down for maintenance.

Control Panel

The control panel incorporates all the necessary electrical control components, transformers, contactors/overloads,fuses etc. to ensure reliable and safe operation of the chiller.




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Plasticraft Fully Automated 12 Stations Anodising Rack LineControl Panel Fascia

The control panel fascia comprises of mains isolator switch and the latest advanced version digital temperaturecontroller. This advanced version offers a vast range of programming facilities allowing the chiller to be set-up andoperated and controlled throughout a very wide range of applications and conditions.

A standard feature of this controller is the interface for easy communication to various external BMS/centralisedsupervisor systems. It also has compressor run and controller alarms indication lamps, remote on/off and volt freealarm facilities.

Fume Exhaust

The fume exhaust system includes the following major items of equipment:-

Fume exhaust hoodsExhaust dampersExhaust fanInlet manifoldOutlet stackChrome demister unitActuateddampersAmbient air inletBasis Of Design

Fumes will be extracted from the Process Line at the following nominal rates with a maximum of one lid being openat any one time.

Stage

Process

With Lids Extraction CFM

3

Warm Rinse

560

4

Clean

818

7

Cr/H2SO4 Pickle

1076

11




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Chrome Anodise

8608

12

Phosphoric Anodise (Future)

1171

Total Extracted Volume :

12,233m/hr

Discharge stack sized to provide a maximum in-stack velocity of 9 m/s and a minimum discharge velocity of 15 m/s.

Process descriptionGeneral extraction

Fumes will be extracted from the process line tanks, at the rates given within the Basis of Design Section.

Full extraction from the total surface area of the tank at all times has been allowed for without lids or lid open. Lidclosed reduces volume to 20% approx.

Fumes are extracted via lip hoods at low level, through manifolds into the main header duct running at high levelalong one side of the plant. The duct drops down into the demister unit, then into the fan and is discharged toatmosphere via the exhaust stack. The stack rises to high level on the outside of the building and has guy wires forstability.

Adjustment of airflow, will be via manual control dampers.

Horizontal Fume Demister

Fume to be treated are extracted from the process tanks and drawn into the horizontal scrubber/demister unitpassing consecutively through the wet sprayed double bank of impingement blade mist eliminators.

The treated saturated air stream flows through the double bank of profiled impingement blade mist eliminators. Inthis section the entrained liquid droplets removed from the air stream agglomerate on the blade surfaces and gravityflow into the casing sump.

On leaving the demister unit the treated fumes are ducted to the extraction fan for discharge to the atmosphere viathe exhaust stack.

Specification Of Equipment

Lip Extraction Hoods – 8 Off Single Sided Low Level




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Single sided lip extraction ducts fitted at tank rim with full length extract slots and fitted with equi-spacedsplitters/stiffeners with plenum take-off, incorporating manually adjustable flow balancing damper. Single sided ductswill be connected into a condenser box.

Materials of Construction:-Fabricated in uPVC reinforced with glass fibre/resin laminate.

Ductwork – 1 Set Comprising:-Flanged connection to each condenser box

The header ductwork will run down the process line at high level and is directed to the inlet of the demister and fan,prior to exhaust to atmosphere.

Each connection will be fitted with pneumatically operated damper via the PLC, to control air flow with lids beingopen or shut.

Ductwork fabricated in uPVC reinforced with glass fibre/resin laminate.

Air Inlet bleed complete with damper to be branched into the manifold system.

Instrumentation1 Off Airflow switch.Extraction Fan – 1 OffForward curved fume exhaust fan, vee belt driven from15kW TEFC (IP55) motor suitable for 400/3/50 supply to provide a duty of 12,300cfm at 127mm wg suppliedcomplete with base frame, motor slides rails, drive guard, access panel, drain socket and flexible connection.Fancasing fabricated in uPVC/GRP.Impeller fabricated in Stainless Steel.Base frame, etc., fabricated in mild steel andpainted finished.Discharge Stack – 1 OffFloor mounted, 12m ffl height round construction, terminating with an effluxcone.Fabricated in flanged sections with all associated brackets wall, gaskets, fixings, guy ropes and samplepoints.Fabricated in uPVC/GRP.Gaskets in pPVC or equivalent.Fasteners in stainless steel.Controls – 1 SetMotorstarters and controls housed in main panel associated with process line.Scrubber/Demister – 1 Off

Horizontal Fume Demister, Comprising:-

Double bank profiled impingement blade type mist eliminators, mounted in cassettes (to provide easy removal fromdemister for inspection and maintenance).Flanged square section casing fitted with inlet and outlet transition boxesand side inspection/access window.

All mounted within the ‘H’ configuration freestanding frame.

Materials of Construction:




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Plasticraft Fully Automated 12 Stations Anodising Rack LineCasings, transition boxes, and recirculation tank in uPVC externally reinforced glass fibre/resin laminate usinggeneral-purpose resin with chopped strand matt glass fibre.Mist eliminators cassettes, valves, pipework, sprayheaders and nozzles in uPVC.Frame welded constructions, in mild steel box sections finished painted.Mist eliminatorblades in polypropylene.Gaskets in pPVC.Fasteners in stainless steel.Pump and sump tank.Group ServiceRequirementsElectricityRequired supply voltage: 415volts 3 phase 50Hz unspiked supply with neutral.Compressed AirDry filtered, oil free and instrument air quality at 5.4 bar will be required for intermittent operation.WaterMake up water: DI Water.Water will be required to replace drag out and evaporative losses from the process tanks and running rinses.PlantSpecificationStation 1 Load and unload station

Width 900 mmLength 2000 mmDepth 1750 mm

Working temp

N/A

Freeboard

N/A

Capacity

N/A

Consisting of

Angle Iron Painted Frame

Stage completed with

This is the load area in which the flight bar trolley is inserted and removed for external loading and unloading of thejigs. The load/unload station has a light guard entry system for operator safety.

Station 2 Warm Air Dry


Working temp

80C




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Plasticraft Fully Automated 12 Stations Anodising Rack LineFreeboard

N/A

Capacity

3200 litres

Consisting of

Mild steel painted outer frame with 304 stainless steel inner chamber banded for strength and insulated with mineralwool


4 x Flight bar location brackets and electrically heated air curtain

Station 3 Warm Rinse


Working temp

35C

Freeboard

150 mm

Capacity

3200 litres

Consisting of

Mild steel painted outer frame with 304 stainless steel inner, banded for strength and insulated with mineral wool,fitted with overflow weir and flanged outlet.


4 x Flight bar location brackets, PTFE electric immersion heater with thermostatic control, low/high level safety cutout and MCB safety device.

Top entry water filler complete with level probes for auto top up.




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Single row PVC air agitation coil with manual control valve.

2 x Pneumatic lids with solenoid valves and open/closed limit switches.

Station 4 Soak cleaner


Working temp

60-70C

Freeboard

300 mm

Capacity

2900 litres

Consisting of

Mild steel painted outer frame with mild steel inner, banded for strength and insulated with mineral wool, fitted withoverflow weir and flanged outlet.


4 x Flight bar location brackets, PTFE electric immersion heater with thermostatic control, low/high level safety cutout and MCB safety device.

Top entry water filler complete with level probes for auto top up.

Stainless steel educator system complete with vertical stainless steel pump and carbon filter chamber.


Station 5 Static Dragout Rinse





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Plasticraft Fully Automated 12 Stations Anodising Rack LineWorking temp

Ambient

Freeboard

100 mm

Capacity

2970 litres

Consisting of

Mild steel painted tank, banded for strength, with overflow weir and flanged outlet and lined with a 2.4 mm PVCcoating.


4 x Flight bar location brackets, and top entry water filler with manual valve.

Station 6 Cold rinse


Working temp

Ambient

Freeboard

100 mm

Capacity

2970 litres

Consisting of

Mild steel painted tank, banded for strength, with overflow flanged outlet and lined with a 2.4 mm PVC coating.


4 x Flight bar location brackets




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Single row PVC air agitation coil with manual control valve

Top entry water filler with manual valve

Top spray bar assembly with solenoid operation.

Station 7 Acid Pickling


Working temp

60-65C

Freeboard

300 mm

Capacity

2900 litres

Consisting of

Mild steel painted tank, banded for strength, and insulated with mineral wool, lined with 8lb/ft chemically pure lead.



PTFE electric immersion heater with thermostatic control, low/high level safety cut out and MCB safety device.

Top entry water filler complete with level probes and solenoid for auto top up.

PVDF educator system complete with PVDF vertical pump and filter chamber.


Station 8 Static Dragout Rinse





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Working temp

Ambient

Freeboard

100 mm

Capacity

2970 litres

Consisting of




Station 9 Spray rinse


Working temp

Ambient

Freeboard

N/A

Capacity

N/A

Consisting of





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Plasticraft Fully Automated 12 Stations Anodising Rack LineStage completed with


Top spray assembly comprising 3 off PVC framed assemblies each with nozzles that have a 0.68 litres flow perminute controlled via solenoid valves.

Station 10 Static drag out rinse


Working temp

Ambient

Freeboard

100 mm

Capacity

2970 litres

Consisting of

Mild steel painted tank, banded for strength, with overflow outlet and lined with a 2.4 mm PVC coating.



Station 11 Double Anodising tank


Working temp

38-42C

Freeboard

300 mm




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Capacity

4640 mm

Consisting of

Mild steel painted tank, banded for strength, with overflow outlet and lined with a 2.4 mm PVC coating.



PTFE electric immersion heater with thermostatic control, low/high level safety cut out and MCB safety device.

Top entry water filler complete with level probes and solenoid for auto top up.

Stainless steel cooling coils with thermostatic control and isolating valves.

3 x Cathode rails ( designed to be removable by the transporter)

CPVC educator system complete with CPVC vertical pump and filter chamber


Station 12 Spare double station


Spare station for the insertion of a double tank for any future requirements.

Note the transporter and current steelwork covers this area.View Plasticraft Fully Automated 12 Stations Anodising Rack Line on our web site athttps://www.rileysurfaceworld.co.uk/machines/27071.htm

PHOTOGRAPHS TAKEN PRIOR TO REFURBISHMENT.




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fully automated 12 stations anodising rack line

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