Richcoat Equipment and Facilities

Why two fully automated anodizing lines?

We had to insure ourselves that strict non-human control of the variables must be addressed. The only way we could achieve the above was through automation with computer control of every anodizing variable; chemical, electrical, and mechanical. With our innovative computer system we are able to analyze and maintain the proper chemistry of the electrolyte as well as the cleaner. It monitors the conductivity of all the rinse tanks and corrects them when they are out of assigned parameters. Along with monitoring and maintaining proper chemistry, all bathes are continually monitored for proper temperatures. This ingenious computer system also regulates the mathematically computed current density of each anodizing cell. Our equipment and computers are designed to handle in excess of 12880 parts per hour and the higher volumes ensure greater control of quality parameters.

Equipment List

ALPHA LINE:

Automated, P.C.C. computer controlled clear / hardcoat anodizing line consisting of 16 stations. All tanks are 4 feet long x 4 feet deep with varying widths constructed of ¾ inch polypropylene.

Station Number & Cycles	Width	Tank Material
1. Load/17/Unload	-	-
16. Dryer	36”	304 S.S.
15. Warm Rinse (D.I.)	36”	Polypropylene
2. Acidic Cleaner	36”	Polypropylene
3. Rinse	30”	Polypropylene
4. Rinse	30”	Polypropylene
5. Conditioner	30”	Polypropylene
6. Rinse	30”	Polypropylene
7. Rinse	30”	Polypropylene
14. Rinse	30”	Polypropylene
13. Rinse	30”	Polypropylene
*8 -12. Hardcoat (5 – Bay)	180”	Polypropylene

*8 – 12 Hardcoat / Clear Anodize (5 – Bay)

Each anodizing cell (bay) is bussed to a rapid power D.C. output air-cooled rectifier rated as follows:

0 – 1500 Amps; 0 – 75 Volts. Each rectifier is equipped with a remote control with the following features:

• Automatic voltage control
• Automatic current control
• Automatic ramping control
• Voltmeter
• Amp meter
• Timer

Production Analysis Alpha Line

30 minute anodizing cycles = 2.0 bars / hours per bay
10 pcs. across x 32 pcs. high back to back = 640 pcs / bar
640 x 2 x 5 = 6400 pcs. per hour

OMEGA LINE:

Automated desk top computer (operator interface computer) controlled hardcoat anodizing line consisting of 12 stations described below:

All tanks are 6 feet long x 5 feet deep with varying widths constructed of 10 ga. 316 stainless steel with stainless steel reinforcements and copolymer with external insulation.

Station Number & Cycles	Width	Tank Material
1. & 11. Load/Unload	-	-
10. Hot D.I. Rinse	36”	316 S.S.
12. Drip / Dry Tank	36”	316 S.S.
2. Acidic Cleaner	30”	316 S.S.
3. Rinse	30”	316 S.S.
4. Rinse w/Rim Spray	30”	316 S.S.
9. Rinse w/Rim Spray	30”	316 S.S.
8. Rinse	30”	316 S.S.
*5,6,7. Hardcoat (3-Bay)	136”	Copolymer (Insulated)

*5 – 7 Hardcoat Anodize (3-Bay)

Each anodizing cell (bay) is bussed to a rapid power D.C. output air-cooled rectifier rated as follows:

0 – 2000 Amps; 0 – 50 Volts. Each rectifier is equipped with a remote control with the following features:

• Automatic voltage control
• Automatic current control
• Automatic ramping control
• Voltmeter
• Amp meter
• Timer

Production Analysis Omega Line

30 minute anodizing cycles = 2.0 bars / hours per bay
15 pcs. across x 36 pcs. high back to back = 1080 pcs.
1080 x 2 x 3 = 6480 pcs. per hour

PS2000 Anodizing Chemical Management / Chemical Process Control System

The PS2000 program is a computerized control center utilizing graphics and data display to provide a user – friendly interface. The Manager coordinates peripheral actions and maintains an interactive database. It schedules analysis, displays and stores the analytical results received from Analyzer or physical reading from LCU, and uses the information to initiate alerts, alarms, and other automated control functions such as chemical replenishment. It records and organizes important process data for easy retrieval and communicates them to the hosts (Alpha and Omega Lines) serviced by PS2000 System.

The Analyzer is a peripheral used to measure certain chemical concentrations accurately in the process baths. It receives analysis request from the Manager and communicates the results back to the Manager.

The Replenisher receives chemical addition or withdrawal instructions from the Manager based on either programmed conditions or manually entered commands. The system is designed to maintain inventories of chemical feedstocks, coordinate and conduct accurate delivery of the feedstocks, report delivery progress, and report chemical consumption.

The LCU is another Manager peripheral responsible for all other process control functions. It monitors physical process parameters such as temperature, level, conductivity, pH, voltage, etc. The LCU is designed to receive digital or analog signals from local control devices and relay the information to the Manager.