Model-based analysis, control and dosing of electroplating electrolytes
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ORIGINAL ARTICLE
Model-based analysis, control and dosing of electroplating electrolytes Alexander Leiden 1 & Stefan Kölle 2 Christoph Herrmann 1,3
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Sebastian Thiede 1
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Klaus Schmid 2
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Martin Metzner 2
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Received: 7 May 2020 / Accepted: 28 September 2020 / Published online: 17 October 2020 # The Author(s) 2020
Abstract Controlling and dosing electrolytes is a key challenge in the operation of electroplating process chains. Electrolyte components are continuously degraded and dragged out during the production process. This process is influenced by a variety of internal and external factors such as process parameters, the electrolyte itself, anodes, the substrates and the production environment. The exact analytical measurement of the electrolyte composition requires extensive analytical equipment and typically cannot be completely realized within an industrial plating company. Therefore, this paper presents a model-based approach, integrated in a cyber-physical production system, for controlling and dosing electrolytes. A mathematical resource flow model is the basis for a dynamic agent-based simulation. This model uses available data from the manufacturing execution system and enterprise resource planning system to model the current composition of the electrolyte. The approach is successfully validated for two different electrolyte substances at an industrial acid zinc–nickel barrel plating process chain for automotive parts. Keywords Electroplating . Electrolyte control . Electrolyte dosing . Cyber-physical production systems . Simulation
1 Introduction Electroplating is a coating process in which metal ions are deposited electrolytically or electroless on a cathode from mostly aqueous solutions that contain metal salts. The deposited coatings enhance the surface properties of a part in order to fulfil a certain functionality, which is not given by the substrate material of the part itself [1]. The coatings from electroplating can lead to a higher corrosion and wear resistance, a defined tribological, optical or decorative behaviour or to a matching
* Alexander Leiden [email protected] 1
Institute of Machine Tools and Production Technology, Chair of Sustainable Manufacturing & Life Cycle Engineering, Technische Universität Braunschweig, Langer Kamp 19b, 38106 Braunschweig, Germany
2
Division Surface Engineering and Materials Technology, Department Electroplating, Fraunhofer-Institute for Manufacturing Engineering and Automation IPA, Nobelstr. 12, 70569 Stuttgart, Germany
3
Fraunhofer Institute of Surface Engineering and Thin Films IST, Bienroder Weg 54 E, 38108 Braunschweig, Germany
interface behaviour [2]. Examples for decorative coatings are glossy chrome-plated bathroom fittings or automotive interior and exterior parts made of plastic. However, functional changes to the surface like corrosion and wear resistance are often in the foreground [3]. Coatings from electroplating can increase the energy and resource efficiency of the product system by increasing the life time of the product as well
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