垂直连续电镀设备(VCP)取代龙门电镀线的必然趋势演示幻灯片.ppt

单击此处编辑母版文本样式,第二级,单击此处编辑母版标题样式,GuangDe Dongwei Plating Equipment Technology Co.,Ltd.,广德东威电镀设备技术有限公司,Jianbo Liu 刘建波,Trend of Replacement from Gantry Plating Equipment to Vertical Continuous Plating Equipment,垂直连续电镀设备（,VCP,）取代,龙门电镀线的必然趋势,1,Advantage-,自主研发，技术领先,2,Comparison Based on:Safety PK,Economy PK,Products Quality PK,etc.,对比基于：安全性对比，经济性对比，电镀产品质量对比等,Capacity per month,：,47,500,m,2,月产能47,500 m,2,；,Panel plating Cu thickness,：,0.4 mil 面铜厚度：10um；,Working hours and days:22 hours per day and 26 days per month 每天生产22 小时，每月生产26天;,Calculation,：计算,Hoist12 plating units,，,width=4.2 m,，,3 sets transporter,龙门线 12缸，宽度4.2米，3台天车,VCP 12Cu,V=2.18 m/min VCP12个铜槽，传动速度2.18米/分钟,VCP vs Hoist Type Plating-VCP,与龙门电镀对比,3,Big fire risks exist in the hoist type plating equipments and many fire hazards are shown on the TVs 龙门线存在较大的火灾风险，而龙门线起火事故在电视中屡见报道,VCP equipments contains special fire-proof design and minimize human factors for fire hazards.Currently no any fire hazard happens。VCP设备具有专门的防火设计，能够最大程度地减少火灾风险。迄今为止，东威公司生产的VCP设备没有发生过一起火灾；,VCP vs Hoist Type Plating Fire Hazards Risks,火灾风险,4,VCP equipment VCP,电镀线,Full sealed working environment and no bad smells,外觀整潔、全封閉式設計，工作環境良好，可实现四季恒溫控制,Hoist type equipment,Noisy,open with bad smells and plates are easy to drop when adding copper,傳統龍門電鍍，環境嘈雜，敞口式設計，（不利于消防喷淋设施）化學品極易揮發，易發生墜落意外,VCP vs Hoist Type Plating Operator Safety,员工安全,5,Equipment type,设备类型,Consumption,耗材,Copper Consumption,铜球消耗,Capacity/m2,产量,Total consumption,总消耗量,Hoist type,龙门线,Copper,磷铜球,25 Kg/100 m2,47,500,11.875 T,VCP,21.3 Kg/100 m2,47,500,10.1174 T,Reason for copper saving:uniformity improvement,省铜理由：均匀性提高,VCP VS Hoist Type Plating Economy,节约磷铜球,6,Hoist type plating,龙门线,VCP,Number of people,人工数,Cost/month/person,人员月工资,Total cost/month,每月成本,Number of people,人工数,Cost/month/person,人员月工资Total cost/month,每月成本,Loading/unloading,上下料,3,3500,10500,0,3500,0,Dry,产品吹干,2,3500,7000,0,3500,0,On-line inspection,巡检,1,3500,3500,1,3500,3500,Maintain,维护,1,3500,3500,0.5,3500,1750,Total cost/8hours,总成本,24500 RMB,5250 RMB,VCP-Robot arm Auto loading&unloading,自动上下料,HTP,-loading&unloading by hands,人工上下料,VCP vs Hoist Type Plating Labor Cost,节约人工,Labor saving monthly:20,000RMB,每月节约人工费：,2,万元,7,傳統龍門式電鍍線,槽名,槽體積,(L),理論溢流量,(L/MIN),更槽頻率,月耗用水量,(L),剝掛架水洗,1600,4,10,天,/,次,143680,水洗,2200,10,每週一次,392000,高位水洗,2200,鍍銅後水洗,1,2200,7.5,298400,鍍銅後水洗,2,2200,酸洗,2200,8800,鍍銅,112,6500*12,水洗烘乾線,酸洗,400,每週一次,1600,酸後水洗,200,7.5,258200,磨刷,400,1600,沖污水洗,200,800,清水洗,200,7.5,258200,月總耗用水量,:,L/Month,1363280,VCP,電鍍線,槽名,槽體積,(L),理論溢流量,(L/MIN),更槽頻率,月耗用水量,(L),剝掛水洗,240,2,每週一次,69600,清潔,400,0,1600,清潔後水洗,150,5,172200,鍍銅,112,2200*12,鍍銅後水洗,1,150,10,每週一次,346600,鍍銅後水洗,2,150,鍍銅後水洗,3,150,預浸,400,0,水洗烘乾線,酸洗,0,每週一次,0,酸後水洗,0,0,0,磨刷,0,0,沖污水洗,00,月總耗用水量,:,L/Month,590000,VCP vs Hoist Type Plating Water Saving,节水,Water saving monthly:760ton,每月节约用水：,760,吨,8,Hoist type plating,龙门线,VCP,Name,名称,KWH,千瓦时,Set,组,/,个,Power/month,KWH,功率,/,千瓦时,/,月,KWH,千瓦时,Set,组,/,个,Power/month,KWH,功率,/,千瓦时,/,月,Filter pump,过滤泵,3.7,18,41558.4,2.2,30,41184,Rectifier,整流机,2,24,29952,2,24,26956.8,Transporter motor,天车马达,5.9,3,11044.8,1.5,1,936,Exhaust system,抽气系统,30,1,18720,7.5,1,4680,Air Blower,吹干,7.5,2,9360,0,0,0,Vibration motor,振动马达,0.05,76,2371.2,0,0,0,Shake motor,摇摆马达,2,2,2496,0,0,0,Power/month,KWH,总耗电量,115,502.4,73,756.8,VCP vs Hoist Type Plating Power Saving,节电,Power saving monthly:40,000KWH,每月节约用水：,4,万度,9,傳統龍門式電鍍線,項目,周工時,周人數,月累計工時,工時折算成工資,添加銅球,4,5,80,1656.80,水洗槽保養,4,1,16,331.36,VCP,電鍍線,項目,周工時,周人數,月累計工時,工時折算成工資,添加銅球,4,0,0,0.00,水洗槽保養,2,1,8,165.68,傳統龍門式電鍍線,項目,程度,備註,工作強度,大,工安,易發生,占地面積,大,40mL*10mW*5mH,故障率,/,維修成本,振動馬達老壞，天車故障,銅排更換,44,只,/,三年,6111.11,硝酸,1200L/10,天4320,地面要求,專業,coating,地面,150000,VCP,電鍍線,項目,程度,備註,工作強度,小,工安,不易發生,占地面積,小,40mL*3mW*3.6mH,故障率,/,維修成本,基本沒有,銅排更換,0%,0,硝酸,400L/,月,480,地面要求,地面不用,coating,，做簡單的防腐處理即可，在產線的底部會按裝防漏盤（裝機時廠商負責）。,VCP vs Hoist Type Plating Consumption Saving,運行維護及其它成本节约,10,VCP VS,Hoist type,VCP,与龙门线对比,VCP vs Hoist Type Plating Appearance PK,外观对比,11,VCP,Project,项目,Standard,标准,RMB,COV,93%,Range,R,值,3um,Throwing power,贯孔能力,95%,Board Scraped,摔飛靶報廢，吊掛報廢,0%,Copper scraped,殘銅報廢,0%,0,Hoist type plating,龙门线,Project,项目,Standard,标准,RMB,COV,85%,Range,R,值,5.5um,Throwing power,贯孔能力,90%,Board Scraped,摔飛靶報廢，吊掛報廢,16.5pcs/day,4290,Copper scraped,殘銅報廢,12.8pcs/day,2662.4,Copper board thickness:10um,面铜,10um,VCP vs Hoist Type Plating Quality/Uniformity PK,均匀性对比,12,Conclusion,：,VCP,running cost down around 25%,；,About 22 months,saving money can buy the equipment replace cost,Hoist type cost/month,龙门线成本,/,月,VCP,cost/month,VCP,成本,/,月,VCP Saving,VCP,节约,Water,（,20RMB/T),水费（,20,元,/,吨）,1363,280,27,266RMB,590,000,11,800RMB,15,466RMB,Power,（,0.8RMB/KWH,）,电费,(0.8,元,/,千瓦时）,115,502,92,402RMB,73,757,59,005RMB,33,397RMB,Copper,（,62,000RMB/T,）,磷铜球（,62000,元,/,吨）,11.875,736,250RMB,10.1175,627,285RMB,108,965RMB,Manpower,(3500RMB/month/person,）,人工费（,3500,元,/,月）,24,500,RMB/Team,49,000RMB,5,250,RMB/Team,10,500RMB,38,500RMB,Maintaining,维护保养费,1,988RMB,166RMB,1,822RMB,Other cost,(scrap,、,HNO3 and copper cathode change,）,其他成本（报废，硝酸，铜排更换等）,10,431RMB,480RMB,9,951RMB,Total cost,总成本,917,337 RMB,709,236 RMB,208,101RMB,VCP vs Hoist Type Plating Conclusions,结论,Money saving monthly:20,000RMB,每月节约费用：,20,万,13,Hoist Type,VS VCP,Safety,安全性,Fire Risk/,火灾风险,Yes/,有风险,No happen/,无风险,Plates Drop Risk,工件掉落风险,Yes/,有风险,No happen/,无风险,Injured Risk/,员工受伤风险,Yes/,有风险,No happen/,无风险,Working Environment,工作环境,Smell bad&Noise&High temperature,气味难闻，噪声大，高温,Clean&More comfort(closed/low noise and A/C control),环境干净舒适，低噪音，空调控温,Running Cost,运营成本,Water Cost/,用水成本,100%,44.9%,Running-supplies Cost,材料消耗成本,100%,85.2%,Service Cost/,维修成本,100%,20%,Uniformity,镀层均匀性,Cu Thickness,：,0.4mil/,铜层厚度：,0.4mil,COV Value/,COV,值,12,5,R Value/,R,值,5um,3um,TP Value/,TP,值,90%,95%,结论：,1.,VCP,運行成本下降,25左右；,2.,22,个月左右，,节约之总金额足以支付,VCP,购买之费用。,VCP VS Hoist Type Plating Conclusions,结论,14,VCP for Ni_Au plating,镀镍金,VCP,产线名称,传统龙门线,金手指线,东威,VCP,图片,说明,生产人力：,6,安全系数：差,车间环境：差,操作：不方便 故障率：高,均匀性：,10u”,生产人力：,6,安全系数：一般,车间环境：一般,操作,:,一般,故障率：中,最大作业尺寸高度：,350,均匀性：极差,5u”,生产人力：,2,安全系数：优,车间环境：优,操作,:,简单,故障率：低,最大尺寸高度：根据客户定义均匀性：极差,4u”,总结,东威镀镍金,VCP,根据行业需求而去改善，改善传统镀镍金龙门线缺点以及优化金手指线产能需求（金手指线超过,350mm,产品需要镀两次，,vcp,只需要镀一次）。,15,Up to present,KSDW has sold out more than 300pcs VCP lines and the cost saving is roughly more than 600 million RMB,迄今为止，东威公司已经制造销售了超过300条VCP电镀线。相比于龙门线，每年节约的生产成本大约超过6个亿人民币！,Also,KSDW has manufactured Ni_Au plating line.Because of the good uniformity,the Cp value of thickness is 1.67.Large quantity of gold is saved and customer benefits more.,东威公司生产的电镀Ni_Au线，由于电镀镀层均匀性控制得当，Cp值大于等于1.67，大大地节约了金盐的用量，为客户每月节约30-40万(镀金层厚度30uin)。,VCP VS Hoist Type Plating Conclusions,结论,16,We are still considering 我们仍然在思考,Using VCP to finish Ni_Au plating job,采用,VCP,设备进行化镍金；,Using VCP to finish PTH job,采用,VCP,设备进行化铜；,Developing VCE to achieve copper cycling in PCB plant,开发垂直连续电解蚀刻,VCE,，解决,PCB,工厂的循环生产，最大程度节约铜资源；,Vacuum sputtering,真空溅射设备取代,PTH,，达到,PTH,不再消耗水的目的；,In the future,未来展望,17,Sheet to Sheet FPC VCP,片对片,VCP,18,Roll to Roll VCP,卷对卷,VCP,19,Rigid Board VCP,硬板,VCP,20,