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電鍍設備生產線的實施方式

　　在(zai)工(gong)業化生(sheng)(sheng)產中，關于(yu)電鍍(du)的實施方式多(duo)種多(duo)樣，最常見的有掛鍍(du)、滾鍍(du)、刷(shua)鍍(du)和高速連續電鍍(du)等。掛鍍(du)主(zhu)要適(shi)用(yong)(yong)(yong)于(yu)外形尺(chi)(chi)寸較大(da)的零件(jian)，滾鍍(du)主(zhu)要適(shi)用(yong)(yong)(yong)于(yu)尺(chi)(chi)寸較小、批量較大(da)的零件(jian)，刷(shua)鍍(du)一般用(yong)(yong)(yong)于(yu)局部修復，而連續電鍍(du)則用(yong)(yong)(yong)于(yu)線(xian)材、帶(dai)材、板材的大(da)批量生(sheng)(sheng)產。隨著技(ji)術的不(bu)斷進(jin)步，可編程序控(kong)(kong)制器、工(gong)控(kong)(kong)機(ji)、變頻調(diao)速器等一系列電控(kong)(kong)器件(jian)在(zai)電鍍(du)生(sheng)(sheng)產中也得(de)到了廣泛應用(yong)(yong)(yong)，電鍍(du)生(sheng)(sheng)產已由手工(gong)操作經機(ji)械化、半自(zi)動化向(xiang)全自(zi)動化方面發(fa)展。

　　1、電鍍設備掛鍍：掛鍍是電鍍生產中最常用的一種方式。掛鍍是將零件懸掛于用導電性能良好的材料制成的掛具上，然后浸沒于欲鍍金屬的電鍍溶液中作為陰極，在兩邊適當的距離放置陽極，通電后使金屬離子在零件表面沉積的一種電鍍方法。掛鍍的特點是適合于各類零件的電鍍;電鍍時單件電流密度較高且不會隨時間而變化，槽電壓低，鍍液溫度升高慢，帶出量小，鍍件的均勻性好;但勞動生產率低，設備和輔助用具維修量大。電鍍設備掛鍍的主要設備包括鍍槽、電源、掛具等。根據鍍液的性質，鍍槽一般采用鋼板或鋼板襯PVC、PVC、PP等材料制成。鍍槽的大小應滿足需加工的最大工件的生產。根據鍍種要求，掛鍍所用電源應具備穩壓或穩流、過流保護、短路保護等功能;某些鍍種對電源的輸出波形有額外的限制，如鍍硬鉻輸出波形的波紋系數等。掛具一般用銅或其合金材料制成，其形狀和形式由受鍍工件的外形決定。此外，掛鍍中有時還會用到一些輔助設備，如陰極移動裝置、壓縮空氣攪拌、連續過濾裝置等。

　　2、滾鍍：滾鍍是電鍍生產中的另一種常用方法。它是將欲鍍零件置于多角形的滾筒中，依靠零件自身的重量來接通陰極，在滾筒轉動的過程中實現金屬電沉積的。與掛鍍相比，電鍍設備滾鍍最大的優點是節省勞動力，提高生產效率，設備維修費用少且占地面積小，鍍件鍍層的均勻性好。但是，滾鍍的使用范圍受到限制，鍍件不宜太大和太輕;單件電流密度小，電流效率低，槽電壓高，槽液溫度升高快，鍍液帶出量大。滾鍍常用設備包括鍍槽、滾筒、電源等。滾鍍用鍍槽與掛鍍基本相同。滾筒大多為六角形，也有圓形、八角形等。滾筒一般由PVC、PP或尼龍制成，分為浸人式水平旋轉滾筒和傾斜式滾筒兩大類，目前工業使用的大部分是浸人式水平旋轉滾筒。這種滾筒以水平軸為中心旋轉，筒側面為多孔狀，又分為全浸式和半浸式兩種。

　　3、刷(shua)鍍(du)(du)：刷(shua)鍍(du)(du)也(ye)被(bei)稱為涂(tu)鍍(du)(du)、局部鍍(du)(du)、選擇性(xing)電(dian)(dian)(dian)(dian)(dian)鍍(du)(du)，其基(ji)本原(yuan)理(li)與(yu)(yu)(yu)(yu)普通(tong)(tong)(tong)電(dian)(dian)(dian)(dian)(dian)鍍(du)(du)原(yuan)理(li)完(wan)全相(xiang)同。它是(shi)(shi)通(tong)(tong)(tong)過有(you)(you)(you)(you)飽吸電(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)包套(tao)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)陽(yang)(yang)極(ji)(ji)(ji)(ji)與(yu)(yu)(yu)(yu)作(zuo)為陰極(ji)(ji)(ji)(ji)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)零(ling)件(jian)(jian)(jian)表面(mian)(mian)接觸，并做相(xiang)對(dui)運(yun)(yun)動(dong)，電(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)中(zhong)(zhong)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)離(li)子在(zai)陰陽(yang)(yang)極(ji)(ji)(ji)(ji)間進行(xing)電(dian)(dian)(dian)(dian)(dian)化(hua)學反應(ying)，使金(jin)(jin)(jin)(jin)屬(shu)離(li)子沉(chen)積(ji)(ji)，在(zai)零(ling)件(jian)(jian)(jian)表面(mian)(mian)形(xing)成(cheng)(cheng)金(jin)(jin)(jin)(jin)屬(shu)鍍(du)(du)層(ceng)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)過程。刷(shua)鍍(du)(du)時(shi)工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)與(yu)(yu)(yu)(yu)專用(yong)(yong)直流電(dian)(dian)(dian)(dian)(dian)源(yuan)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)負極(ji)(ji)(ji)(ji)相(xiang)連(lian)，鍍(du)(du)筆上(shang)(shang)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)不(bu)(bu)(bu)溶(rong)性(xing)陽(yang)(yang)極(ji)(ji)(ji)(ji)與(yu)(yu)(yu)(yu)正極(ji)(ji)(ji)(ji)相(xiang)連(lian)，陽(yang)(yang)極(ji)(ji)(ji)(ji)上(shang)(shang)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)包套(tao)蘸(zhan)上(shang)(shang)專用(yong)(yong)電(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)，工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)與(yu)(yu)(yu)(yu)鍍(du)(du)筆做相(xiang)對(dui)運(yun)(yun)動(dong)，電(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)中(zhong)(zhong)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)金(jin)(jin)(jin)(jin)屬(shu)離(li)子在(zai)電(dian)(dian)(dian)(dian)(dian)場(chang)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)作(zuo)用(yong)(yong)下向工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)表面(mian)(mian)擴散(san)，并在(zai)工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)(陰極(ji)(ji)(ji)(ji)〉表面(mian)(mian)得到電(dian)(dian)(dian)(dian)(dian)子后(hou)沉(chen)積(ji)(ji)，形(xing)成(cheng)(cheng)刷(shua)鍍(du)(du)層(ceng)。由(you)于刷(shua)鍍(du)(du)時(shi)鍍(du)(du)筆與(yu)(yu)(yu)(yu)工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)做相(xiang)對(dui)運(yun)(yun)動(dong)，溶(rong)液(ye)(ye)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)濃(nong)(nong)差(cha)極(ji)(ji)(ji)(ji)化(hua)很(hen)小(xiao)，而專用(yong)(yong)電(dian)(dian)(dian)(dian)(dian)解(jie)液(ye)(ye)中(zhong)(zhong)金(jin)(jin)(jin)(jin)屬(shu)離(li)子濃(nong)(nong)度(du)較(jiao)(jiao)高(gao)，可(ke)使用(yong)(yong)較(jiao)(jiao)大(da)電(dian)(dian)(dian)(dian)(dian)流密度(du)，因此鍍(du)(du)層(ceng)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)沉(chen)積(ji)(ji)速度(du)較(jiao)(jiao)快。刷(shua)鍍(du)(du)不(bu)(bu)(bu)需要電(dian)(dian)(dian)(dian)(dian)鍍(du)(du)槽，具有(you)(you)(you)(you)設(she)(she)備(bei)簡單(dan)、工(gong)(gong)(gong)(gong)藝靈活、沉(chen)積(ji)(ji)速度(du)快、鍍(du)(du)層(ceng)與(yu)(yu)(yu)(yu)基(ji)體材(cai)(cai)料(liao)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)結合(he)力好、鍍(du)(du)后(hou)不(bu)(bu)(bu)需要加(jia)工(gong)(gong)(gong)(gong)、對(dui)環境污染(ran)小(xiao)等(deng)(deng)(deng)一(yi)系(xi)列優點，普遍用(yong)(yong)于填補(bu)零(ling)件(jian)(jian)(jian)表面(mian)(mian)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)劃傷、凹坑(keng)、斑蝕和孔洞(dong)，修復(fu)加(jia)工(gong)(gong)(gong)(gong)超(chao)差(cha)和尺(chi)(chi)寸磨損，以(yi)及局部性(xing)能的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)改善(shan)，但不(bu)(bu)(bu)適(shi)于面(mian)(mian)積(ji)(ji)大(da)、尺(chi)(chi)差(cha)大(da)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)零(ling)件(jian)(jian)(jian)修復(fu)，也(ye)不(bu)(bu)(bu)能用(yong)(yong)于大(da)批量(liang)鍍(du)(du)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)生產。目前(qian)，可(ke)用(yong)(yong)刷(shua)鍍(du)(du)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)方法沉(chen)積(ji)(ji)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)單(dan)金(jin)(jin)(jin)(jin)屬(shu)有(you)(you)(you)(you)20多種，合(he)金(jin)(jin)(jin)(jin)約(yue)10種。刷(shua)鍍(du)(du)溶(rong)液(ye)(ye)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)組成(cheng)(cheng)一(yi)般是(shi)(shi)供應(ying)商(shang)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)專利，其特(te)點是(shi)(shi)金(jin)(jin)(jin)(jin)屬(shu)離(li)子濃(nong)(nong)度(du)高(gao)，溶(rong)液(ye)(ye)中(zhong)(zhong)含(han)有(you)(you)(you)(you)有(you)(you)(you)(you)機(ji)絡合(he)劑。在(zai)刷(shua)鍍(du)(du)時(shi)，工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)鍍(du)(du)前(qian)處理(li)與(yu)(yu)(yu)(yu)普通(tong)(tong)(tong)電(dian)(dian)(dian)(dian)(dian)鍍(du)(du)基(ji)本一(yi)樣，但使用(yong)(yong)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)溶(rong)液(ye)(ye)組成(cheng)(cheng)也(ye)屬(shu)供應(ying)商(shang)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)專利。刷(shua)鍍(du)(du)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)常(chang)用(yong)(yong)設(she)(she)備(bei)包括電(dian)(dian)(dian)(dian)(dian)源(yuan)、鍍(du)(du)筆等(deng)(deng)(deng)。刷(shua)鍍(du)(du)用(yong)(yong)電(dian)(dian)(dian)(dian)(dian)源(yuan)應(ying)具備(bei)輸出(chu)換向、過電(dian)(dian)(dian)(dian)(dian)流保護(hu)、電(dian)(dian)(dian)(dian)(dian)量(liang)計量(liang)等(deng)(deng)(deng)功能，其輸出(chu)電(dian)(dian)(dian)(dian)(dian)壓在(zai)0?50乂之間可(ke)任(ren)意調節。鍍(du)(du)筆通(tong)(tong)(tong)常(chang)由(you)不(bu)(bu)(bu)溶(rong)性(xing)陽(yang)(yang)極(ji)(ji)(ji)(ji)和導電(dian)(dian)(dian)(dian)(dian)手柄(bing)兩部分組成(cheng)(cheng)，兩者一(yi)般采用(yong)(yong)螺紋連(lian)接。使用(yong)(yong)最多的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)不(bu)(bu)(bu)溶(rong)性(xing)陽(yang)(yang)極(ji)(ji)(ji)(ji)材(cai)(cai)料(liao)是(shi)(shi)高(gao)純石墨(mo)，其他材(cai)(cai)料(liao)還(huan)有(you)(you)(you)(you)含(han)鉑90^的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)鉑-銥合(he)金(jin)(jin)(jin)(jin)、不(bu)(bu)(bu)鎊鋼(gang)、鉛、鉛-銻合(he)金(jin)(jin)(jin)(jin)、鉛-錫合(he)金(jin)(jin)(jin)(jin)等(deng)(deng)(deng)。為適(shi)應(ying)受鍍(du)(du)工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)形(xing)狀，陽(yang)(yang)極(ji)(ji)(ji)(ji)可(ke)設(she)(she)計成(cheng)(cheng)圓柱、半(ban)圓、月牙、帶(dai)狀、平板、三角、梯(ti)形(xing)等(deng)(deng)(deng)形(xing)狀。陽(yang)(yang)極(ji)(ji)(ji)(ji)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)導電(dian)(dian)(dian)(dian)(dian)手柄(bing)根據允許通(tong)(tong)(tong)過的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)電(dian)(dian)(dian)(dian)(dian)量(liang)分為大(da)、中(zhong)(zhong)、小(xiao)3種。此外，在(zai)實施刷(shua)鍍(du)(du)時(shi)，還(huan)應(ying)準(zhun)備(bei)陽(yang)(yang)極(ji)(ji)(ji)(ji)包套(tao)、接液(ye)(ye)盤或槽、絕緣膠帶(dai)、研磨用(yong)(yong)具等(deng)(deng)(deng)輔(fu)助工(gong)(gong)(gong)(gong)具。為了減輕勞(lao)動(dong)強度(du)，不(bu)(bu)(bu)太大(da)的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)在(zai)刷(shua)鍍(du)(du)修復(fu)時(shi)，一(yi)般將其夾(jia)持(chi)在(zai)可(ke)無級調速的(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)(de)車床上(shang)(shang);工(gong)(gong)(gong)(gong)件(jian)(jian)(jian)不(bu)(bu)(bu)能旋轉時(shi)，可(ke)使用(yong)(yong)旋轉鍍(du)(du)筆。

　4、連續電鍍：電鍍設備連續電鍍主要用于薄板、金屬絲和帶的電鍍，在工業上有極其重要的地位。鍍錫鋼板、鍍鋅薄板和鋼帶、電子元器件引線、鍍鋅鐵絲等的生產都采用連續電鍍技術。連續電鍍有3種方式：垂直浸入式、水平運動式和盤繞式。垂直浸人式節省空間，但啟動時操作難度較大;水平運動式操作方便，但設備占地面積大，維修量大;盤繞式占地面積小，但一次只能加工一根金屬絲。連續電鍍時金屬絲或帶在鍍槽中連續通過，電鍍時間較短，因此要求使用高電流密度、導電性好、沉積速度快、鍍液各成分變化不顯著和對雜質不敏感等的鍍液。

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