Plating Plant Automation and SCADA

Plating Plant Automation and SCADA

Plating plant automation is controlled through an advanced SCADA software. The system can be accessed from an on-site PC or remotely via devices such as PCs and tablets. The communication infrastructure is established through an Ethernet network.

Centralized Control and Monitoring with SCADA

The SCADA software enables:

  • Control,

  • Real-time monitoring,

  • Data logging of all active and passive instruments across the facility. Robots within the plant communicate with the main system via wireless connectivity. Robot positions are adjusted with high precision using laser distance sensors or barcode positioning control systems.

Recipe Management and Process Control

Recipes created through the system contain all critical parameters of the plating process:

  • Route map for racks or barrels

  • Immersion and dripping (drain) times

  • Rectifier current and voltage values

  • Delayed start times

  • Lift-and-dip repetition counts

  • Current density settings

  • Barrel rotation and rack oscillation (shaking) options

  • Dripper control and speed settings

Up to 1,000 recipes can be created in total. New recipes can be prepared quickly by copying from existing ones.

 

PLC-Supported Automated Operation

At least 20 of the active recipes are stored in the PLC memory for automated operation. Racks or barrels can be operated seamlessly with different recipes in succession. In the event of a PC failure, automated operation can continue without interruption by selecting recipes directly via the operator panel (HMI).

Flexible Automation and Manual Control

When the system is in automatic mode, one robot can operate in manual mode while the other continues in automatic mode. This structure provides high production flexibility and operational control. Operators can intervene in the following parameters within an active recipe:

  • Recipe and recipe steps

  • Immersion/dwell times

  • Current and voltage values

  • Work orders, lot, and box numbers

  • Quantity and weight information

  • Busbar or barrel numbers

Smooth Motion and Product Protection

Through the SCADA system, the following robot dynamics can be controlled:

  • Horizontal and vertical movements

  • Acceleration and deceleration ramps

This ensures smooth robot motion, minimizing material oscillation and protecting the workload.

  • Defines the sequence and specific tanks the rack or barrel will pass through during the process.

  • Optimizes plating quality by adjusting dwell and drainage times between tanks.

  • Enables precise control of current and voltage values suitable for the plating process.

  • Ensures that rectifiers and equipment are activated with defined time delays.

  • Reduces material loss and splashing by controlling dripping and movement speeds.
Automated Plating Line Control
Plating SCADA Software
Industrial Recipe Management
PLC-Based Surface Treatment
Chemical Drag-out Control

Surface Treatment Automation

Quality Control, Alarm, and Reporting

Limits can be defined based on parameters such as:

  • Processing time (Dwell time) in the tank

  • Drawn current

  • Applied temperature

Based on these limits, the OK / REJECT status of the products can be visually monitored, and detailed historical reports can be generated. All malfunctions and alarm conditions are archived within the system and can be analyzed using product-based filtering.