What Are the Benefits of Automated Plating?

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The trend of automation is gaining traction, especially for high-volume tasks that demand precision. This technology minimizes the variabilities often seen in manual processes. Below, we explore some key advantages of automated plating.

1. Increased Efficiency

Automation in plating systems significantly enhances productivity. Even with limited staff, these systems ensure substantial output. This is particularly beneficial when dealing with large items that require plating.

For instance, wind turbine blades benefit greatly from plating, which enhances their resistance to corrosion and environmental damage. A common material for coating the blades is silver. However, as rotor blades increase in length, the plating process becomes more complex. This complexity led a Dutch tech firm to test an autonomous mobile robot designed to coat a 100-meter blade within 90 minutes.

The robot autonomously moves to prescribed spots and applies the coating, progressing until completion of the blade’s surface. The developers believe this technology could extend beyond plating to assist in various turbine blade production tasks such as inspection and surface cleaning.

2. Improved Quality Control

As businesses face stiffer competition, leaders are finding compelling reasons to adopt automation. A Michigan-based company specializing in electroless nickel plating for the automotive and gas sectors implemented automation in their seven plating baths due to labor costs and variations from human error.

This transition was intended to enhance production capacity, improve chemical usage, and reduce variability in the plating process. Automated systems remove the uncertainties associated with manual operations and enable quick diagnosis of production issues. The chosen automated system was reported to maintain nickel concentration levels in baths at significantly higher rates compared to manual methods.

Initial assessments showed remarkable improvements within just a week, leading to swift re-evaluations of operational strategies.

3. Cost Reduction

Plating companies must ensure uniformity in their operations while simultaneously managing costs. Automation facilitates greater efficiency in the plating process, reducing waste and financial losses. For example, gold is frequently used in electronic component plating to shield from heat, thanks to its high melting point of 1,943°F.

With precise application capabilities, automated systems minimize mistakes and generate sustainable production practices. Toyota’s dip-free plating system showcases this; its waste solution is reportedly reduced to one-thirtieth of prior methods.

4. Lower Environmental Impact

Certain companies leverage automation for sustainable material sourcing. Notably, Apple’s iPhone 13 utilizes certified 100% recycled gold on its main logic board and camera wiring. Their specialized disassembly robot 'Daisy' aids recyclers in extracting reusable materials from old devices.

According to Apple, just one metric ton of certain disassembled iPhone components can yield the equivalent of 150 metric tons of gold and copper from conventional mining. While such automated material sourcing is still emerging, its potential aligns with growing environmental safeguards.

5. Enhanced Safety and Comfort for Operators

Incorporating automation within plating processes can significantly reduce health risks to operators. Manual plating methods expose workers to harmful chemicals and dust, leading to issues ranging from short-term discomfort to serious long-term conditions.

By automating operations, employees can supervise processes from a safe distance and reduce the likelihood of spills or accidents. Moreover, ergonomic designs alleviate physical strain on workers, allowing automation to decrease the total workforce required for tasks and thus reduce fatigue.

Conclusion: The Value of Plating Automation

These insights underline the sound business rationale for introducing automation into plating operations. However, it’s crucial to consider specific project requirements and client expectations to avoid potential issues. A comprehensive understanding of objectives from the outset is essential for success.