PRODUCTS & PROCESSES
Automating selective electroplating repairs for power generation components
Quality , speed and reliability is paramount to power generation component repairs . Derek Kilgore , Engineering Manager at SIFCO ASC discusses how automated selective electroplating can meet these demands and looks at how Powell Electrical Systems Inc . drastically reduced its process time to plate copper bus bars .
Without doubt , the power generation industry is entering into difficult times . According to Enerdata , there was a significant slowdown in global power generation growth in 2019 due to lower electricity demand because of milder weather conditions and slower economic growth . Global power generation , which had increased by nearly 3 %/ year over the 2000-2018 period , slowed down to just + 1 % growth globally .
With less demand , competition is growing , as players strive to get a slice of the pie , and to remain competitive , minimising downtime and maximising output is crucial . Maintenance process and repair costs must be kept down without compromising performance , while OEM components must be manufactured to exacting standards . That is why more and more power generation companies are investing in automation .
Selective plating gets the automation treatment
Selective plating , also known as brush plating , is already a widely used method of surface enhancement and the benefits of this technique are well known . The process involves applying electroplated deposits onto localised areas of components with high quality electrolyte solutions and precision anodes which minimises waste and environmental impact .
Alongside its core benefits , however , selective plating can be an operator-intensive process , with skilled individuals remaining close to the work area to handle the chemicals and tooling throughout the process .
That ’ s where automation comes in . Minimising the need for operator intervention , the process becomes safer and the results are more consistent . An intricate system using a power pack , pumps , valves , anodes and solutions work together , prepping , changing , catching , plating and then circulating the plating solution .
Through mechanization of the process , the operator ’ s direct contact with tooling and chemicals is significantly reduced . A computer program – programmed by the operator – then controls the volts , amps , polarity and ampere-hours required for the specific application , including pre-treatment and plating steps .
For the power generation industry particularly , this technology can lead to much better outcomes , from increased throughput , quality and accuracy , to reduced downtime and cost savings .
The Case of Copper Bus Bars for Powell Electrical Systems Inc .
One company which has greatly benefited from automating its selective plating process is Powell Electrical Systems Inc . The Delta / Unibus Division has significantly reduced the process time taken to selectively plate each side of its copper bus bars by 90 percent , saving approximately $ 100,000 in labor costs , thanks to a unique semi-automated workstation developed by SIFCO ASC .
Copper bus bars play an important role in conducting electricity through distribution networks within the power generation industry . These components need to be manufactured to an exacting standard that permits carrying very high currents across mating bus connections with minimal contact resistance . The industry practice to decrease electrical contact resistance at mating bus connections is to electroplate them with a suitable
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60 NOVEMBER 2020 read online : www . surfaceworld . com