Increasing efficiency in galvanotechnical coating bathrooms and design of switched power supply

Electroplating is used to protect materials against corrosion, improve their appearance and increase their durability. In this study, designs were made on the plating baths in the production section, which provide printing cylinders to the flexible packaging industry and perform galvanotechnical plating in copper and chrome plating baths in the process, to increase production quality and efficiency, applications were made, situations and results were examined. The currents were measured with the shunt resistors installed on the electric current bars of the chrome-plated baths in my production department, and the current information obtained from the shunt resistors was first converted into 0-10 V analog signal from ENDA 242 signal converters and transferred to the Siemens S7-1200 programmable logic controller (PLC). According to the program written on the PLC and the limit values entered to the program via the human machine interface (HMI), the differences of the current values measured on the machine were calculated, and the system was enabled to inform the employees about the current status according to the warning and alarm limits. In addition to the current measurement, pH, temperature and solution amount values that may affect the coating quality were measured with sensors and processed on the Arduino Nano control card and sent to the PLC as an analog signal. As the current is evaluated in the PLC, these values are also evaluated and it is provided to give a warning according to the process limit values. In addition to the measurement and control system, a switched mode power supply (SMPS) design and prototype application has been carried out that can be used in coating baths. The designed SMPS circuit with full-wave rectifier input of 230 V AC and output of 12 V 10 A DC has been turned into a circuit by simulating SMPSs that can have enough power to be used in the coating process. A metal oxide semiconductor field-effect transistor (MOSFET) is used as the switching element. These MOSFETs are triggered on the Arduino Mega with 31 kHz. By using SMPS instead of standard type rectifiers in coating baths, less current and voltage fluctuations can be achieved. As a result of the study, the productivity increase in the coating baths was achieved with the PLC warning system and SMPS.