垂直连续电镀设备VCP取代龙门电镀线的必然趋势专课件.ppt

1、垂直连续电镀设备(VCP)(VCP)取代龙门电镀线的必然趋势Advantage-Advantage-自主研发，技术领先自主研发，技术领先Comparison Based on: Safety PK, Economy PK, Products Quality PK, etc. 对比基于：安全性对比，经济性对比，电镀产品质量对比等 Capacity per month：47,500 m2 月产能47,500 m2；Panel plating Cu thickness：0.4 mil 面铜厚度：10um；Working hours and days: 22 hours per day and 26

2、days per month 每天生产22 小时，每月生产26天;Calculation：计算 Hoist12 plating units，width=4.2 m，3 sets transporter 龙门线 12缸，宽度4.2米，3台天车 VCP 12Cu, V=2.18 m/min VCP12个铜槽，传动速度2.18米/分钟VCP vs Hoist Type Plating - VCPVCP vs Hoist Type Plating - VCP与龙门电镀对比与龙门电镀对比Big fire risks exist in the hoist type plating equipments a

3、nd many fire hazards are shown on the TVs 龙门线存在较大的火灾风险，而龙门线起火事故在电视中屡见报道VCP equipments contains special fire-proof design and minimize human factors for fire hazards. Currently no any fire hazard happens。 VCP设备具有专门的防火设计，能够最大程度地减少火灾风险。迄今为止，东威公司生产的VCP设备没有发生过一起火灾；VCP vs Hoist Type Plating Fire Hazards R

4、isksVCP vs Hoist Type Plating Fire Hazards Risks火灾风险火灾风险VCP equipment VCP电镀线Full sealed working environment and no bad smells 外觀整潔、全封閉式設計，工作環境良好，可实现四季恒溫控制Hoist type equipmentNoisy, open with bad smells and plates are easy to drop when adding copper傳統龍門電鍍，環境嘈雜，敞口式設計，（不利于消防喷淋设施）化學品極易揮發，易發生墜落意外VCP vs H

5、oist Type Plating Operator Safety VCP vs Hoist Type Plating Operator Safety 员工安全员工安全Equipment type设备类型Consumption耗材Copper Consumption 铜球消耗Capacity/m2产量Total consumption总消耗量Hoist type龙门线Copper磷铜球25 Kg/100 m247,50011.875 TVCP21.3 Kg/100 m247,50010.1174 TReason for copper saving: uniformity improvement

6、省铜理由：均匀性提高VCP VS Hoist Type Plating Economy VCP VS Hoist Type Plating Economy 节约磷铜球节约磷铜球Hoist type plating 龙门线龙门线VCPNumber of people人工数人工数Cost/month/person人员月工资Total cost/month每月每月成本成本Number of people人工数人工数Cost/month/person人员月工资人员月工资Total cost/month每月成本每月成本Loading/unloading上下料上下料3350010500035000Dry

7、产品吹干产品吹干235007000035000On-line inspection巡检巡检1 350035001 35003500Maintain 维护维护1 350035000.5 35001750Total cost/8hours总成本总成本24500 RMB5250 RMBVCP-Robot arm VCP-Robot arm Auto loading & Auto loading & unloadingunloading自动上下料自动上下料HTPHTP-loading & -loading & unloading by unloading by handshands人工上下料VCP v

8、s Hoist Type Plating Labor Cost VCP vs Hoist Type Plating Labor Cost 节约人工节约人工Labor saving monthly: 20,000RMB每月节约人工费：2万元傳統龍門式電鍍線槽名槽體積(L)理論溢流量(L/MIN)更槽頻率月耗用水量(L)剝掛架水洗1600410天/次143680水洗220010每週一次392000高位水洗2200鍍銅後水洗122007.5298400鍍銅後水洗22200酸洗22008800鍍銅1126500*12水洗烘乾線 酸洗400每週一次1600酸後水洗2007.5258200磨刷400160

9、0沖污水洗200800清水洗2007.5258200月總耗用水量:L/Month1363280VCP電鍍線電鍍線槽名槽體積(L)理論溢流量(L/MIN)更槽頻率月耗用水量(L)剝掛水洗2402每週一次69600清潔40001600清潔後水洗1505172200鍍銅1122200*12鍍銅後水洗115010每週一次346600鍍銅後水洗2150鍍銅後水洗3150預浸4000水洗烘乾線 酸洗0每週一次0酸後水洗000磨刷00沖污水洗00月總耗用水量:L/Month590000VCP vs Hoist Type Plating Water SavingVCP vs Hoist Type Platin

10、g Water Saving节水节水Water saving monthly: 760ton每月节约用水：760吨Hoist type plating龙门线龙门线VCP Name名称KWH千瓦时Set 组/个Power/monthKWH功率/千瓦时/月KWH千瓦时Set组/个Power/monthKWH功率/千瓦时/月Filter pump过滤泵3.71841558.42.23041184Rectifier 整流机2242995222426956.8Transporter motor天车马达5.9311044.81.51936Exhaust system抽气系统301187207.514680

11、Air Blower 吹干7.529360000Vibration motor振动马达0.05762371.2000Shake motor摇摆马达222496000Power/monthKWH总耗电量115,502.473,756.8VCP vs Hoist Type Plating Power SavingVCP vs Hoist Type Plating Power Saving节电节电Power saving monthly: 40,000KWH每月节约用水：4万度傳統龍門式電鍍線項目周工時周人數月累計工時工時折算成工資添加銅球45801656.80 水洗槽保養4116331.36 VC

12、P電鍍線項目周工時周人數月累計工時工時折算成工資添加銅球4000.00 水洗槽保養218165.68 傳統龍門式電鍍線傳統龍門式電鍍線項目程度備註工作強度大工安易發生占地面積大40mL*10mW*5mH故障率/維修成本振動馬達老壞，天車故障銅排更換44只/三年6111.11 硝酸1200L/10天4320地面要求專業coating地面150000VCP電鍍線電鍍線項目程度備註工作強度小工安不易發生占地面積小40mL*3mW*3.6mH故障率/維修成本基本沒有銅排更換0%0硝酸400L/月480地面要求地面不用coating，做簡單的防腐處理即可，在產線的底部會按裝防漏盤（裝機時廠商負責）。VC

13、P vs Hoist Type Plating Consumption SavingVCP vs Hoist Type Plating Consumption Saving運行維護及其它成本节约VCP VS Hoist typeVCP与龙门线对比 VCP vs Hoist Type Plating Appearance PK VCP vs Hoist Type Plating Appearance PK 外观对比外观对比VCP Project 项目Standard 标准RMBCOV93%Range R值3umThrowing power 贯孔能力95%Board Scraped摔飛靶報廢，吊掛

14、報廢0%Copper scraped殘銅報廢 0%0Hoist type plating龙门线龙门线Project 项目Standard 标准RMBCOV85%Range R值5.5umThrowing power 贯孔能力90%Board Scraped摔飛靶報廢，吊掛報廢16.5pcs/day4290Copper scraped殘銅報廢 12.8pcs/day2662.4Copper board thickness:10um 面铜10umVCP vs Hoist Type Plating Quality/Uniformity PKVCP vs Hoist Type Plating Qual

15、ity/Uniformity PK均匀性对比均匀性对比Conclusion ：VCP running cost down around 25%；1. About 22 months, saving money can buy the equipment replace cost Hoist type cost/month龙门线成本/月VCP cost/monthVCP成本/月VCP SavingVCP节约Water （20RMB/T)水费（20元/吨）1363,280 27,266RMB590,00011,800RMB15,466RMBPower （0.8RMB/KWH）电费(0.8元/千瓦时

16、）115,50292,402RMB73,75759,005RMB33,397RMBCopper（62,000RMB/T）磷铜球（62000元/吨）11.875736,250RMB10.1175627,285RMB108,965RMBManpower(3500RMB/month/person）人工费（3500元/月）24,500RMB/Team49,000RMB5,250RMB/Team10,500RMB38,500RMBMaintaining 维护保养费1,988RMB166RMB1,822RMBOther cost(scrap、HNO3 and copper cathode change）其

17、他成本（报废，硝酸，铜排更换等）10,431RMB480RMB9,951RMBTotal cost 总成本917,337 RMB709,236 RMB208,101RMBVCP vs Hoist Type Plating ConclusionsVCP vs Hoist Type Plating Conclusions结论结论Money saving monthly: 20,000RMB每月节约费用：20万Hoist TypeHoist Type VS VCPVS VCPSafetySafety安全性安全性Fire Risk/火灾风险Yes / 有风险 No happen/无风险Plates D

18、rop Risk工件掉落风险Yes /有风险 No happen/无风险Injured Risk/员工受伤风险Yes /有风险 No happen/无风险Working Environment工作环境Smell bad & Noise & High temperature 气味难闻，噪声大，高温Clean & More comfort( closed / low noise and A/C control )环境干净舒适，低噪音，空调控温RunningRunning Cost Cost运营成本运营成本Water Cost/用水成本 100% 44.9%Running-supplies Cost

19、材料消耗成本100% 85.2%Service Cost/维修成本100%20%UniformityUniformity镀层均匀性镀层均匀性Cu ThicknessCu Thickness：0.4mil/0.4mil/铜铜层厚度：层厚度：0.4mil 0.4mil COV Value/COV值 125R Value/R值 5um3umTP Value/TP值 90%95%结论：结论：1. 1. VCP運行成本下降25%左右； 2. 22个月左右，节约之总金额足以支付VCP购买之费用。 VCP VS Hoist Type Plating Conclusions VCP VS Hoist Type

20、 Plating Conclusions 结论结论VCP for Ni_Au plating VCP for Ni_Au plating 镀镍金镀镍金VCPVCP产线名称传统龙门线金手指线东威VCP图片说明生产人力： 6安全系数：差车间环境： 差操作：不方便 故障率： 高均匀性： 10u”生产人力：6安全系数：一般车间环境：一般操作: 一般故障率： 中最大作业尺寸高度：350均匀性： 极差5u”生产人力：2安全系数：优车间环境：优操作: 简单故障率： 低最大尺寸高度：根据客户定义；均匀性：极差4u”总结东威镀镍金VCP根据行业需求而去改善，改善传统镀镍金龙门线缺点以及优化金手指线产能需求（金手

21、指线超过350mm产品需要镀两次，vcp只需要镀一次）。Up to present, KSDW has sold out more than 300pcs VCP lines and the cost saving is roughly more than 600 million RMB 迄今为止，东威公司已经制造销售了超过300条VCP电镀线。相比于龙门线，每年节约的生产成本大约超过6个亿人民币！Also, KSDW has manufactured Ni_Au plating line. Because of the good uniformity, the Cp value of thi

22、ckness is 1.67. Large quantity of gold is saved and customer benefits more. 东威公司生产的电镀Ni_Au线，由于电镀镀层均匀性控制得当，Cp值大于等于1.67，大大地节约了金盐的用量，为客户每月节约30-40万(镀金层厚度30uin)。 VCP VS Hoist Type Plating Conclusions VCP VS Hoist Type Plating Conclusions 结论结论We are still considering 我们仍然在思考uUsing VCP to finish Ni_Au plating job 采用VCP设备进行化镍金；uUsing VCP to finish PTH job 采用VCP设备进行化铜；uDeveloping VCE to achieve copper cycling in PCB plant 开发垂直连续电解蚀刻VCE，解决PCB工厂的循环生产，最大程度节约铜资源；uVacuum sputtering 真空溅射设备取代PTH，达到PTH不再消耗水的目的；In the future 未来展望Sheet to Sheet FPC VCP 片对片VCPRoll to Roll VCP 卷对卷VCPRigid Board VCP 硬板VCP