By Dean Mckinstry

National Diploma ProjectElectro Plating Fixture

Design Brief

I am going to produce a fixture for electro plating increasing productivity at T.J plating's production for one product line

ProcessElectroplating is the process of plating one metal onto another, most commonly for decorative purposes or to prevent corrosion of a metal.

Major Design Parameters

Increase productivity

Fisher engineering parts

Mass is 1.1kg

25mm clearance between parts

Set up by one person

Offers flexibility

Major Customer Requirements

The costumers main demand is the quantity per dip, which means he is wanting a fixture that will support more work and he also wants a quicker set up time. The main purpose of his demand is to boost production.

Product Design Specification

When I was at the factory I was able to get lots of information such as:

The type of acid that is used for plating is hydrochloric acid

The bath is 400mm wide and the rail used to hold the jig is 2400mm long.

The product I will be working with is 45mm box section and 1080mm long and the spacing between hooks will have to be 80mm apart for a high quality plating job.

The motor used for the crane is 5hp.

The maximum load the crane can withstand is 1000kg

Testing

I have come up with a testing frame which will allow me to test different fixtures out to see which design could work the best

Concepts

The limitation is, this will be difficult to set up because its hanging, fixture would need to be balanced on the frame

This design is balanced but it doesn’t have any fixed positions, it possibly hasn’t got enough circulation

This is the best solution but I wanted to try and improve it to be easier to manufacture.

Concept selection

• Simple to make• Welded frame • Fits to existing

hanger• Uses no tools to

secure

• High stress and high loading may mean its difficult to lift

Design development

Modular i.e. 3 sections

Make 1 section

750mm long sections

Capacity of 54/3

Loading gantry is 54 x 1.1kg i.e. 59.4Kg, fully loaded

Spacing of 80mm meaning 50mm circulation

Detailed Design

Demand is 1500 parts plated per week

Cost £2,50 per part per job

Demand is 250 per working day

18 per batch, 3hour cycle time

16 hours per working day

Old capacity – 14 x 18 units = 252 per day

1512 per week

New capacity 14 x 54 units = 756 per day

5 day week = 3780

6 day week = 4536

Or no night shift i.e. 8am to 4pm

54 x 6 x 6 = 1944 parts plated on a 6 day week

I.e. night shift wages reduced by 8 x 6 x £15=£720 per week

Productivity

• Output increased by 150%

• Saving over £35000 per year on labour

18 units at £2.00 = £3646 units at £2.00 = £92

Profit increased by £56 per batch

At R1F x D= MCM= ACM2.4 R2= 103 x 0.075m + 206 x 0.825 + 206 x 1.575 + 103 x 2.325= 7.725 + 169.95 + 324.45 + 239.4752.4R1= 741.6 NmR1= 309N

How my fixture was made:• Measured out 4 pieces of

30x30mm angle iron, two were 750mm and the others were 300mm

• Cut a 45 degree angle at each corner

• Welded each corner together with a MIG welder

• Measured and cut holes with 80mm spacing

• Welded a mounting bracket to each end of the fixture