Program Details

Vertical Electroplating (VCP/VOP) Voltage Abnormality Causes System Shutdown

This article delves into the core challenges of frequent, unexplained shutdowns in VCP/VOP vertical continuous electroplating production lines, uncovering the real culprit behind these issues: voltage sags in the utility power supply (commonly referred to as "voltage flicker"). Shenzhen Topworx Power Supply Co., Ltd.'s dynamic voltage regulator solution not only effectively prevents such failures but also enables the recording of power quality data, ensuring stable production and safeguarding product quality—making it a trusted power partner for electroplating enterprises.

2025-10-15

VCP/VOP line process characteristics:

VCP/VOP typically refers to Vertical Continuous Plating or Vertical Orientation Plating—two similar electroplating processes where the workpieces are positioned vertically and continuously pass through individual plating tanks. This approach enables efficient, uninterrupted plating production, enhancing both manufacturing efficiency and coating uniformity. VOP is particularly well-suited for electroplating certain specialized electronic components that demand high-quality fill-in performance within their holes.
 
Existing pain points:

More than ten sudden line shutdowns occur at work each year, resulting in complete damage to the products in the plating tanks. These incidents require inspection before the lines can be restarted. This has resulted in significant direct and indirect losses for production, while the damage to goodwill is truly incalculable. , the reason is unclear—there's an urgent need to find a solution.

 

Cause Analysis
The line consists of the following parts:
  1. “Control System”: Precisely controls and monitors parameters such as temperature, current, voltage, and plating time on the production line, ensuring stable and consistent plating quality.
  2. “The pre-treatment system” performs preliminary operations such as cleaning, micro-etching, and activation on the parts to be plated, removing surface impurities, oxides, and other contaminants to enhance the adhesion between the plating layer and the workpiece surface.
  3. “The core part of the electroplating tank,” Mainly Damaged Product Parts Inside, there is an electroplating solution (containing copper ions and other components). By applying electricity through electrodes, copper ions are deposited onto the surface of the workpiece and within the holes, forming a copper plating layer.
  4. "After-processing systems" perform water washing, passivation, drying, and other treatments on workpieces after electroplating, enhancing the coating's corrosion resistance and stability.

True reason: The customer turned to Shenzhen Topwor Power Supply Co., Ltd. After engineers analyzed the historical alarm data, they found that most issues involved communication failures, PLC malfunctions, inverter problems, and module failures awaiting resolution. Combined with the company's years of industry experience, it was confirmed that the root cause was mains power-related issues. Caused by voltage sags (lightning-induced or voltage flicker), typically lasting less than 1 second. Most electricity Pressure Reduction Rate Between 10% and 5% 0% , making it difficult to detect in time.

 

Solution

A "dynamic" device is added to the front end of the power supply line. State Voltage Regulator - AVC "After the issue was effectively resolved, the product's qualification rate, stability, and brand reputation were all improved—and every time the mains power experienced a temporary voltage dip..." State Voltage Regulator - AVC "It will faithfully record the temporary pressure drop, providing a reliable basis for assessing abnormalities in other equipment."

         

Solution