US20240149394A1 - Method for producing textured plated steel sheet, and apparatus for producing textured plated steel sheet - Google Patents

Method for producing textured plated steel sheet, and apparatus for producing textured plated steel sheet Download PDF

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Publication number
US20240149394A1
US20240149394A1 US18/281,413 US202218281413A US2024149394A1 US 20240149394 A1 US20240149394 A1 US 20240149394A1 US 202218281413 A US202218281413 A US 202218281413A US 2024149394 A1 US2024149394 A1 US 2024149394A1
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Prior art keywords
plating
grinding
plating layer
steel sheet
amount
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Takashi FUTABA
Yukihiro UESUGI
Takuya Yokomichi
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Nippon Steel Corp
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Nippon Steel Corp
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    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D21/00—Processes for servicing or operating cells for electrolytic coating
    • C25D21/12—Process control or regulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/02—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent
    • B24B49/03—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent according to the final size of the previously ground workpiece
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B49/00—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation
    • B24B49/02—Measuring or gauging equipment for controlling the feed movement of the grinding tool or work; Arrangements of indicating or measuring equipment, e.g. for indicating the start of the grinding operation according to the instantaneous size and required size of the workpiece acted upon, the measuring or gauging being continuous or intermittent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B24—GRINDING; POLISHING
    • B24B—MACHINES, DEVICES, OR PROCESSES FOR GRINDING OR POLISHING; DRESSING OR CONDITIONING OF ABRADING SURFACES; FEEDING OF GRINDING, POLISHING, OR LAPPING AGENTS
    • B24B7/00—Machines or devices designed for grinding plane surfaces on work, including polishing plane glass surfaces; Accessories therefor
    • B24B7/10—Single-purpose machines or devices
    • B24B7/12—Single-purpose machines or devices for grinding travelling elongated stock, e.g. strip-shaped work
    • B24B7/13—Single-purpose machines or devices for grinding travelling elongated stock, e.g. strip-shaped work grinding while stock moves from coil to coil
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/04—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor characterised by the coating material
    • C23C2/06—Zinc or cadmium or alloys based thereon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/26—After-treatment
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C2/00—Hot-dipping or immersion processes for applying the coating material in the molten state without affecting the shape; Apparatus therefor
    • C23C2/50—Controlling or regulating the coating processes
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D3/00—Electroplating: Baths therefor
    • C25D3/02—Electroplating: Baths therefor from solutions
    • C25D3/22—Electroplating: Baths therefor from solutions of zinc
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/34—Pretreatment of metallic surfaces to be electroplated
    • C25D5/36—Pretreatment of metallic surfaces to be electroplated of iron or steel
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48—After-treatment of electroplated surfaces
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D7/00—Electroplating characterised by the article coated
    • C25D7/06—Wires; Strips; Foils

Definitions

  • the present disclosure relates to a method for producing a textured plated steel sheet, and an apparatus for producing a textured plated steel sheet.
  • a textured plated steel sheet includes, on the surface thereof, a plating layer on the surface of which a texture typified by a hairline texture is formed.
  • Patent Literature 1 Japanese Patent Application Publication No. 2006-124824 (Patent Literature 1) and International Application Publication No. WO2008/054419 (Patent Literature 2).
  • Patent Literature 1 discloses forming a zinc plating layer on the surface of a steel sheet, and forming hairlines on the surface of the zinc plating layer by grinding the surface of the zinc plating layer using a belt sander (abrasive belt) ranging from about #60 to #320.
  • a belt sander abrasive belt
  • Patent Literature 2 proposes a method for polishing a metal alloy-plated steel sheet article.
  • the polishing method disclosed in Patent Literature 2 is a method for polishing a metal alloy-plated steel sheet article to form a polished plated surface having a continuous and consistent stainless steel-like appearance, the method including: a) a step of providing a metal alloy-plated steel sheet article having a minimized spangle plating film; b) a step of embossing the minimized spangle plating film to form an intermediate metal alloy-plated steel sheet article having a plating film that is embossed with a textured pattern that provides the continuous and consistent stainless steel-like appearance when polished; and c) a step of polishing the plating film that is embossed with the textured pattern to produce the continuous and consistent stainless steel-like appearance.
  • a textured plated steel sheet is produced by grinding the surface of a plating layer, in some cases the thickness of the plating layer is insufficient, or the texture is not sufficiently formed and there is an appearance defect, and thus a product defect occurs. It is preferable that the cause of a product defect can be quickly identified. If the cause of a product defect can be quickly identified and the cause of the product defect eliminated, the occurrence of product defects can be suppressed.
  • An objective of the present disclosure is to provide a method for producing a textured plated steel sheet that can suppress the occurrence of product defects which are based on an insufficient thickness of a plating layer and an appearance defect, and also provide an apparatus for producing a textured plated steel sheet with which the cause of product defects which are based on an insufficient thickness of a plating layer and an appearance defect is easy to identify.
  • a method for producing a textured plated steel sheet according to the present disclosure includes:
  • An apparatus for producing a textured plated steel sheet according to the present disclosure includes:
  • the method for producing a textured plated steel sheet according to the present disclosure can suppress the occurrence of product defects which are based on an insufficient thickness of a plating layer and an appearance defect.
  • the apparatus for producing a textured plated steel sheet according to the present disclosure easily identifies a cause of product defects which are based on an insufficient thickness of a plating layer and an appearance defect.
  • FIG. 1 is a general view of an apparatus for producing a textured plated steel sheet according to a first embodiment.
  • FIG. 2 is a cross-sectional view illustrating a schematic configuration of one example of an electrogalvanizing apparatus.
  • FIG. 3 is a side view illustrating a schematic configuration of one example of a hot-dip galvanizing apparatus.
  • FIG. 4 is a cross-sectional view illustrating a schematic configuration of one example of a grinding apparatus.
  • FIG. 5 is a general view of an apparatus for producing a textured plated steel sheet in a case where the apparatus is equipped with a control unit, according to a second embodiment.
  • FIG. 6 is a functional block diagram of a control unit.
  • FIG. 7 is a functional block diagram illustrating one example of a hardware configuration of a control unit.
  • FIG. 8 is an operation flowchart of the apparatus for producing a textured plated steel sheet which is equipped with the control unit.
  • FIG. 9 is an operation flowchart of the apparatus for producing a textured plated steel sheet which is equipped with the control unit, in a case where second plating thickness information is more than a reference range.
  • FIG. 10 is an operation flowchart of the apparatus for producing a textured plated steel sheet which is equipped with the control unit, in a case where second plating thickness information is less than the reference range.
  • FIG. 11 is an operation flowchart of the apparatus for producing a textured plated steel sheet which is equipped with the control unit, in a case where second plating thickness information is within the reference range.
  • a method for producing a textured plated steel sheet includes a plating layer forming process, and a grinding process after the plating layer forming process.
  • a plating layer is formed on a surface of a steel sheet to produce a plated steel sheet.
  • the grinding process is performed after the plating layer forming process.
  • the surface of the plating layer of the plated steel sheet is ground to form a texture on the surface of the plating layer.
  • the texture is a pattern formed by unevenness on the surface of the plating layer.
  • Examples of the texture include hairline texture and vibration texture.
  • the hairline texture is a pattern formed by a large number of fine linear grooves.
  • the vibration texture is a pattern formed by a large number of fine arcuate grooves.
  • the plating layer of the textured plated steel sheet is formed on the surface of the steel sheet. That is, on the textured plated steel sheet, a plating layer is arranged that has a final thickness which is the thickness of the plating layer after the plating layer is formed and ground.
  • the plating layer of the textured plated steel sheet increases the corrosion resistance of the textured plated steel sheet. If the final thickness of the plating layer is less than a certain value, that is, if there is an insufficient final thickness, the corrosion resistance of the textured plated steel sheet will decrease. Accordingly, when the final thickness of the plating layer is less than a certain value, it will result in a product defect.
  • the texture will be sufficiently formed. In this case, the design property of the textured plated steel sheet will be enhanced.
  • the present inventors considered that when the plating layer is sufficiently ground, the final thickness of the plating layer becomes a certain value or less.
  • the present inventors considered that the final thickness of the plating layer can be used as an index that indicates the corrosion resistance and a design property of the textured plated steel sheet.
  • the present inventors considered that if a reference range is provided for the final thickness of the plating layer, and the final thickness of the plating layer is within the reference range, it can be determined that the textured plated steel sheet has excellent corrosion resistance and an excellent design property.
  • the present inventors set a reference range for the final thickness of the plating layer of a textured plated steel sheet.
  • the present inventors considered that if the operating conditions are adjusted based on the final thickness of the plating layer, product defects which are based on an insufficient final thickness of the plating layer and an appearance defect can be suppressed.
  • the final thickness of the plating layer is insufficient.
  • the final thickness of the plating layer will be less than a reference range even if the plating amount of the plating layer that is formed in the plating layer forming process is increased in order to increase the final thickness of the plating layer.
  • Such a case is one where the grinding amount of the plating layer that is ground in the grinding process is too much.
  • the grinding amount of the plating layer that is ground in the grinding process is decreased in order to increase the final thickness of the plating layer, the texture will not be sufficiently formed, which will result in an appearance defect.
  • Such a case is one where the plating amount of the plating layer that is formed in the plating layer forming process is too small. In this case, it is necessary to increase the grinding amount of the plating layer that is ground in the grinding process, and at the same time to also increase the plating amount of the plating layer that is formed in the plating layer forming process.
  • a case will be assumed in which a texture is not sufficiently formed, and an appearance defect occurs.
  • the grinding amount of the plating layer that is ground in the grinding process is increased in order to sufficiently form a texture, the final thickness of the plating layer will be less than the reference range.
  • Such a case is one where the plating amount of the plating layer that is formed in the plating layer forming process is too small. In this case, it is necessary to increase the grinding amount of the plating layer that is ground in the grinding process, and at the same time to also increase the plating amount of the plating layer that is formed in the plating layer forming process.
  • the final thickness of a plating layer cannot be used as an index that indicates the corrosion resistance and a design property of a textured plated steel sheet. From the investigation described above, it was found that the final thickness and appearance of a plating layer are influenced by the following two factors: (1) the plating amount of the plating layer formed in the plating layer forming process, and (2) the grinding amount of the plating layer that is ground in the grinding process. The present inventors found that by only measuring the final thickness of the plating layer, it is not possible to identify whether a product defect which is based on an insufficient final thickness of the plating layer and/or an appearance defect has occurred due to (1) and/or (2).
  • first plating thickness information information relating to the thickness of a plating layer of a plated steel sheet at a time that is after the plating layer forming process and is before the grinding process.
  • second plating thickness information information relating to the thickness of a plating layer of a plated steel sheet after the grinding process.
  • the present inventors considered that if not just the second plating thickness information relating to the plating thickness after grinding, but also the first plating thickness information relating to the plating thickness before grinding can both be obtained, the cause of a product defect which is based on an insufficient final thickness of the plating layer and/or an appearance defect can be quickly identified.
  • the present inventors considered that if the operating conditions are adjusted based on both the first plating thickness information and the second plating thickness information, the occurrence of product defects which are based on a decrease in corrosion resistance due to an insufficient final thickness of a plating layer and also an appearance defect with respect to a textured plated steel sheet can be suppressed.
  • An apparatus for producing a textured plated steel sheet that is uses in the aforementioned method for producing a textured plated steel sheet includes, for example, a plating apparatus and a grinding apparatus.
  • the plating apparatus forms a plating layer on a steel sheet surface to produce a plated steel sheet.
  • the grinding apparatus is arranged downstream of the plating apparatus, and grinds the surface of the plating layer of the plated steel sheet to form a texture on the surface of the plating layer.
  • the apparatus for producing a textured plated steel sheet also includes a first plating thickness determining apparatus and a second plating thickness determining apparatus.
  • the first plating thickness determining apparatus determines first plating thickness information relating to the thickness before grinding of the plating layer, and outputs the first plating thickness information.
  • the second plating thickness determining apparatus is arranged downstream of the grinding apparatus, and determines second plating thickness information relating to the thickness of the plating layer that has been ground, and outputs the second plating thickness information.
  • an apparatus for producing a textured plated steel sheet has the aforementioned configuration, it will be easy to identify whether the cause of a product defect that occurs is (1) the plating amount of the plating layer formed in the plating layer forming process, and/or (2) the grinding amount of the plating layer that is ground in the grinding process.
  • a method for producing a textured plated steel sheet of the present embodiment which has been completed based on the above findings, is as follows.
  • a method for producing a textured plated steel sheet including:
  • An apparatus for producing a textured plated steel sheet including:
  • the apparatus for producing a textured plated steel sheet according to any one of [12] to [15], further including:
  • the apparatus for producing a textured plated steel sheet according to any one of [12] to [16], further including:
  • FIG. 1 is a general view of an apparatus for producing a textured plated steel sheet in a first embodiment.
  • an apparatus for producing a textured plated steel sheet 1 includes a plating apparatus 2 , a grinding apparatus 3 , a first plating thickness determining apparatus 4 , and a second plating thickness determining apparatus 5 .
  • the apparatus for producing a textured plated steel sheet 1 of the present embodiment is a continuous line type production apparatus.
  • the plating apparatus 2 and the grinding apparatus 3 are arranged on the same continuous line.
  • the grinding apparatus 3 is arranged downstream of the plating apparatus 2 .
  • a straight line in FIG. 1 is a straight line indicating a production line.
  • the apparatus for producing a textured plated steel sheet 1 of the present embodiment includes an uncoiling apparatus and a coiling apparatus that are not illustrated in the drawing.
  • the uncoiling apparatus is arranged upstream of the plating apparatus 2 , and uncoils a prepared steel sheet coil.
  • the coiling apparatus is arranged downstream of the grinding apparatus 3 , and winds the produced textured plated steel sheet into a coil. Because the apparatus for producing a textured plated steel sheet 1 is a continuous line type apparatus, a coiling apparatus and an uncoiling apparatus are not arranged between the plating apparatus 2 and the grinding apparatus 3 .
  • the plating apparatus 2 performs hot-dip plating or electroplating to form a plating layer on the surface of a steel sheet to produce a plated steel sheet.
  • the hot-dip plating is selected, for example, from the group consisting of hot-dip galvanizing and hot-dip aluminum plating.
  • the electroplating is selected, for example, from the group consisting of electrogalvanizing, copper electroplating, and nickel electroplating.
  • the plating apparatus 2 is not particularly limited as long as the plating apparatus 2 performs hot-dip plating or electroplating.
  • the plating apparatus 2 is a hot-dip galvanizing apparatus that performs hot-dip galvanizing, or is an electrogalvanizing apparatus that performs electrogalvanizing.
  • an electrogalvanizing apparatus is used and a case where a hot-dip galvanizing apparatus is used are described as examples.
  • FIG. 2 is a cross-sectional view illustrating a schematic configuration of one example of an electrogalvanizing apparatus 200 .
  • the electrogalvanizing apparatus 200 includes a plurality of conductor rolls 201 , a plurality of anodes 202 , and a plurality of plating tanks 203 .
  • the conveying direction of a steel sheet 6 that has been conveyed into the electrogalvanizing apparatus 200 is changed to the downward direction by one of the conductor rolls 201 .
  • the steel sheet 6 passes through the vicinity of the anodes 202 and is conveyed continuously into the plating tank 203 .
  • a zinc plating solution is stored in the plating tank 203 .
  • the anodes 202 are immersed in the zinc plating solution.
  • the steel sheet 6 that is conveyed into the plating tank 203 is continuously immersed in the zinc plating solution.
  • a zinc plating layer is formed on the surface of the steel sheet 6 as a result of a current flowing from the anodes 202 to the steel sheet 6 .
  • the conveying direction of the steel sheet 6 is changed from downward to upward by the conductor roll 201 inside each plating tank 203 .
  • a zinc plating layer is further formed on the steel sheet 6 while passing through the vicinity of the anodes 202 within the plating tank 203 .
  • the steel sheet 6 on which the zinc plating layer is formed is continuously conveyed to outside of the plating tank 203 .
  • the electrogalvanizing apparatus 200 includes a plurality of the plating tanks 203 . Each time the steel sheet 6 passes through the inside of each of the plurality of plating tanks 203 , a zinc plating layer is formed thereon. By this means, a plated steel sheet 7 is continuously produced.
  • the electrogalvanizing apparatus 200 in FIG. 2 includes a plurality of the plating tanks 203 .
  • the number of plating tanks 203 may be one.
  • each plating tank 203 has an opening at an upper part thereof.
  • the steel sheet 6 passes through the opening at the upper part of the plating tank 203 to be conveyed into the plating tank 203 .
  • the steel sheet 6 or the plated steel sheet 7 that passes through the opening at the upper part of the plating tank 203 is conveyed to outside of the plating tank 203 .
  • the plating tank 203 in FIG. 2 is a so-called “vertical type” plating tank 203 .
  • the plating tank 203 may be a so-called “horizontal type” plating tank 203 which has one opening in each of two side faces which face each other.
  • the steel sheet 6 passes through the opening in one side face of the plating tank 203 and is conveyed into the plating tank 203 .
  • the steel sheet 6 or the plated steel sheet 7 that passes through the opening in the other side face of the plating tank 203 is conveyed to outside of the plating tank 203 .
  • FIG. 3 is a side view illustrating a schematic configuration of one example of a hot-dip galvanizing apparatus 210 .
  • the hot-dip galvanizing apparatus 210 includes a molten zinc pot 211 , a sink roll 212 , support rolls 213 , a gas wiping apparatus 214 , a turn-down roll 215 , a top roll 216 , a plurality of transfer rolls 217 , and a skin pass mill 218 .
  • a hot-dip galvanizing bath is stored in the molten zinc pot 211 .
  • the conveying direction of the steel sheet 6 conveyed into the hot-dip galvanizing apparatus 210 is changed to the downward direction by the turn-down roll 215 .
  • the steel sheet 6 is continuously immersed in the hot-dip galvanizing bath stored in the molten zinc pot 211 .
  • the sink roll 212 is arranged inside the molten zinc pot 211 .
  • the sink roll 212 is immersed in the hot-dip galvanizing bath.
  • the sink roll 212 changes the conveying direction of the steel sheet 6 from downward to upward.
  • the support rolls 213 are arranged in the hot-dip galvanizing bath, at a position above the sink roll 212 .
  • the support rolls 213 sandwich the steel sheet 6 , and support the steel sheet 6 that is conveyed upward.
  • the gas wiping apparatus 214 is arranged at a position that is above the liquid surface of the hot-dip galvanizing bath.
  • the gas wiping apparatus 214 includes a pair of gas spraying apparatuses.
  • the pair of gas spraying apparatuses have gas spraying nozzles which face each other.
  • the steel sheet 6 passes between the pair of gas spraying nozzles of the gas wiping apparatus 214 .
  • the pair of gas spraying nozzles spray a wiping gas against the surface of the steel sheet 6 which is pulled up from the hot-dip galvanizing bath. By this means, some of the molten zinc that adhered to the surface of the steel sheet 6 is scraped off.
  • the steel sheet 7 from which a part of the molten zinc on the surface was scraped off is conveyed to the skin pass mill 218 by the top roll 216 and the transfer rolls 217 .
  • the skin pass mill 218 includes a pair of work rolls and a pair of backup rolls.
  • the pair of work rolls includes an upper work roll 219 and a lower work roll 220 .
  • the pair of backup rolls includes an upper backup roll 221 and a lower backup roll 222 .
  • the steel sheet 6 is conveyed between the upper work roll 219 and the lower work roll 220 by the transfer rolls 217 .
  • the steel sheet 6 that is sandwiched by the upper work roll 219 and the lower work roll 220 is rolled.
  • the hot-dip galvanizing apparatus 210 may further include an alloying furnace and a cooling furnace.
  • the grinding apparatus 3 is arranged downstream of the plating apparatus 2 , and grinds the surface of a plating layer of the plated steel sheet 7 to form a texture on the surface of the plating layer.
  • Examples of the texture include a hairline texture and a vibration texture.
  • FIG. 4 is a cross-sectional view illustrating a schematic configuration of one example of the grinding apparatus 3 .
  • the grinding apparatus 3 includes a plurality of transfer rolls 31 , a pair of contact rolls 32 , and an annular abrasive belt 33 .
  • the pair of contact rolls 32 supports the annular abrasive belt 33 . Rotation of the pair of contact rolls 32 causes the annular abrasive belt 33 to move between the pair of contact rolls 32 .
  • the plated steel sheet 7 is conveyed by the transfer rolls 31 .
  • the plated steel sheet 7 is conveyed between the corresponding transfer roll 31 and the annular abrasive belt 33 by the transfer rolls 31 .
  • the plated steel sheet 7 is pressed against the annular abrasive belt 33 by one of the pair of contact rolls 32 and the transfer roll 31 .
  • the annular abrasive belt 33 grinds the plating layer on the surface of the plated steel sheet 7 .
  • a texture is formed on the surface of the plating layer.
  • the grinding apparatus 3 in FIG. 4 is an abrasive belt type grinding apparatus 3 .
  • the grinding apparatus 3 is not limited thereto.
  • the grinding apparatus 3 may include a grinding brush.
  • the first plating thickness determining apparatus 4 determines first plating thickness information relating to the thickness before grinding of the plating layer, and outputs the first plating thickness information.
  • the first plating thickness determining apparatus 4 includes a screen, and the first plating thickness information may be output onto the screen.
  • the first plating thickness information is information relating to the thickness before grinding of the plating layer.
  • the first plating thickness information may be a thickness ( ⁇ m) of the plating layer before grinding, may be a plating amount (g/m 2 ) of the plating layer before grinding, or may be plating conditions in the plating apparatus 2 .
  • the plating conditions in the plating apparatus 2 are, for example, a metal ion concentration in the plating solution, a line speed of the steel sheet into the plating solution, a width direction length of the steel sheet, a temperature and/or pH of the plating solution and the like.
  • the plating conditions may be a metal ion concentration in the plating solution, the line speed of the steel sheet into the plating solution, the width direction length of the steel sheet, the current density, the current efficiency, and/or the temperature of the plating solution.
  • the plating conditions may be the line speed of the steel sheet into the plating solution, an impact pressure of a wiping gas, and/or a rolling reduction at the skin pass mill 218 . That is, the term “first plating thickness information” includes the plating thickness before grinding and all information that can be used to estimate the plating thickness before grinding.
  • the first plating thickness determining apparatus 4 determines the first plating thickness information relating to the thickness before grinding of the plating layer.
  • the first plating thickness information may be determined by measurement. Specifically, the thickness ( ⁇ m) of the plating layer at a time that is after the plating layer is formed by the plating apparatus 2 and is before grinding of the plating layer is performed by the grinding apparatus 3 may be measured, or the plating amount (g/m 2 ) of the plating layer before grinding may be measured, and the measured thickness ( ⁇ m) or plating amount (g/m 2 ) may be determined as the first plating thickness information.
  • the first plating thickness determining apparatus 4 is, for example, a fluorescent X-ray film thickness meter.
  • the first plating thickness information may be a plating condition at the plating apparatus 2 .
  • the first plating thickness determining apparatus 4 may measure the plating condition.
  • the first plating thickness determining apparatus 4 is, for example, a voltmeter, an ammeter, an ion meter, a thermometer, or a gas pressure meter.
  • the thickness ( ⁇ m) of the plating layer before grinding or the plating amount (g/m 2 ) of the plating layer before grinding may be calculated based on a plating condition at the plating apparatus 2 , and determined as the first plating thickness information.
  • the first plating thickness determining apparatus 4 measures the plating condition, and calculates the thickness ( ⁇ m) of the plating layer before grinding or the plating amount (g/m 2 ) of the plating layer before grinding based on the measured plating conditions, and outputs the calculation result.
  • the first plating thickness determining apparatus 4 may include a memory that stores a plating thickness determination table.
  • the first plating thickness determining apparatus 4 may, for example, in the plating thickness determination table, identify a thickness ( ⁇ m) of the plating layer before grinding or a plating amount (g/m 2 ) of the plating layer before grinding that corresponds to a line speed of a steel sheet, a width direction length of a steel sheet, and a measured plating condition which were input in advance, and determine the identified thickness ( ⁇ m) or plating amount (g/m 2 ) as the first plating thickness information.
  • the first plating thickness determining apparatus 4 may calculate the thickness ( ⁇ m) of the plating layer before grinding or the plating amount (g/m 2 ) of the plating layer before grinding using, for example, a pre-stored calculation program based on a line speed of a steel sheet, a width direction length of a steel sheet, and a measured plating condition which were input in advance, and determine the calculated thickness ( ⁇ m) or plating amount (g/m 2 ) as the first plating thickness information.
  • the second plating thickness determining apparatus 5 is arranged downstream of the grinding apparatus 3 , and determines second plating thickness information relating to the thickness of the plating layer that has been ground, and outputs the second plating thickness information.
  • the second plating thickness determining apparatus 5 includes a screen, and the second plating thickness information may be output onto the screen.
  • the second plating thickness information may be a thickness ( ⁇ m) of the plating layer after grinding, or may be a plating amount (g/m 2 ) of the plating layer after grinding.
  • the second plating thickness information is determined by measurement. Specifically, the thickness ( ⁇ m) of the plating layer after grinding of the plating layer is performed by the grinding apparatus 3 may be measured, or the plating amount (g/m 2 ) of the plating layer after grinding may be measured, and the measured thickness ( ⁇ m) or plating amount (g/m 2 ) may be determined as the second plating thickness information.
  • the second plating thickness determining apparatus 5 is, for example, a fluorescent X-ray film thickness meter.
  • the aforementioned apparatus for producing a textured plated steel sheet 1 includes not only the second plating thickness determining apparatus 5 , but also includes the first plating thickness determining apparatus 4 . Therefore, in a case where product defects which are based on an insufficient thickness of a plating layer and an appearance defect occur, from among two factors which are (1) the plating amount of the plating layer formed in the plating layer forming process and (2) the grinding amount of the plating layer that has been ground in the grinding process, it is easy to identify which of the factors caused the product defect to occur.
  • the method for producing a textured plated steel sheet of the present embodiment includes a plating layer forming process, a grinding process, a plating thickness determining process, and an adjusting process.
  • a plating layer is formed on the surface of the steel sheet 6 by an electroplating method or a hot-dip plating method to produce the plated steel sheet 7 .
  • the plating apparatus 2 is, for example, the electrogalvanizing apparatus 200 .
  • the plating apparatus 2 is, for example, the hot-dip galvanizing apparatus 210 .
  • the electrogalvanizing process may be performed by a well-known method.
  • the term “electrogalvanizing process” also includes a zinc alloy electroplating process. It suffices to use a well-known plating solution as the plating solution used in the electrogalvanizing process.
  • the electrogalvanizing solution is, for example, a sulfate bath, a chloride bath, a zincate bath, a cyanide bath, a pyrophosphate bath, a boric acid bath, a citrate bath, another complex bath, or a combination of these baths.
  • the zinc alloy electroplating solution contains, for example, in addition to Zn ions, one or more kinds of single ions or complex ions selected from the group consisting of Fe, Ni, Co, Cr and C. Further, an appropriate organic addition agent or the like may be added to the plating solution in order to obtain a desired effect such as a leveling effect or an increase in hardness.
  • a plating solution containing zinc sulfate heptahydrate: 200 to 400 g/L, and sodium sulfate: 15 to 100 g/L, and having a pH of 1.0 to 2.5 can be used as the plating solution that is used in the electrogalvanizing process.
  • a zinc ion concentration, a temperature, a pH, a line speed of the steel sheet 6 , a current density and the like in the electrogalvanizing solution and the zinc alloy electroplating solution can be appropriately set.
  • the zinc ion concentration in the plating solution is, for example, 0.8 to 1.5 mol/L.
  • the temperature of the plating solution is, for example, 40 to 60° C.
  • the line speed of the steel sheet 6 is, for example, 20 to 200 m/min.
  • the current density is, for example, 10 to 200 A/dm 2 .
  • the thickness of the plating layer formed by performing the electrogalvanizing process can be adjusted, for example, by adjusting the line speed of the steel sheet 6 into the plating solution and/or the current density when performing the electrogalvanizing process. By this means, a plating layer is formed on the surface of the steel sheet 6 , and the plated steel sheet 7 can be produced.
  • the hot-dip galvanizing process may be performed by a well-known method. It suffices to use a well-known plating bath as the plating bath that is used in the hot-dip galvanizing process.
  • a plating bath containing Al with the balance being Zn and an impurity can be used as the hot-dip galvanizing bath.
  • the impurity is, for example, Fe.
  • the hot-dip galvanizing bath may include, in addition to Zn, Al, and Fe, one or more kinds of element selected from the group consisting of Mg, Si, Ca, Y, La, Ce, Sn, Bi, In, Cr, Ti, Ni, Co, V, Nb, Cu, Mn, Sr, Sb, Pb, and B.
  • the Al concentration, the Fe concentration, and the concentration of other elements in the hot-dip galvanizing bath, as well as the temperature, the pH, the line speed of the steel sheet 6 , the impact pressure of wiping gas, and the rolling reduction at the skin pass mill 218 can be appropriately set.
  • the Al concentration is, for example, 0.1 to 60.0% by mass.
  • the Fe concentration is, for example, 0.01 to 0.5% by mass.
  • the hot-dip galvanizing bath contains, in addition to Zn, Al, and Fe, one or more kinds of element selected from the group consisting of Mg, Si, Ca, Y, La, Ce, Sn, Bi, In, Cr, Ti, Ni, Co, V, Nb, Cu, Mn, Sr, Sb, Pb, and B, the content of these elements is, for example, 0.0 to 15.0% by mass in total.
  • the temperature of the hot-dip galvanizing bath is for example, 430 to 630° C.
  • the line speed of the steel sheet 6 is, for example, 60 to 150 m/min.
  • the impact pressure of the wiping gas is, for example, 0 to 200 kPa.
  • the rolling reduction at the skin pass mill 218 is, for example, 0 to 3.0%.
  • the thickness of the plating layer that is formed by performing the hot-dip galvanizing process can be adjusted, for example, by adjusting the line speed of the steel sheet 6 into the plating solution, the impact pressure of the wiping gas, and/or the rolling reduction at the skin pass mill 218 when performing the hot-dip galvanizing process. By this means, a plating layer is formed on the surface of the steel sheet 6 , and the plated steel sheet 7 can be produced.
  • the surface of the plating layer of the plated steel sheet 7 is ground to form a texture on the surface of the plating layer.
  • the texture is, for example, a hairline texture.
  • the surface of the plating layer is ground by the grinding apparatus 3 having the abrasive belt 33 to form a hairline texture on the surface of the plating layer.
  • the line speed of the plated steel sheet 7 to the grinding apparatus 3 is, for example, 20 to 200 m/min.
  • the rotational speed of the contact rolls 32 is, for example, 10 to 1500 rpm.
  • the rolling force with which the contact roll 32 presses against the plated steel sheet 7 is, for example, 0.01 to 0.10 MPa.
  • the grinding amount of the plating layer that is ground in the grinding process can be adjusted by adjusting the rotational speed of the contact rolls 32 , and the rolling force with which the contact roll 32 presses against the plated steel sheet 7 .
  • the grinding amount can be adjusted by adjusting the rotational speed of the grinding brush, and/or the rolling force with which the grinding brush presses against the plated steel sheet 7 .
  • first plating thickness information relating to the thickness of the plating layer of the plated steel sheet 7 at a time that is after the plating layer forming process and is before the grinding process, and second plating thickness information relating to the thickness of the plating layer of a plated steel sheet 8 after the grinding process are determined.
  • the first plating thickness information may be determined by measuring the thickness of the plating layer of the plated steel sheet at a time that is after the plating layer forming process and is before the grinding process.
  • the first plating thickness information may be a plating condition in the plating layer forming process.
  • the first plating thickness information may be determined based on a plating condition in the plating layer forming process.
  • the second plating thickness information may be determined by measuring the thickness of the plating layer of the plated steel sheet after the grinding process.
  • the plating amount of the plating layer formed in the plating layer forming process, and the grinding amount of the surface of the plating layer that is ground in the grinding process are adjusted based on the first and second plating thickness information.
  • the plating amount of the plating layer formed in the plating layer forming process may be decreased and the grinding amount of the plating layer that is ground in the grinding process may be increased.
  • the reduction of the plating amount of the plating layer that is formed in the plating layer forming process and the increase of the grinding amount of the plating layer that is ground in the grinding process may be performed at the same time.
  • the first plating thickness information may be checked, and if the first plating thickness information is more than the reference range, the plating amount of the plating layer that is formed in the plating layer forming process may be decreased while maintaining the grinding amount of the plating layer that is ground in the grinding process, and thereafter the second plating thickness information may be checked, and if the second plating thickness information is more than the reference range, the grinding amount of the plating layer that is ground in the grinding process may be increased while maintaining the plating amount of the plating layer that is formed in the plating layer forming process.
  • the plating amount of the plating layer that is formed in the plating layer forming process can be decreased by the following method.
  • the line speed (m/min) of the steel sheet 6 into the plating solution may be made faster.
  • the current density (A/dm 2 ) may be lowered.
  • the plating amount of the plating layer that is formed in the plating layer forming process can be decreased by the following method.
  • the line speed (m/min) of the steel sheet 6 into the plating solution may be made faster.
  • the impact pressure of the wiping gas may be raised.
  • the rolling reduction at the skin pass mill 218 may be increased.
  • only any one of the conditions may be adjusted, or a combination of a plurality of the conditions may be adjusted.
  • the line speed (m/min) of the plated steel sheet 7 into the grinding apparatus 3 may be made slower, the rotational speed (rpm) of the contact roll 32 may be made faster, or the rolling force (MPa) with which the contact roll 32 presses against the plated steel sheet 7 may be increased.
  • the rotational speed of the grinding brush may be made faster, or the rolling force with which the grinding brush presses against the plated steel sheet 7 may be increased.
  • only any one of the conditions may be adjusted, or a combination of a plurality of the conditions may be adjusted.
  • the plating amount of the plating layer formed in the plating layer forming process may be decreased and the grinding amount of the plating layer that is ground in the grinding process may be decreased.
  • the reduction of the plating amount of the plating layer that is formed in the plating layer forming process and the reduction of the grinding amount of the plating layer that is ground in the grinding process may be performed at the same time.
  • the first plating thickness information may be checked, and if the first plating thickness information is more than the reference range, the plating amount of the plating layer that is formed in the plating layer forming process may be decreased while maintaining the grinding amount of the plating layer that is ground in the grinding process, and thereafter the second plating thickness information may be checked, and if the second plating thickness information is less than the reference range, the grinding amount of the plating layer that is ground in the grinding process may be decreased while maintaining the plating amount of the plating layer that is formed in the plating layer forming process.
  • the line speed (m/min) of the plated steel sheet 7 into the grinding apparatus 3 may be made faster, the rotational speed (rpm) of the contact roll 32 may be made slower, or the rolling force (MPa) with which the contact roll 32 presses against the plated steel sheet 7 may be lowered.
  • the rotational speed of the grinding brush may be made slower, or the rolling force with which the grinding brush presses against the plated steel sheet 7 may be lowered.
  • only any one of the conditions may be adjusted, or a combination of a plurality of the conditions may be adjusted.
  • the plating amount of the plating layer that is formed in the plating layer forming process may be maintained and the grinding amount of the plating layer that is ground in the grinding process may be increased.
  • the plating amount of the plating layer that is formed in the plating layer forming process is maintained and the grinding amount of the plating layer that is ground in the grinding process is maintained.
  • the plating amount of the plating layer that is formed in the plating layer forming process may be maintained and the grinding amount of the plating layer that is ground in the grinding process may be decreased.
  • the plating amount of the plating layer that is formed in the plating layer forming process may be increased and the grinding amount of the plating layer that is ground in the grinding process may be increased.
  • the increasing of the plating amount of the plating layer that is formed in the plating layer forming process and the increasing of the grinding amount of the plating layer that is ground in the grinding process may be performed at the same time.
  • the first plating thickness information may be checked, and if the first plating thickness information is less than the reference range, the plating amount of the plating layer that is formed in the plating layer forming process may be increased while maintaining the grinding amount of the plating layer that is ground in the grinding process, and thereafter the second plating thickness information may be checked, and if the second plating thickness information is more than the reference range, the grinding amount of the plating layer that is ground in the grinding process may be increased while maintaining the plating amount of the plating layer that is formed in the plating layer forming process.
  • the plating amount of the plating layer that is formed in the plating layer forming process can be increased by the following method.
  • the line speed (m/min) of the steel sheet 6 into the plating solution may be made slower.
  • the current density (A/dm 2 ) may be increased.
  • the plating amount of the plating layer that is formed in the plating layer forming process can be increased by the following method.
  • the line speed (m/min) of the steel sheet 6 into the plating solution may be made slower.
  • the impact pressure of the wiping gas may be lowered.
  • the rolling reduction at the skin pass mill 218 may be decreased.
  • only any one of the conditions may be adjusted, or a combination of a plurality of the conditions may be adjusted.
  • the plating amount of the plating layer formed in the plating layer forming process may be increased and the grinding amount of the plating layer that is ground in the grinding process may be decreased.
  • the increasing of the plating amount of the plating layer that is formed in the plating layer forming process and the decreasing of the grinding amount of the plating layer that is ground in the grinding process may be performed at the same time.
  • the first plating thickness information may be checked, and if the first plating thickness information is less than the reference range, the plating amount of the plating layer that is formed in the plating layer forming process may be increased while maintaining the grinding amount of the plating layer that is ground in the grinding process, and thereafter the second plating thickness information may be checked, and if the second plating thickness information is less than the reference range, the grinding amount of the plating layer that is ground in the grinding process may be decreased while maintaining the plating amount of the plating layer that is formed in the plating layer forming process.
  • the method for producing a textured plated steel sheet of the present embodiment is performed using a continuous line-type apparatus for producing a textured plated steel sheet. Accordingly, coiling of the steel sheet and uncoiling of the steel sheet are not performed between the plating layer forming process and the grinding process. Further, in the method for producing a textured plated steel sheet of the present embodiment, in the adjusting process, the plating amount and the grinding amount are adjusted based on the first and second plating thickness information, with respect to the same steel sheet coil as the steel sheet coil from which the first and second plating thickness information were acquired.
  • the reference range of the first plating thickness information can be appropriately set, and is not particularly limited.
  • the reference range of the first plating thickness information may be, for example, 10 to 320 g/m 2 .
  • the reference range of the first plating thickness information may be, for example, 1 to 20 kA/m 2 .
  • the reference range of the first plating thickness information may be, for example, 30 to 200 m/min.
  • the reference range of the first plating thickness information may be, for example, 0 to 200 kPa.
  • the reference range of the first plating thickness information may be, for example, 0 to 3.0%.
  • the reference range of the second plating thickness information can be appropriately set, and is not particularly limited.
  • the reference range of the second plating thickness information may be, for example, 5 to 300 g/m 2 .
  • the first plating thickness information relating to the thickness of the plating layer before grinding is also determined, not just the second plating thickness information relating to the thickness of the plating layer after grinding, and furthermore, in the adjusting process, the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process are adjusted based on the first and second plating thickness information.
  • FIG. 5 is a general view of an apparatus for producing a textured plated steel sheet 1 that includes a control unit, according to a second embodiment.
  • the apparatus for producing a textured plated steel sheet 1 includes the same configuration as the apparatus for producing a textured plated steel sheet 1 of the first embodiment, and also includes a control unit 9 .
  • the first plating thickness determining apparatus 4 outputs the first plating thickness information to the control unit 9
  • the second plating thickness determining apparatus 5 outputs the second plating thickness information to the control unit 9 .
  • the control unit 9 controls the plating apparatus 2 so as to adjust the plating amount of the plating layer to be formed on the surface of the steel sheet 6 by the plating apparatus 2 , based on the first plating thickness information and the second plating thickness information, and controls the grinding apparatus 3 so as to adjust the grinding amount of the surface of the plating layer to be ground by the grinding apparatus 3 , based on the first plating thickness information and the second plating thickness information.
  • the apparatus for producing a textured plated steel sheet 1 includes the control unit 9 , the apparatus for producing a textured plated steel sheet 1 more easily identifies the cause of product defects which are based on an insufficient thickness of a plating layer and an appearance defect.
  • the apparatus for producing a textured plated steel sheet 1 includes the control unit 9 , in addition to suppressing the occurrence of product defects, the apparatus for producing a textured plated steel sheet 1 can also facilitate suppressing unnecessary production costs.
  • FIG. 6 is a functional block diagram of the control unit 9 .
  • the control unit 9 includes an adjustment portion 91 , a plating apparatus control portion 92 , and a grinding apparatus control portion 93 .
  • the adjustment portion 91 determines the manner in which the plating apparatus 2 and the grinding apparatus 3 are to be controlled, and outputs the result.
  • the plating apparatus control portion 92 controls the plating apparatus 2 based on the result determined by the adjustment portion 91 .
  • the plating apparatus control portion 92 controls the line speed (m/min) of the steel sheet 6 into the plating solution and/or the current density (A/dm 2 ).
  • the plating apparatus control portion 92 controls the line speed (m/min) of the steel sheet 6 into the plating solution, the impact pressure (kPa) of the wiping gas, and/or the rolling reduction (%) at the skin pass mill 218 .
  • the grinding apparatus control portion 93 controls the grinding apparatus 3 based on the result determined by the adjustment portion 91 .
  • the grinding apparatus control portion 93 controls the line speed (m/min) of the plated steel sheet 7 to the grinding apparatus 3 , the rotational speed (rpm) of the contact rolls 32 , and the rolling force (MPa) with which the contact roll 32 presses against the plated steel sheet 7 .
  • the grinding apparatus control portion 93 controls the rotational speed of the grinding brush, and the rolling force with which the grinding brush presses against the plated steel sheet 7 . By this means, the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 is adjusted.
  • FIG. 7 is a functional block diagram illustrating an example of a hardware configuration of the control unit 9 .
  • the control unit 9 includes a central processing unit (CPU) 94 , a memory 95 , an interface 96 (indicated by “I/F” in FIG. 7 ), and a hard disk 97 (indicated by “HDD” in FIG. 7 ). These components are connected to each other by a bus.
  • a plating conditions adjustment program and a grinding conditions adjustment program are stored on the hard disk 97 .
  • the hard disk 97 is not particularly limited as long as it is a storage medium.
  • the hard disk 97 may be an SSD.
  • FIGS. 8 to 11 are operation flowcharts of the apparatus for producing a textured plated steel sheet 1 including the control unit 9 .
  • the control unit 9 acquires the first plating thickness information that is output from the first plating thickness determining apparatus 4 (S 1 ).
  • the control unit 9 acquires the second plating thickness information that is output from the second plating thickness determining apparatus 5 (S 2 ).
  • the second plating thickness information is acquired after the first plating thickness information is acquired.
  • the control unit 9 may acquire the first plating thickness information after acquiring the second plating thickness information, or may acquire the first and second plating thickness information at the same time.
  • the adjustment portion 91 of the control unit 9 determines grinding amount information that is information relating to a grinding amount at the grinding apparatus 3 , based on the obtained first plating thickness information and second plating thickness information (S 3 ). For example, in a case where the first and second plating thickness information are each a thickness ( ⁇ m) of the plating layer, the adjustment portion 91 determines the grinding amount information ( ⁇ m) by subtracting the second plating thickness information ( ⁇ m) that is the thickness of the plating layer after grinding from the first plating thickness information ( ⁇ m) that is the thickness of the plating layer before grinding. The same applies in a case where the first and second plating thickness information are each a plating amount (g/m 2 ).
  • the adjustment portion 91 of the control unit 9 may calculate the thickness ( ⁇ m) before grinding of the plating layer or the plating amount (g/m 2 ) before grinding of the plating layer based on the plating condition at the plating apparatus 2 .
  • the grinding amount information may be determined by subtracting a measured second plating thickness ( ⁇ m) or a measured second plating amount (g/m 2 ) from a calculated first plating thickness ( ⁇ m) or a calculated first plating amount (g/m 2 ).
  • the operations after the grinding amount information is determined (S 3 ) are performed according to any one of patterns 1 to 9.
  • the adjustment portion 91 of the control unit 9 determines whether the second plating thickness information is within a reference range (S 4 in FIG. 8 ). If the second plating thickness information is more than the reference range (“more than reference range” in S 4 in FIG. 8 ), the adjustment portion 91 of the control unit 9 then determines whether the grinding amount information is within a reference range (S 5 in FIG. 9 ). Depending on whether the grinding amount information is more than the reference range, is less than the reference range, or is within the reference range, the adjustment portion 91 of the control unit 9 issues instructions according to one of patterns 1 to 3.
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is more than the reference range and that the grinding amount information is more than the reference range, and issues instructions according to pattern 1 (S 6 ).
  • the second plating thickness information is more than the reference range and the grinding amount information is more than the reference range
  • the plating amount of the plating layer that is formed by the plating apparatus 2 is too large, and in addition, the plating layer is being ground more than necessary by the grinding apparatus 3 , and therefore there is an unnecessary increase in cost. Therefore, when taking the cost into consideration, it is preferable to change the operating conditions to decrease the plating amount of the plating layer that is formed by the plating apparatus 3 and to also decrease the grinding amount of the plating layer that is ground by the grinding apparatus 2 .
  • pattern 1 instructions are issued so as to control the plating apparatus 2 so as to decrease the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to decrease the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the plating apparatus control portion 92 controls the plating apparatus 2 so as to decrease the plating amount of the plating layer that is formed by the plating apparatus 2 .
  • the grinding apparatus control portion 93 controls the grinding apparatus 3 so as to decrease the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is more than the reference range and that the grinding amount information is less than the reference range, and issues instructions according to pattern 2 (S 7 in FIG. 9 ).
  • the second plating thickness information is more than the reference range and the grinding amount information is less than the reference range
  • the grinding amount information is less than the reference range
  • the second plating thickness information is more than the reference range
  • it is necessary to change the operating conditions so as to increase the grinding amount of the plating layer that is ground by the grinding apparatus 3 and form a sufficient texture on the surface of the plating layer.
  • instructions are issued so as to control the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to increase the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the grinding apparatus control portion 93 controls the plating apparatus 2 so as to maintain the plating amount of the plating layer formed by the plating apparatus 2 , and controls the grinding apparatus 3 so as to increase the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is more than the reference range and that the grinding amount information is within the reference range, and issues instructions according to pattern 3 (S 8 in FIG. 9 ).
  • the second plating thickness information is more than the reference range and the grinding amount information is within the reference range, because the plating amount of the plating layer that is formed by the plating apparatus 2 is too large, there is an unnecessary increase in cost. Therefore, when taking the cost into consideration, it is preferable to change the operating conditions so as to decrease the plating amount of the plating layer that is formed by the plating apparatus 2 .
  • instructions are issued so as to control the plating apparatus 2 so as to decrease the plating amount of the plating layer formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to maintain the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the plating apparatus control portion 92 controls the plating apparatus 2 so as to decrease the plating amount of the plating layer that is formed by the plating apparatus 2 , and controls the grinding apparatus 3 so as to maintain the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines whether the second plating thickness information is within a reference range (S 4 in FIG. 8 ). If the second plating thickness information is less than the reference range (“less than reference range” in S 4 in FIG. 8 ), the adjustment portion 91 of the control unit 9 then determines whether the grinding amount information is within a reference range (S 9 in FIG. 10 ). Depending on whether the grinding amount information is more than the reference range, is less than the reference range, or is within the reference range, the adjustment portion 91 of the control unit 9 issues instructions according to one of patterns 4 to 6.
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is less than the reference range and that the grinding amount information is more than the reference range, and issues instructions according to pattern 4 (S 10 in FIG. 10 ).
  • the corrosion resistance of the textured plated steel sheet will decrease due to an insufficient final thickness of the plating layer, which will result in a product defect.
  • the grinding amount information is more than the reference range, it is known that a product defect is occurring that is caused by the grinding amount of the plating layer that has been ground by the grinding apparatus 3 . In this case, it is necessary to change the operating conditions so as to decrease the grinding amount of the plating layer that is ground by the grinding apparatus 3 .
  • pattern 4 instructions are issued so as to control the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to decrease the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the grinding apparatus control portion 93 controls the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and controls the grinding apparatus 3 so as to decrease the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is less than the reference range and that the grinding amount information is less than the reference range, and issues instructions according to pattern 5 (S 11 in FIG. 10 ).
  • the corrosion resistance of the textured plated steel sheet will decrease due to an insufficient final thickness of the plating layer, which will result in a product defect.
  • the grinding amount information is less than the reference range, the surface of the plating layer is not sufficiently ground by the grinding apparatus 3 , and therefore a sufficient texture is not being formed on the surface of the plating layer, which results in an appearance defect.
  • the second plating thickness information is less than the reference range, it is known that a product defect is occurring that is caused by both the plating amount of the plating layer that is formed by the plating apparatus 2 and the grinding amount of the plating layer that is ground by the grinding apparatus 3 . In this case, it is necessary to change the operating conditions to increase the plating amount of the plating layer that is formed by the plating apparatus 2 , and to increase the grinding amount of the plating layer that is ground by the grinding apparatus 3 .
  • instructions are issued so as to control the plating apparatus 2 so as to increase the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to increase the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the plating apparatus control portion 92 controls the plating apparatus 2 so as to increase the plating amount of the plating layer that is formed by the plating apparatus 2 .
  • the grinding apparatus control portion 93 controls the grinding apparatus 3 so as to increase the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is less than the reference range and the grinding amount information is within the reference range, and issues instructions according to pattern 6 (S 12 in FIG. 10 ).
  • the corrosion resistance of the textured plated steel sheet will decrease due to an insufficient final thickness of the plating layer, which will result in a product defect.
  • the grinding amount information is within the reference range, it is known that the plating amount of the plating layer that is formed by the plating apparatus 2 is insufficient. In this case, it is necessary to change the operating conditions so as to increase the plating amount of the plating layer that is formed by the plating apparatus 2 .
  • instructions are issued so as to control the plating apparatus 2 so as to increase the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to maintain the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the plating apparatus control portion 92 controls the plating apparatus 2 so as to increase the plating amount of the plating layer that is formed by the plating apparatus 2 , and controls the grinding apparatus 3 so as to maintain the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines whether the second plating thickness information is within a reference range (S 4 in FIG. 8 ). If the second plating thickness information is within the reference range (“within reference range” in S 4 in FIG. 8 ), the adjustment portion 91 of the control unit 9 then determines whether the grinding amount information is within a reference range (S 13 in FIG. 11 ). Depending on whether the grinding amount information is more than the reference range, is less than the reference range, or is within the reference range, the adjustment portion 91 of the control unit 9 issues instructions according to one of patterns 7 to 9.
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is within the reference range and the grinding amount information is more than the reference range, and issues instructions according to pattern 7 (S 14 in FIG. 11 ).
  • the second plating thickness information is within the reference range and the grinding amount information is more than the reference range
  • the surface of the plating layer is being grinded by more than the necessary amount by the grinding apparatus 3 . Consequently, there is an unnecessary increase in cost. Therefore, when taking the cost into consideration, it is preferable to decrease the grinding amount of the plating layer that is ground by the grinding apparatus 3 .
  • pattern 7 instructions are issued so as to control the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to decrease the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the grinding apparatus control portion 93 controls the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and controls the grinding apparatus 3 so as to decrease the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is within the reference range and the grinding amount information is less than the reference range, and issues instructions according to pattern 8 (S 15 in FIG. 11 ).
  • the second plating thickness information is within the reference range and the grinding amount information is less than the reference range
  • the grinding amount information is less than the reference range
  • the surface of the plating layer is not being sufficiently ground by the grinding apparatus 3 , and hence a sufficient texture is not formed on the surface of the plating layer, which results in an appearance defect.
  • the second plating thickness information is within the reference range, it is known that a product defect is occurring that is caused by the grinding amount of the plating layer that is ground by the grinding apparatus 3 . In this case, it is necessary to increase the grinding amount of the plating layer that is ground by the grinding apparatus 3 .
  • pattern 8 instructions are issued so as to control the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to increase the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the grinding apparatus control portion 93 controls the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and controls the grinding apparatus 3 so as to increase the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the adjustment portion 91 of the control unit 9 determines that the second plating thickness information is within the reference range and the grinding amount information is within the reference range, and issues instructions according to pattern 9 (S 16 in FIG. 11 ).
  • the second plating thickness information is within the reference range and the grinding amount information is within the reference range, it is known that a product defect which is based on either an insufficient final thickness of the plating layer or an appearance defect is not occurring, and in addition, that the cost is also being appropriately maintained. In this case, it suffices to maintain the operating conditions.
  • pattern 9 instructions are issued so as to control the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and so as to control the grinding apparatus 3 so as to maintain the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the plating apparatus control portion 92 controls the plating apparatus 2 so as to maintain the plating amount of the plating layer that is formed by the plating apparatus 2 , and controls the grinding apparatus 3 so as to maintain the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 .
  • the apparatus for producing a textured plated steel sheet 1 of the present embodiment produces a textured plated steel sheet 8 while using the control unit 9 to control the plating apparatus 2 so as to adjust the plating amount of the plating layer that is formed on the surface of the steel sheet 6 by the plating apparatus 2 and to control the grinding apparatus 3 so as to adjust the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 , based on the first plating thickness information and the second plating thickness information.
  • the control unit 9 to control the plating apparatus 2 so as to adjust the plating amount of the plating layer that is formed on the surface of the steel sheet 6 by the plating apparatus 2 and to control the grinding apparatus 3 so as to adjust the grinding amount of the surface of the plating layer that is ground by the grinding apparatus 3 , based on the first plating thickness information and the second plating thickness information.
  • the apparatus for producing a textured plated steel sheet 1 can also easily suppress production costs in addition to suppressing the occurrence of product defects.
  • a method for producing a textured plated steel sheet that includes the use of the control unit 9 of the present embodiment is the same as in the first embodiment except that the apparatus for producing a textured plated steel sheet that includes the control unit 9 is used.
  • control unit 9 is used in the second embodiment, a configuration may also be adopted in which, without using the control unit 9 , the grinding amount information that is information relating to the grinding amount at the grinding apparatus is determined based on the first plating thickness information and the second plating thickness information, and the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process are adjusted based on the second plating thickness information and the grinding amount information.
  • An apparatus for producing a textured plated steel sheet 1 that is used in the third embodiment is the same as in the first embodiment.
  • a method for producing a textured plated steel sheet according to the third embodiment includes a plating layer forming process, a grinding process, a plating thickness determining process, and an adjusting process.
  • the processes other than the adjusting process are the same as in the first embodiment.
  • the grinding amount information that is information relating to a grinding amount at the grinding apparatus is determined, and the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process are adjusted based on the second plating thickness information and the grinding amount information.
  • the grinding amount information is determined based on the first plating thickness and the second plating thickness.
  • the method for determining the grinding amount information is the same as in the second embodiment, except that the control unit 9 is not used.
  • the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process are adjusted based on the following patterns 1 to 9.
  • adjusting is performed so as to decrease the plating amount of the plating layer that is formed in the plating layer forming process and to decrease the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for decreasing the plating amount of the plating layer that is formed in the plating layer forming process, and the adjustment method for decreasing the grinding amount of the surface of the plating layer that is ground in the grinding process are the same as in the first embodiment.
  • adjusting is performed so as to maintain the plating amount of the plating layer that is formed in the plating layer forming process and to increase the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for increasing the grinding amount of the surface of the plating layer that is ground in the grinding process is the same as in the first embodiment.
  • adjusting is performed so as to decrease the plating amount of the plating layer that is formed in the plating layer forming process and to maintain the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for decreasing the plating amount of the plating layer that is formed in the plating layer forming process is the same as in the first embodiment.
  • adjusting is performed so as to maintain the plating amount of the plating layer that is formed in the plating layer forming process and to decrease the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for decreasing the grinding amount of the surface of the plating layer that is ground in the grinding process is the same as in the first embodiment.
  • adjusting is performed so as to increase the plating amount of the plating layer that is formed in the plating layer forming process and to increase the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for increasing the plating amount of the plating layer that is formed in the plating layer forming process, and the adjustment method for increasing the grinding amount of the surface of the plating layer that is ground in the grinding process are the same as in the first embodiment.
  • adjusting is performed so as to increase the plating amount of the plating layer that is formed in the plating layer forming process and to maintain the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for increasing the plating amount of the plating layer that is formed in the plating layer forming process is the same as in the first embodiment.
  • adjusting is performed so as to maintain the plating amount of the plating layer that is formed in the plating layer forming process and to decrease the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for decreasing the grinding amount of the surface of the plating layer that is ground in the grinding process is the same as in the first embodiment.
  • adjusting is performed so as to maintain the plating amount of the plating layer that is formed in the plating layer forming process and to increase the grinding amount of the surface of the plating layer that is ground in the grinding process.
  • the adjustment method for increasing the grinding amount of the surface of the plating layer that is ground in the grinding process is the same as in the first embodiment.
  • adjusting is performed so as to maintain the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process. Specifically, the plating conditions in the plating layer forming process and the grinding conditions in the grinding process are maintained.
  • the production cost can also be suppressed.
  • the apparatus for producing a textured plated steel sheet 1 may also include a coating film forming apparatus, in addition to the plating apparatus 2 , the grinding apparatus 3 , the first plating thickness determining apparatus 4 , and the second plating thickness determining apparatus 5 .
  • the coating film forming apparatus is arranged downstream of the grinding apparatus 3 , and forms a coating film on the surface of the plating layer that has been ground.
  • the method for producing a textured plated steel sheet includes a coating film forming process in addition to the plating layer forming process, the grinding process, the plating thickness determining process, and the adjusting process.
  • a well-known method may be used as the method for forming a coating film.
  • a coating material constituting an organic coating is prepared.
  • the prepared coating material is applied onto the plating layer by a spray method, a roll coater method, a curtain coater method, or a dip and lift method or the like. Thereafter, the coating material on the plating layer is subjected to natural drying or to baking to form an organic coating film.
  • the drying temperature, drying time, baking temperature, and baking time can be adjusted as appropriate.
  • a chemical agent for an inorganic coating film is applied onto the plating layer by a roll coater method, a dip ringer method, a spray ringer method, an electrolytic method, or the like.
  • the chemical agent applied onto the plating layer is subjected to natural drying or to baking to form an inorganic coating film.
  • the drying temperature, drying time, baking temperature, and baking time can be adjusted as appropriate.
  • the apparatus for producing a textured plated steel sheet 1 may include one or a plurality of gloss meters in addition to the plating apparatus 2 , the grinding apparatus 3 , the first plating thickness determining apparatus 4 , and the second plating thickness determining apparatus 5 .
  • Each gloss meter is arranged downstream of the grinding apparatus 3 , and evaluates the appearance of the surface of the plated steel sheet having the plating layer that has been ground.
  • the gloss meters may be two gloss meters which are a gloss meter that measures a glossiness of the surface of the plated steel sheet in the longitudinal direction of the plated steel sheet, and a gloss meter that measures a glossiness of the surface of the plated steel sheet in the sheet width direction of the plated steel sheet.
  • a gloss meter that measures a glossiness of the surface of the plated steel sheet in the longitudinal direction of the plated steel sheet
  • a gloss meter that measures a glossiness of the surface of the plated steel sheet in the sheet width direction of the plated steel sheet.
  • the method for producing a textured plated steel sheet includes an appearance evaluating process in addition to the plating layer forming process, the grinding process, the plating thickness determining process, and the adjusting process.
  • the appearance evaluating process the appearance of the plated steel sheet after the grinding process is evaluated based on a glossiness.
  • the appearance of the plated steel sheet after the grinding process is evaluated based on a glossiness.
  • the appearance of the plated steel sheet may be evaluated based on two glossinesses, namely, a glossiness of the surface of the plated steel sheet measured in the longitudinal direction of the plated steel sheet, and a glossiness of the surface of the plated steel sheet measured in the sheet width direction of the plated steel sheet.
  • the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process are adjusted based on the first plating thickness information, the second plating thickness information, and the glossiness of the surface of the plated steel sheet after the grinding process.
  • the appearance of the plated steel sheet can be evaluated with greater accuracy compared to a case of estimating the appearance based on the first plating thickness information and the second plating thickness information. Therefore, in the case of evaluating the appearance of the plated steel sheet based on a glossiness, a stricter condition can be set with respect to a standard for the appearance of the plated steel sheet. However, in this case, a situation may occur in which, even though the first plating thickness information and the second plating thickness information are each within the relevant reference range, based on the appearance evaluation of the plated steel sheet that is based on the glossiness it is determined that the texture is not sufficiently formed and an appearance defect has occurred. In this case, the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process may be adjusted.
  • the grinding amount of the plating layer that is ground in the grinding process may be increased while maintaining the plating amount of the plating layer that is formed in the plating layer forming process.
  • a method for increasing the grinding amount of the plating layer that is ground in the grinding process is the same as in the first embodiment.
  • the second plating thickness information is within the reference range, the second plating thickness information is close to the lower limit value of the reference range or the like, if it is expected that the second plating thickness information will become less than the reference range if the grinding amount of the plating layer that is ground in the grinding process is increased while maintaining the plating amount of the plating layer that is formed in the plating layer forming process, the plating amount of the plating layer that is formed in the plating layer forming process may be increased and the grinding amount of the plating layer that is ground in the grinding process may be increased.
  • a method for increasing the plating amount of the plating layer that is formed in the plating layer forming process is the same as in the first embodiment.
  • an operation table that includes plating conditions in the plating layer forming process which correspond to glossiness, and grinding conditions in the grinding process which correspond to glossiness may be created, and the plating amount of the plating layer that is formed in the plating layer forming process and the grinding amount of the surface of the plating layer that is ground in the grinding process may be adjusted based on a measured glossiness.

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US18/281,413 2021-03-19 2022-02-28 Method for producing textured plated steel sheet, and apparatus for producing textured plated steel sheet Pending US20240149394A1 (en)

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