Model-based analysis, control and dosing of electroplating electrolytes

Alexander Leiden*, Stefan Kölle, Sebastian Thiede, Klaus Schmid, Martin Metzner, Christoph Herrmann

*Corresponding author for this work

Research output: Contribution to journalArticleAcademicpeer-review

2 Citations (Scopus)
94 Downloads (Pure)


Controlling and dosing electrolytes is a key challenge in the operation of electroplating process chains. Electrolyte components are continuously degraded and dragged out during the production process. This process is influenced by a variety of internal and external factors such as process parameters, the electrolyte itself, anodes, the substrates and the production environment. The exact analytical measurement of the electrolyte composition requires extensive analytical equipment and typically cannot be completely realized within an industrial plating company. Therefore, this paper presents a model-based approach, integrated in a cyber-physical production system, for controlling and dosing electrolytes. A mathematical resource flow model is the basis for a dynamic agent-based simulation. This model uses available data from the manufacturing execution system and enterprise resource planning system to model the current composition of the electrolyte. The approach is successfully validated for two different electrolyte substances at an industrial acid zinc–nickel barrel plating process chain for automotive parts.

Original languageEnglish
Pages (from-to)1751-1766
Number of pages16
JournalInternational journal of advanced manufacturing technology
Issue number5-6
Early online date17 Oct 2020
Publication statusPublished - 1 Nov 2020
Externally publishedYes


  • Cyber-physical production systems
  • Electrolyte control
  • Electrolyte dosing
  • Electroplating
  • Simulation


Dive into the research topics of 'Model-based analysis, control and dosing of electroplating electrolytes'. Together they form a unique fingerprint.

Cite this