Plant for hot-dip galvanizing and hot-dip galvanizing process

Abstract

Plant (1) for hot-dip galvanizing components (2) with a conveying device (3) with at least one workpiece carrier (7) for the grouped conveying of a plurality of components to be attached to the workpiece carrier (7), a degreasing device (9) for degreasing the components (2), a surface treatment device, a flux application device (21) for applying flux to the surface of the components (2) and a hot-dip galvanizing device (25) for hot-dip galvanizing the components (2) with a galvanizing bath (28) containing a molten zinc-aluminium alloy, wherein a singulation device (31) is provided for feeding, immersing and extracting a component (2) separated from the workpiece carrier (7) into the galvanizing bath (28) of the hot-dip galvanizing device (27), wherein the singulation device (31) comprises at least one singulation means (32), wherein the singulation means (32) is designed such that a singulated component (2) is immersed in an immersion area of ​​the galvanizing bath (28), then moved from the immersion area to an adjacent dipping area and subsequently dipped out in the dipping area and wherein the singulation means (32) is designed to move each singulated component (2) after it has been removed from the galvanizing bath (28) by special rotary and / or steering movements in such a way as to avoid zinc drips.

Description

[0001] The present invention relates to the technical field of galvanizing iron-based or iron-containing components, in particular steel-based or steel-containing components (steel components), preferably for the automotive or motor vehicle industry, by means of hot-dip galvanizing (hot-dip galvanizing).

[0002] In particular, the present invention relates to a plant and a method for hot-dip galvanizing (immersion galvanizing) of components (i.e., iron-based or iron-containing components, in particular steel-based or steel-containing components (steel components)), especially for the large-scale hot-dip galvanizing of a large number of identical or similar components (e.g., automotive components) in discontinuous operation (so-called batch galvanizing).

[0003] Metallic components of all kinds made from ferrous materials, especially steel components, often require effective corrosion protection due to their application. In particular, steel components for motor vehicles (e.g., cars, trucks, commercial vehicles, etc.) require effective corrosion protection that can withstand long-term stress.

[0004] In this context, it is well known that steel-based components are protected against corrosion by means of galvanizing (galvanizing). During galvanizing, the steel is coated with a generally thin layer of zinc to protect it from corrosion. Various galvanizing processes can be used to galvanize steel components, i.e., to coat them with a metallic zinc coating. These include, in particular, hot-dip galvanizing (also known as hot-dip galvanizing), spray galvanizing (flame spraying with zinc wire), diffusion galvanizing (Sherard galvanizing), electroplating (electrolytic galvanizing), non-electrolytic galvanizing using zinc flake coatings, and mechanical galvanizing.There are significant differences between the aforementioned galvanizing processes, particularly with regard to the execution of the process, but also with regard to the nature and properties of the zinc layers or zinc coatings produced.

[0005] The most important method for corrosion protection of steel using metallic zinc coatings is hot-dip galvanizing. In this process, steel is continuously (e.g., strip and wire) or piecewise (e.g., components) immersed in a heated kettle of liquid zinc at temperatures of approximately 450 °C to 600 °C (melting point of zinc: 419.5 °C). This results in the formation of a resistant alloy layer of iron and zinc on the steel surface, and above that, a very firmly adhering layer of pure zinc.

[0006] Hot-dip galvanizing is divided into batch galvanizing (see, for example, DIN EN ISO 1461) and continuous coil galvanizing (DIN EN 10143 and DIN EN 10346). Both batch and coil galvanizing are standardized processes. Coil-galvanized steel is a semi-finished product that is further processed after galvanizing, particularly by forming, punching, cutting, etc. In contrast, components to be protected by batch galvanizing are first fully manufactured and only then hot-dip galvanized (thus providing all-around protection against corrosion). Batch and coil galvanizing also differ in terms of zinc coating thickness, resulting in different service lives.The zinc layer thickness of strip-galvanized sheets is usually at most 20 to 25 micrometers, whereas the zinc layer thickness of hot-dip galvanized steel parts is typically in the range of 50 to 200 micrometers and even more.

[0007] Hot-dip galvanizing provides both active and passive corrosion protection. Passive protection is achieved through the barrier effect of the zinc coating. Active corrosion protection results from the cathodic effect of the zinc coating. Compared to more noble metals in the electrochemical series, such as iron, zinc acts as a sacrificial anode, protecting the underlying iron from corrosion until it itself is completely corroded.

[0008] Hot-dip galvanizing, also known as batch galvanizing according to DIN EN ISO 1461, is the process of coating mostly larger steel components and structures. Steel blanks or finished workpieces (components) are immersed in a molten zinc bath after pretreatment. This immersion process allows for effective coating of internal surfaces, welds, and other hard-to-reach areas of the workpieces or components.

[0009] Conventional hot-dip galvanizing is based primarily on immersing iron or steel components in molten zinc, forming a zinc coating on the surface of the components. To ensure adhesion, a continuous and uniform zinc coating, careful surface preparation of the components to be galvanized is generally required beforehand. This typically includes degreasing followed by rinsing, subsequent acid pickling followed by rinsing, and finally flux treatment followed by drying.

[0010] The typical process flow for conventional hot-dip galvanizing is usually as follows. For reasons of process efficiency and cost-effectiveness, identical or similar components (e.g., in the series production of automotive parts) are typically grouped together for the entire process (especially using a common workpiece carrier, such as a crossbeam or rack, or a common holding or fastening device for a large number of these identical or similar components). For this purpose, several components are attached to the workpiece carrier using holding devices such as slings, ties, or the like. The components are then conveyed in their grouped state via the workpiece carrier to the subsequent processing steps or stages.

[0011] First, the surfaces of the grouped components undergo degreasing to remove residues of fats and oils. Aqueous alkaline or acidic degreasers are typically used for this purpose. Following cleaning in the degreasing bath, a rinsing process usually takes place, typically by immersion in a water bath. This prevents the degreasing agents from being carried over with the parts to be galvanized into the subsequent pickling process. This is particularly important when switching from alkaline to acidic degreasing.

[0012] The next step is a pickling treatment, which serves primarily to remove inherent impurities, such as rust and scale, from the steel surface. Pickling is usually carried out in diluted hydrochloric acid, with the duration of the pickling process depending, among other things, on the degree of contamination (e.g., rustiness) of the material to be galvanized, as well as the acid concentration and temperature of the pickling bath. To prevent or minimize the transfer of acid and / or salt residues to the material being galvanized, a rinsing process is typically performed after pickling.

[0013] The next step is the so-called fluxing (flux treatment), in which the previously degreased and pickled steel surface is treated with a flux, typically an aqueous solution of inorganic chlorides, most often a mixture of zinc chloride (ZnCl2) and ammonium chloride (NH4Cl). The flux serves two purposes: firstly, to perform a final, intensive cleaning of the steel surface before it reacts with the molten zinc, to dissolve the oxide layer on the zinc surface, and to prevent further oxidation of the steel surface until the galvanizing process. Secondly, the flux increases the wettability between the steel surface and the molten zinc.After flux treatment, drying is usually carried out to create a solid flux film on the steel surface and to remove adhering water, thus preventing subsequent undesirable reactions (especially the formation of water vapor) in the liquid zinc dip bath.

[0014] The components pretreated in the aforementioned manner are then hot-dip galvanized by immersion in molten zinc. In hot-dip galvanizing with pure zinc, the zinc content of the melt is at least 98.0 wt.% according to DIN EN ISO 1461. After immersion, the workpiece remains in the molten zinc bath for a sufficient period of time, in particular until it has reached the bath temperature and is coated with a zinc layer. Typically, the surface of the molten zinc is cleaned, especially of oxides, zinc ash, flux residues, and the like, before the workpiece is withdrawn from the molten zinc. The hot-dip galvanized component is then subjected to a cooling process (e.g., in air or in a water bath). Finally, any holding devices for the component, such as lifting slings, ties, or the like, are removed.Following the galvanizing process, a sometimes complex post-processing or post-treatment is usually carried out. This involves removing as much excess zinc residue as possible, especially so-called drips from the zinc solidifying at the edges, as well as oxide or ash residues adhering to the component.

[0015] One criterion for the quality of hot-dip galvanizing is the thickness of the zinc coating in µm (micrometers). The standard DIN EN ISO 1461 specifies the minimum required coating thicknesses for hot-dip galvanizing, depending on the material thickness. In practice, the coating thicknesses are significantly higher than the minimum thicknesses specified in DIN EN ISO 1461. Generally, zinc coatings produced by hot-dip galvanizing have a thickness in the range of 50 to 200 micrometers and even more.

[0016] During the galvanizing process, a coating of differently composed iron / zinc alloy layers forms on the steel part as a result of the mutual diffusion of liquid zinc with the steel surface. When the hot-dip galvanized objects are removed from the process, a layer of zinc—also known as the pure zinc layer—remains adhered to the uppermost alloy layer. This layer's composition corresponds to that of the molten zinc. Due to the high temperatures during hot-dip galvanizing, a relatively brittle layer based on an alloy (solid solution) between iron and zinc initially forms on the steel surface, followed by the pure zinc layer. While the relatively brittle iron / zinc alloy layer improves the adhesion to the base material, it makes the galvanized steel more difficult to form.Higher silicon contents in steel, such as those used for the so-called "settling" of the steel during its production, lead to increased reactivity between the zinc melt and the base material, resulting in significant growth of the iron / zinc alloy layer. This leads to the formation of relatively thick layers. While this provides a very long corrosion protection lifespan, the risk of the layer spalling under mechanical stress, especially localized, sudden impacts, increases with the thickness of the zinc layer, thus compromising its corrosion protection.

[0017] To counteract the previously described problem of the rapidly growing, brittle, and thick iron / zinc alloy layer and to enable thinner layers with simultaneously high corrosion protection during galvanizing, it is known from the prior art to add aluminum to the zinc melt or the liquid zinc bath. For example, adding 5 wt% aluminum to a liquid zinc melt produces a zinc-aluminum alloy with a lower melting point compared to pure zinc. By using a zinc / aluminum melt (Zn / Al melt) or...Hot-dip galvanizing with a liquid zinc / aluminium bath (Zn / Al bath) allows for significantly thinner layers for reliable corrosion protection (generally below 50 micrometers). Furthermore, the formation of the brittle iron / tin alloy layer is prevented because the aluminum—without adhering to a specific theory—initially forms a barrier layer on the steel surface of the component, onto which the actual zinc layer is then deposited. Components hot-dip galvanized with a zinc / aluminium melt can therefore be easily formed, yet still exhibit improved corrosion protection properties despite the significantly thinner layer compared to conventional hot-dip galvanizing with a virtually aluminum-free zinc melt. A zinc-aluminum alloy used in the hot-dip galvanizing bath also exhibits improved fluidity properties compared to pure zinc.Furthermore, zinc coatings produced by hot-dip galvanizing using such zinc-aluminum alloys exhibit greater corrosion resistance (two to six times better than that of pure zinc), improved formability, and better paintability than zinc coatings made from pure zinc. Moreover, this technology also allows for the production of lead-free zinc coatings.

[0018] Such a hot-dip galvanizing process using a zinc / aluminium melt or a zinc / aluminium hot-dip galvanizing bath is known, for example, from WO 2002 / 042 512 A1 and the relevant publication equivalents to this patent family (e.g., EP 1 352 100 B1, DE 601 24 767 T2 and US 2003 / 0 219 543 A1). Suitable fluxes for hot-dip galvanizing using zinc / aluminium melt baths are also disclosed therein, since flux compositions for zinc / aluminium hot-dip galvanizing baths differ from those for conventional hot-dip galvanizing with pure zinc. The process disclosed therein enables the production of corrosion protection coatings with very low layer thicknesses (generally well below 50 micrometers and typically in the range of 2 to 20 micrometers) and with very low weight at high cost efficiency, which is why the process described therein is commercially available under the name microZINQ. ®-Procedure is applied.

[0019] In hot-dip galvanizing of components in zinc / aluminium molten baths, a problem arises, particularly in the high-volume hot-dip galvanizing of numerous identical or similar components (e.g., high-volume hot-dip galvanizing of automotive components or in the automotive industry). This is due to the more difficult wettability of the steel with the zinc / aluminium molten metal and the thinness of the zinc coatings. The challenge lies in subjecting identical or similar components to identical process conditions and processes in an economical manner, and in reliably and reproducibly achieving high-precision hot-dip galvanizing that delivers identical dimensional accuracy for all identical or similar components.In the state of the art, this is achieved – in addition to elaborate pretreatment, in particular by selecting special fluxes – typically through special process control during the galvanizing process, such as extended immersion times of the components in the zinc / aluminium melt, since only in this way can it be ensured that no defects occur in the relatively thin zinc coatings or that no areas are not coated or are incompletely coated.

[0020] In order to make the process flow of the known hot-dip galvanizing of identical or similar components, especially in large-scale hot-dip galvanizing, economical and to ensure an identical process flow, the prior art involves grouping a large number of the identical or similar components to be galvanized, e.g. on a common carrier or the like, and passing them through the individual process stages, and especially the galvanizing bath, in their grouped state.

[0021] However, the well-known hot-dip galvanizing process has several disadvantages. With multiple layers of parts on the workpiece carrier, and especially with the same immersion and withdrawal movements of the carrier, the components or component sections inevitably remain in the molten zinc for different lengths of time. This results in varying reaction times between the component material and the molten zinc, and consequently, different zinc layer thicknesses on the components. Furthermore, for components sensitive to high temperatures, particularly those made of high-strength and ultra-high-strength steels, such as spring steels, chassis and body components, and press-hardened formed parts, these varying residence times in the molten zinc affect the steel's mechanical properties. To ensure defined component properties, adherence to specific process parameters for each individual component is essential.

[0022] Furthermore, when components are removed from the molten zinc, zinc inevitably flows off and drips from the component edges and corners. This creates zinc drips on the component. Removing these drips afterward, which is usually done manually, represents a significant cost factor, especially when galvanizing large quantities and / or meeting stringent tolerance requirements. With a fully loaded workpiece carrier, it is generally impossible to reach all components and individually remove the zinc drips directly at the galvanizing point. Typically, the galvanized components must be removed from the workpiece carrier after galvanizing and individually inspected and reworked manually, which is very time-consuming.

[0023] Furthermore, in the conventional hot-dip galvanizing process, the immersion and removal of the workpiece carrier in and out of the galvanizing bath occurs at the same point. Due to the process-related formation of zinc ash as a reaction product of the flux and the molten zinc after immersion, which accumulates on the surface of the zinc bath, it is essential to remove the zinc ash from the surface by scraping or rinsing before immersion. This prevents the ash from adhering to the galvanized components during removal and thus minimizes contamination. Given the large number of components in the zinc bath and the relatively poor accessibility of the bath surface, removing the zinc ash from the bath surface is regularly a very time-consuming and sometimes problematic process.Firstly, removing the zinc ash from the surface of the galvanizing bath results in a delay in the process while simultaneously reducing productivity, and secondly, it creates a source of error with regard to the galvanizing quality of the individual components.

[0024] German patent application DE 20 14 600 A describes a device for producing a metal coating on an elongated metal object using a hot-dip process, particularly for hot-dip galvanizing pipes. A dipping device receives the metal objects and introduces them individually into the zinc bath. The individual metal objects or pipes can be guided over the metal bath by a roller and then transferred from the rollers into dipping forks, which are part of a metering device and serve to transfer the objects to the dipping device. The dipping forks are lowered and immerse the individual metal object or pipe into the zinc bath.

[0025] The metal object or pipe is then transferred to a withdrawal device after a defined dwell time in the galvanizing bath.

[0026] German patent application DE 195 37 664 A1 relates to a workpiece carrier for a transport and / or coating system, the design of which allows several workpiece carriers to be transported as a single block. The patent describes a possible singulation of several workpiece carriers for a coating process and a subsequent re-assembly of the individual coated workpiece carriers into a single block. An enamelling process using electrophoresis is given as an example of a coating process, whereby the treatment process in the electric field requires the singulation of the workpiece carriers.

[0027] US Patent 3,639,142 A discloses a method for hot-dip galvanizing elongated steel components. For this purpose, the components are fed to various pretreatment units, such as pickling and fluxing, before being conveyed via a belt conveyor to a preheating furnace. The components are conveyed in groups, in this case in groups of three. After passing through the preheating furnace, the grouped components are lifted from the conveyor belt by a hook, which is height-adjustable and mounted on a guide rail. Subsequently, the components to be galvanized are fed into the galvanizing bath, such that the hook lowers, the components are immersed in the galvanizing bath, and the hook then rises again.Following this, the now galvanized components – still in their grouped state – are fed to a conveyor belt, which then feeds the components into a quenching tank.

[0028] International patent application WO 95 / 04607 A1 relates to a method and apparatus for hot-dip galvanizing steel components, in particular steel pipes. The components are grouped in a system with a trolley, conveyed through devices and process steps for pretreatment, and subsequently passed through a zinc-aluminum bath.

[0029] US Patent 3,978,816 A relates to a device and an automatic method for conveying elongated objects into and out of a hot-dip galvanizing kettle or the like, comprising a screw feed conveying system that continuously maintains control over the elongated objects during feeding and removal at a uniform, predetermined speed. The screw feed conveying system includes at least two generally U-shaped screws rotated about their axes to feed the elongated objects, which are placed horizontally on opposite diametrically opposed sides of the screws, through the galvanizing kettle, the screws optionally having turns with selectively varying pitches to incline the objects for entry into and removal from the kettle.

[0030] Ultimately, with conventional hot-dip galvanizing, impurities and zinc drips remain on the galvanized components, requiring manual rework. This rework is regularly very costly and time-consuming. It's important to note that rework here refers not only to cleaning and repairs, but also, and especially, to visual inspection. Due to the nature of the process, all components are at risk of developing impurities or zinc drips that must be removed. Therefore, each component must be inspected individually. This inspection alone, without considering any subsequent necessary work steps, represents a very high cost, particularly in high-volume production with numerous components to inspect and stringent quality requirements.

[0031] The problem underlying the present invention therefore consists in providing a system or a method for the batch galvanizing of iron-based or iron-containing components, in particular steel-based or steel-containing components (steel components) by means of hot-dip galvanizing (hot-dip galvanizing) in a zinc / aluminium melt (i.e. in a liquid zinc / aluminium bath), preferably for the large-scale hot-dip galvanizing of a large number of identical or similar components (e.g. automotive components), wherein the disadvantages of the prior art described above are to be at least largely avoided or at least mitigated.

[0032] In particular, such a plant or process should be provided which, compared to conventional hot-dip galvanizing plants or processes, enables improved process economy and a more efficient, especially more flexible, process flow.

[0033] To solve the problem described above, the present invention proposes – according to a first aspect of the present invention – a hot-dip galvanizing plant according to claim 1; further, in particular special and / or advantageous embodiments of the plant according to the invention are the subject of the relevant dependent plant claims.

[0034] Furthermore, according to a second aspect of the present invention, the present invention relates to a method for hot-dip galvanizing according to the independent method claim above; further, in particular special and / or advantageous embodiments of the method according to the invention are the subject of the corresponding dependent method claims.

[0035] It goes without saying that the following explanations state that embodiments, designs, advantages and the like, which are described below for the purpose of avoiding repetition only with regard to one aspect of the invention, naturally also apply to the other aspects of the invention without the need for separate mention.

[0036] With regard to all the relative or percentage weight-related specifications mentioned below, in particular relative quantity or weight specifications, it should also be noted that, within the scope of the present invention, these must be selected by the person skilled in the art in such a way that, in sum, including all components or ingredients, in particular as defined below, they always add up to 100% or 100% by weight; however, this is self-evident to the person skilled in the art.

[0037] Furthermore, it should be noted that the person skilled in the art may, if necessary, deviate from the scope specifications listed below, depending on the application or the specific circumstances, without leaving the scope of the present invention.

[0038] Furthermore, it should be noted that all values ​​or parameters mentioned below, or the like, can generally be determined using standardized or explicitly specified determination methods, or alternatively, using determination or measurement methods that are generally familiar to those skilled in the field.

[0039] Having said that, the present invention will now be explained in detail below.

[0040] The invention relates to a plant for hot-dip galvanizing orHot-dip galvanizing of components, preferably for the mass production of a large number of identical or similar components, particularly in discontinuous operation, preferably for batch galvanizing, with a conveying device with at least one workpiece carrier for the grouped conveying of a plurality of components to be attached to the workpiece carrier, a possibly decentralized degreasing device for degreasing the components, a surface treatment device, in particular pickling device, preferably for chemical, in particular wet-chemical and / or mechanical surface treatment of the components, preferably for pickling the surfaces of the components, a flux application device for applying flux to the surface of the components and a hot-dip galvanizing device for hot-dip galvanizing the components with a galvanizing bath containing a molten zinc-aluminium alloy.

[0041] According to the invention, in a system of the aforementioned type, a singulation device is provided for the preferably automated feeding, immersion and removal of a component separated from the workpiece carrier into the galvanizing bath of the hot-dip galvanizing system to solve the underlying problem. wherein the singulation device comprises at least one singulation means, wherein the singulation device is designed such that a singulated component is immersed in an immersion area of ​​the galvanizing bath, then moved from the immersion area to an adjacent dipping area and subsequently dipped out in the dipping area and wherein the singulation device is designed in such a way as to move each singulated component after it has been removed from the galvanizing bath by special rotary and / or steering movements in such a way as to avoid zinc drips.

[0042] The invention relates to a method for hot-dip galvanizing or hot-dip galvanizing of components using a molten zinc-aluminum alloy, preferably for the mass production of a large number of identical or similar components, particularly in batch operation, and preferably for batch galvanizing. It is provided that the components are attached to a carrier for grouped conveying before hot-dip galvanizing. Subsequently, the components undergo a surface treatment, preferably a chemical, especially wet-chemical, and / or mechanical surface treatment, in particular pickling. The components are then coated with a flux on their surface and subsequently hot-dip galvanized in a galvanizing bath containing a molten zinc-aluminum alloy.

[0043] According to the invention, the aforementioned method provides that, during hot-dip galvanizing, the components are fed from the workpiece carrier separately and / or in the separated state, preferably automatically, into the galvanizing bath, immersed therein and subsequently removed from it. wherein a single component is immersed in an immersion area of ​​the galvanizing bath, then moved from the immersion area to an adjacent exchange area and subsequently dipped out in the exchange area and During singulation, each component is moved by special rotary and steering movements when being pulled out of the exchange area in such a way that drips of the liquid zinc-aluminum alloy are avoided.

[0044] As a result, the invention differs from the prior art in that the components are separated from their originally grouped state and, in their separated state, fed into the zinc-aluminum alloy galvanizing bath. This measure, which at first glance appears uneconomical and process-delaying, has surprisingly proven to be particularly advantageous, especially with regard to the production of high-precision hot-dip galvanized components.

[0045] With regard to economic aspects, the solution according to the invention was initially rejected, since in the prior art batch galvanizing process, depending on the size and weight, several hundred components are sometimes attached to a workpiece carrier and galvanized simultaneously. Singulating the components from the workpiece carrier before galvanizing and galvanizing them in their separated state thus significantly increases the duration of the actual galvanizing process.

[0046] In connection with the invention, it has been recognized that, particularly with certain components, such as high-strength and ultra-high-strength steels, which are temperature-sensitive, targeted and optimized handling of the components during the actual galvanizing process is necessary. With individual galvanizing using the system or method according to the invention, it can readily be ensured that each component is subject to identical process parameters. This is particularly important for spring steels or chassis and body components made of high-strength and ultra-high-strength steels, such as press-hardened formed parts. By separating the components for galvanizing, it is possible to ensure that the reaction times between the steel and the molten zinc are always the same. This ultimately results in a consistently uniform zinc layer thickness.Furthermore, the characteristic values ​​of the components are affected in an identical way by the galvanizing, since the invention ensures that the components have each been exposed to identical process parameters.

[0047] A further significant advantage of the invention arises from the fact that, during the singulation process according to the invention, each component can be precisely manipulated and treated by means of specific rotational and steering movements of the component as it is withdrawn from the molten metal. This significantly reduces the need for post-processing, in some cases eliminating it entirely. Furthermore, the invention offers the possibility of significantly reducing and, in some cases, even preventing zinc ash adhesion. This is possible because the process according to the invention is controlled such that, in the singulated state, a component to be galvanized is moved away from the immersion point after dipping and towards a point further away from the immersion point. Subsequently, it is withdrawn. While zinc ash rises to the surface in the area of ​​the immersion point, there are few or no zinc ash residues at the withdrawal point.This special technique can significantly reduce or even eliminate zinc ash deposits.

[0048] In connection with the present invention, it has been found that, taking into account the fact that some post-processing is no longer necessary with the invention, the overall production time for the manufacture of galvanized components can even be reduced compared to the prior art, meaning that the invention ultimately delivers higher productivity, particularly because the manual post-processing is very time-consuming in the prior art.

[0049] Another advantage of single-stage galvanizing is that only a narrow galvanizing kettle is required, rather than a wide and deep one. This reduces the surface area of ​​the galvanizing bath, which can then be better shielded, thus significantly reducing heat loss.

[0050] As a result of the invention, with its selective galvanizing process, components are produced with higher quality and surface cleanliness, whereby the components themselves are subjected to identical process conditions and thus possess the same component characteristics. From an economic perspective, the invention also offers advantages over the prior art, as the production time can be reduced by up to 20%, taking into account the elimination or significant reduction of post-processing.

[0051] In the invention, it is possible that, after the initial grouping of the components on or via the workpiece carrier, singulation takes place after surface treatment or flux application. According to the device, singulation of the components from the workpiece carrier via the singulation device is then provided following degreasing or surface treatment, in particular pickling, or following flux application. Cost-benefit tests have shown that it is most advantageous for the components to be singulated from the workpiece carrier after flux application, i.e., the singulation device is located between the hot-dip galvanizing unit and the flux application unit.In this embodiment of the invention, degreasing, surface treatment and flux application take place in the grouped state of the components, while only galvanizing is carried out in the individual state.

[0052] In a preferred embodiment of the invention, the singulation device comprises at least one singulation element arranged between the flux application device and the hot-dip galvanizing device. This singulation element is preferably designed to remove one component from the group of components and then feed it to the hot-dip galvanizing device for hot-dip galvanizing. The singulation element can either take the component directly from the workpiece carrier or remove it from the group of components that has already been placed on the workpiece carrier. It is understood that it is also possible, in principle, to have more than one singulation element, thus allowing a plurality of singulated components to be hot-dip galvanized simultaneously in their singulated state.In this context, it is understood that at least the galvanizing process of the individual components is carried out in an identical manner, even if components from different singulation devices are passed through the hot-dip galvanizing device or the galvanizing bath simultaneously or at different times and independently of each other.

[0053] In an alternative embodiment of the inventive system and the associated method, the singulation device is designed to remove one component from the group of components, but does not directly feed the removed component to the galvanizing process. The singulation device can, for example, transfer the component removed from the group of components to a conveyor system belonging to the singulation device, such as a workpiece carrier or a monorail, via which the singulated component is then galvanized in its singulated state.Ultimately, in this embodiment, the singulation device is provided to have at least two singulation means, namely a first singulation means that singulates the components from the group of components, and at least a second singulation means, for example in the form of a conveyor system, which then guides the singulated component through the galvanizing bath.

[0054] According to the invention, the singulation device is designed such that a singulated component is immersed in an immersion area of ​​the bath, then moved from the immersion area to an adjacent expulsion area, and subsequently re-immersed in the expulsion area. As previously explained, zinc ash forms on the surface of the immersion area as a reaction product of the flux with the molten zinc. Due to the movement of the component immersed in the molten zinc from the immersion area to the expulsion area, there is little or no zinc ash on the surface of the expulsion area. In this way, the surface of the re-immersed galvanized component remains free, or at least substantially free, of zinc ash deposits. It is understood that the immersion area is adjacent to the expulsion area; that is, they are spatially separated and, in particular, do not overlap areas of the galvanizing bath.

[0055] In a preferred embodiment of the aforementioned invention, it is further provided that the component remains in the immersion zone of the galvanizing bath after immersion at least until the reaction time between the component surface and the zinc-aluminum alloy of the galvanizing bath is complete. This ensures that the zinc ash, which rises within the melt, spreads only on the surface of the immersion zone. The component can then be moved to the recovery zone, which is essentially free of zinc ash, and dipped there.

[0056] In tests conducted in connection with the invention, it has been found that it is advantageous for the component to remain in the immersion zone for 20% to 80%, preferably at least 50%, of the galvanizing time before being moved to the removal zone. From a plant engineering perspective, this means that the singulation device or the associated singulation means are designed and, if necessary, coordinated by a suitable control system so that the aforementioned process sequence can be carried out without problems.

[0057] Particularly with components made of temperature-sensitive steels and with customer-specific requirements for components with as identical product properties as possible, the plant and process design ensures that the singulation device is configured so that all components separated from the workpiece carrier are guided through the galvanizing bath in an identical manner, specifically with identical movement, in identical arrangement, and / or for the same duration. This can ultimately be achieved without difficulty through appropriate control of the singulation unit or the at least one associated singulation device. Due to this identical handling, identical components—that is, components made of the same material and with the same shape—have identical product properties.This includes not only identical zinc layer thicknesses, but also identical characteristic values ​​of the galvanized components, since these were each passed through the galvanizing bath in the same way.

[0058] Furthermore, the invention, as designed in the system and process, offers the advantage of easier prevention of zinc drips through singulation. For this purpose, a scraper is provided downstream of the exchange area. In a preferred embodiment of this invention, the singulation device is designed such that all components separated from the workpiece carrier are guided past the scraper in an identical manner after dipping to remove any liquid zinc. In an alternative embodiment, which can also be implemented in combination with the scraper, all components separated from the workpiece carrier are moved in an identical manner after dipping to remove drips of liquid zinc, in particular by allowing them to drip off and / or be evenly distributed on the component surfaces.The invention makes it possible, as a result, to guide each individual component not only through the galvanizing bath, but also either in a specific positioning, for example an inclined position of the component, and to move it past one or more scrapers, whereby it is provided according to the invention that the component is moved by special rotational and / or steering movements after immersion in such a way that zinc drips are avoided.

[0059] Furthermore, the system according to the invention preferably has a plurality of rinsing devices, optionally with several rinsing stages. A rinsing device is preferably provided downstream of the degreasing device and / or downstream of the surface treatment device. The individual rinsing devices ultimately ensure that the degreasing agents used in the degreasing device or the surface treatment agents used in the surface treatment device are not carried into the next process stage.

[0060] Furthermore, the system according to the invention preferably includes a drying device downstream of the flux application device, so that the flux is dried after being applied to the surface of the components. This prevents any liquid from the flux solution from entering the galvanizing bath.

[0061] In a preferred embodiment of the invention, a cooling device, in particular a quenching device, is provided following the hot-dip galvanizing device, in which the component is cooled or quenched after hot-dip galvanizing.

[0062] Furthermore, a post-treatment unit can be provided, particularly downstream of the cooling unit. This post-treatment unit serves, in particular, for passivation, sealing, or coloring of the galvanized components. The post-treatment stage can also include, for example, rework, especially the removal of contaminants and / or zinc drips. As previously explained, the post-treatment step in the invention is significantly reduced and, in some cases, even unnecessary compared to methods known in the prior art.

[0063] Furthermore, the invention relates to a system and / or a method of the aforementioned type, wherein the components are iron-based and / or iron-containing components, in particular steel-based and / or steel-containing components, so-called steel components, preferably automotive components or components for the automotive sector. Alternatively or additionally, the galvanizing bath contains zinc and aluminum in a zinc / aluminum weight ratio in the range of 55-99.999:0.001-45, preferably 55-99.97:0.03-45, in particular 60-98:2-40, preferably 70-96:4-30. Alternatively or additionally, the galvanizing bath has the following composition, in which the weight specifications refer to the galvanizing bath and the sum of all components of the composition results in 100 wt.%: (i) Zinc, in particular in amounts in the range of 55 to 99.999 wt.%, preferably 60 to 98 wt.%, (ii) Aluminium, in particular in amounts from 0.001 wt.%, preferably from 0.005 wt.%, more preferably in the range of 0.03 to 45 wt.%, more preferably between 0.1 to 45 wt.%, (iii) optionally silicon, in particular in amounts in the range of 0.0001 to 5 wt.%, preferably 0.001 to 2 wt.%; (iv) optionally at least one further ingredient and / or optionally at least one impurity, in particular from the group of alkali metals such as sodium and / or potassium, alkaline earth metals such as calcium and / or magnesium and / or heavy metals such as cadmium, lead, antimony, bismuth, in particular in total amounts in the range of 0.0001 to 10 wt.%, preferably 0.001 to 5 wt.%.

[0064] In connection with the tests carried out, it has been found that very thin and very homogeneous coatings can be achieved on the component using zinc baths with the previously specified composition, which in particular meet the high requirements for component quality in automotive engineering.

[0065] Alternatively or additionally, a flux for the flux application device has the following composition, where the weight specifications refer to the flux and the sum of all components of the composition results in 100 wt.%: (i) Zinc chloride (ZnCl2), in particular in amounts in the range of 50 to 95 wt.%, preferably 58 to 80 wt.%; (ii) Ammonium chloride (NH4Cl), in particular in amounts in the range of 5 to 50 wt.%, preferably 7 to 42 wt.%; (iii) optionally at least one alkali and / or alkaline earth salt, preferably sodium chloride and / or potassium chloride, in particular in total amounts in the range of 1 to 30 wt.%, preferably 2 to 20 wt.%; (iv) optionally at least one metal chloride, preferably a heavy metal chloride, preferably selected from the group consisting of nickel chloride (NiCl2), manganese chloride (MnCl2), lead chloride (PbCl2), cobalt chloride (CoCl2), tin chloride (SnCl2), antimony chloride (SbCl3) and / or bismuth chloride (BiCl3), in particular in total amounts in the range of 0.0001 to 20 wt.%, preferably 0.001 to 10 wt.%; (v) optionally at least one further additive, preferably a wetting agent and / or surfactant, in particular in amounts in the range of 0.001 to 10 wt.%, preferably 0.01 to 5 wt.%.

[0066] Alternatively or additionally, it is provided that the flux application device, in particular the flux bath of the flux application device, contains the flux in a preferably aqueous solution, in particular in quantities and / or concentrations of the flux in the range of 200 to 700 g / l, in particular 350 to 550 g / l, preferably 500 to 550 g / l, and / or that the flux is used as a preferably aqueous solution, in particular with quantities and / or concentrations of the flux in the range of 200 to 700 g / l, in particular 350 to 550 g / l, preferably 500 to 550 g / l.

[0067] Tests with a flux of the aforementioned composition and / or concentration, particularly in combination with the previously described zinc-aluminum alloy, have shown that very thin layers, especially less than 20 µm, can be achieved, resulting in lower weight and reduced costs. These are essential criteria, especially in the automotive sector.

[0068] Further features, advantages, and applications of the present invention will become apparent from the following description of exemplary embodiments with reference to the drawing and the drawing itself. All features described and / or illustrated, individually or in any combination, constitute the subject matter of the present invention, irrespective of their compilation in the claims or their cross-reference.

[0069] It shows: Fig. 1 a schematic sequence of the individual stages of the method according to the invention, Fig. 2 a schematic representation of a system according to the invention and of the process of the method according to the invention in one process step, Fig. 3 a schematic representation of a system according to the invention and of the process according to the invention in a further process step and Fig. 4 a schematic representation of a system according to the invention and of the process according to the invention in a further process step.

[0070] In Fig. Figure 1 schematically illustrates a process of the inventive method in an inventive system 1. It should be noted that the flowchart shown represents one possible method according to the invention; individual process steps may be omitted or implemented in a different sequence than shown and described below. Additional process steps may also be included. Furthermore, it is not necessary for all process stages to be located in a single, spatially integrated system 1. Decentralized implementation of individual process stages is also possible.

[0071] In the Fig. In the flowchart shown in Figure 1, stage A represents the delivery and placement of components 2 to be galvanized at a connection point. In this example, the components 2 have already undergone mechanical surface treatment, in particular sandblasting. This is optional.

[0072] In stage B, the components 2 are connected to a workpiece carrier 7 of a conveyor system 3 to form a group of components 2. In some cases, the components 2 are also connected to each other and thus only indirectly to the workpiece carrier 7. It is also possible that the workpiece carrier 7 has a basket, a rack, or the like, into which the components 2 are placed.

[0073] In stage C, the components 2 are degreased. Alkaline or acidic degreasing agents 11 are used to remove residues of fats and oils from the components 2.

[0074] In stage D, the degreased components 2 are rinsed, particularly with water. This rinses off any remaining degreasing agent 11 from the components 2.

[0075] In procedure E, the surfaces of components 2 are pickled, i.e., a wet-chemical surface treatment is performed. Pickling is usually carried out in diluted hydrochloric acid.

[0076] Stage E is followed by stage F, which again involves rinsing, particularly with water, to prevent the pickling agent from being carried over into the subsequent process stages.

[0077] The appropriately cleaned and pickled components 2, to be galvanized, are then fluxed, i.e., subjected to a flux treatment, still grouped together on the workpiece carrier 7. In this case, the flux treatment in stage H also takes place in an aqueous flux solution. After a sufficient residence time in the flux 23, the workpiece carrier 7 with the components 2 is subjected to drying in stage I to create a solid flux film on the surface of the components 2 and to remove any adhering water.

[0078] In process step J, the components 2, previously grouped together, are separated, i.e., removed from the group, and then processed further in their separated state. This separation can be achieved by either removing the components 2 individually from the carrier 7 or by first placing the group of components 2 on the carrier 7 and then removing the components 2 individually from the group.

[0079] After singulation in step J, the components 2 are now hot-dip galvanized in stage K. For this purpose, the components 2 are each individually immersed in a galvanizing bath 28 and re-immersed after a specified dwell time.

[0080] Following the galvanizing process step K, the still liquid zinc is drained off in stage L. This draining is achieved, if necessary, by moving the galvanized component 2 along one or more wipers of a wiper device, but at least by predetermined pivoting and rotating movements of the component 2, which either causes the zinc to drain off or results in a uniform distribution of the zinc on the component surface.

[0081] The galvanized component is then quenched in step M.

[0082] The quenching process in step M is followed by a post-treatment in stage N, which may involve, for example, passivation, sealing, or the application of an organic or inorganic coating to the galvanized component 2. This post-treatment also includes any necessary reworking of component 2.

[0083] In the Fig. 2, Fig. 3 to Fig. Figure 4 is an embodiment of a system 1 according to the invention, shown schematically.

[0084] In the Fig. 2, Fig. 3 to Fig. Figure 4 shows a schematic representation of an embodiment of a system 1 according to the invention for hot-dip galvanizing of components 2. The system 1 is designed for hot-dip galvanizing a large number of identical components 2 in batch operation, the so-called unit galvanizing. In particular, the system 1 is designed and suitable for hot-dip galvanizing of components 2 in large series. Large series galvanizing refers to a galvanizing process in which more than 100, in particular more than 1,000, and preferably more than 10,000 identical components 2 are galvanized successively without any components 2 of a different shape and size being galvanized in between.

[0085] The system 1 includes a conveying device 3 for conveying or simultaneously transporting a number of components 2 grouped together. In this case, the conveying device 3 is a crane track with a rail guide 4, along which a trolley 5 with a lifting mechanism can travel. A load carrier 7 is connected to the trolley 5 via a lifting cable 6. The load carrier 7 serves to hold and secure the components 2. The components 2 are typically connected to the load carrier 7 at a connection point 8 of the system, where the components 2 are grouped for connection to the load carrier 7.

[0086] A degreasing unit 9 is connected to the connection point 8. The degreasing unit 9 has a degreasing tank 10 containing a degreasing agent 11. The degreasing agent 11 can be acidic or basic. A rinsing unit 12 is connected to the degreasing unit 9. This rinsing unit has a rinsing tank 13 containing a rinsing agent 14. In this case, the rinsing agent 14 is water. Downstream of the rinsing unit 12, i.e., in the direction of the process, is a surface treatment unit designed as a pickling unit 15 for the wet-chemical surface treatment of the components 2. The pickling unit 15 has a pickling tank 16 containing a pickling agent 17. In this case, the pickling agent 17 is dilute hydrochloric acid.

[0087] Following the pickling unit 15, a rinsing unit 18 with a sink 19 and rinsing agent 20 contained therein is provided. The rinsing agent 20 is again water.

[0088] Downstream of the rinsing device 18 in the direction of the process, a flux application device 21 is located, comprising a flux reservoir 22 and flux 23. In a preferred embodiment, the flux contains zinc chloride (ZnCl₂) in an amount of 58 to 80 wt.% and ammonium chloride (NH₄Cl) in an amount of 7 to 42 wt.%. Furthermore, small amounts of alkali and / or alkaline earth salts, and optionally a further reduced amount of a heavy metal chloride, are provided. A wetting agent is also optionally provided in small amounts. It is understood that the aforementioned weight specifications refer to the flux 23 and represent 100 wt.% of the total composition. The flux 23 is present in aqueous solution at a concentration in the range of 500 to 550 g / l.

[0089] It should be noted that the aforementioned facilities 9, 12, 15, 18, and 21 can each, in principle, have multiple pools. These individual pools, as well as the pools described previously, are arranged in a cascade-like sequence.

[0090] A drying device 24 is connected to the flux application device 21 in order to remove adhering water from the flux film located on the surface of the components 2.

[0091] Furthermore, Annex 1 includes a hot-dip galvanizing unit 25 in which the components 2 are hot-dip galvanized. The hot-dip galvanizing unit 25 has a galvanizing bath 26, optionally with an enclosure 27 at the top. The galvanizing bath 26 contains a galvanizing bath 28, which contains a zinc-aluminum alloy. Specifically, the galvanizing bath 28 contains 60 to 98 wt.% zinc and 2 to 40 wt.% aluminum. Furthermore, small amounts of silicon and, optionally in further reduced proportions, small amounts of alkali and / or alkaline earth metals as well as heavy metals are included. It is understood that the aforementioned weight specifications refer to the galvanizing bath 28 and that the total composition of all components amounts to 100 wt.%.

[0092] Downstream of the hot-dip galvanizing unit 25, a cooling unit 29 is located, which is intended for quenching the components 2 after hot-dip galvanizing. Finally, downstream of the cooling unit 29, a post-treatment unit 30 is provided, in which the hot-dip galvanized components 2 can be post-treated and / or reworked.

[0093] Between the drying unit 24 and the hot-dip galvanizing unit 25 is a singulation unit 31, which is designed for the automated feeding, immersion, and removal of a component 2 separated from the workpiece carrier 7 into the galvanizing bath 28 of the hot-dip galvanizing unit 25. In the illustrated embodiment, the singulation unit 31 has a singulation means 32, which is designed for handling the components 2, namely for removing a component 2 from the group of components 2 or for removing the grouped components 2 from the workpiece carrier 7, as well as for feeding, immersing, and removing the separated component 2 into the galvanizing bath 28.

[0094] For singulation, a transfer point 33 is located between the singulation device 32 and the drying unit 24, where the components 2 are either deposited or, in particular, removed from the workpiece carrier 7 and thus from the group, or singulated. For this purpose, the singulation device 32 is preferably designed such that it is movable towards and away from the transfer point 33 and / or towards and away from the galvanizing unit 25.

[0095] Furthermore, the singulation device 32 is designed such that it moves a component 2, which has been individually immersed in the galvanizing bath 28, from the immersion area to an adjacent dipping area and then emerges in the dipping area. The immersion area and the dipping area are spaced apart from each other and therefore do not correspond to each other. In particular, the two areas do not overlap. The movement from the immersion area to the dipping area only occurs after a predetermined time period has elapsed, namely after the reaction time of the flux 23 with the surface of the respective components 2 to be galvanized has been completed.

[0096] Furthermore, the singulation device 31 centrally and / or the singulation means 32 locally has a control device according to which the movement of the singulation means 32 is carried out in such a way that all components 2 singulated by the workpiece carrier 7 are guided through the galvanizing bath 28 with identical movement, in identical arrangement and with identical time.

[0097] Not shown is a scraper of a scraping device (not shown) located above the galvanizing bath 28 and still within the housing 27, which is designed to remove liquid zinc. Furthermore, according to the invention, the singulation means 32 can also be controlled via the associated control device such that an already galvanized component 2 is moved within the housing 27 by corresponding rotary movements in such a way that excess zinc drips off and / or, alternatively, is evenly distributed on the component surface.

[0098] In the Fig. 2, Fig. 3 to Fig. Figure 4 shows different states during the operation of plant 1. Fig. Figure 2 shows a state in which a plurality of components 2 to be galvanized are placed at the connection point 8. The workpiece carrier 7 is located above the group of components 2. After lowering the workpiece carrier 7, the components 2 are attached to it. In the illustrated embodiment, the components 2 are arranged in layers. Each component 2 can be connected to the workpiece carrier 7. However, it is also possible that only the upper layer of components 2 is connected to the workpiece carrier 7, while the next layer is connected to the layer above it. It is also possible for the group of components 2 to be arranged in a basket-like frame or the like.

[0099] In Fig. 3 The group of components 2 is located above the pickling unit 15. Stages C and D, namely degreasing and rinsing, have already been carried out.

[0100] In Fig. 4. The group of components 2 has been deposited at transfer point 33. The trolley 5 is on its way back to connection point 8, where components 2 to be re-galvanized are already located as a group. From the group of components 2 deposited at transfer point 33, one component 2 has already been removed via the singulation device 32 and is about to be fed into the hot-dip galvanizing unit 25. Reference symbol list: 1 Annex 2 components 3 Funding facility 4 rail guide 5 trolley 6 hoist rope 7 merchandise carriers 8 Connection point 9 Degreasing device 10 degreasing basins 11 Degreasing agents 12 Flushing device 13 sinks 14 dishwashing liquids 15 Pickling equipment 16 pickling tanks 17 pickling agents 18 Flushing device 19 sinks 20 dishwashing liquids 21 Flux application device 22 flux basins 23 fluxes 24 drying equipment 25 Hot-dip galvanizing equipment 26 galvanizing tanks 27 Enclosure 28 Galvanizing bath 29 Cooling device 30 Aftercare facility 31. Single-person control device 32 singulation devices 33 Handover point

Claims

Plant (1) for hot-dip galvanizing components (2) comprising a conveying device (3) with at least one workpiece carrier (7) for the grouped conveying of a plurality of components to be attached to the workpiece carrier (7), a degreasing device (9) for degreasing the components (2), a surface treatment device, a flux application device (21) for applying flux to the surface of the components (2), and a hot-dip galvanizing device (25) for hot-dip galvanizing the components (2) with a galvanizing bath (28) containing a molten zinc-aluminium alloy, wherein a singulation device (31) is provided for feeding, immersing, and removing a component (2) separated from the workpiece carrier (7) into the galvanizing bath (28) of the hot-dip galvanizing device (27), wherein the singulation device (31) comprises at least one singulation means (32), wherein the singulation means (32) is designed such that is,that a singulated component (2) is immersed in an immersion area of ​​the galvanizing bath (28), then moved from the immersion area to an adjacent dipping area and subsequently dipped out in the dipping area, wherein the singulating means (32) is designed to move each singulated component (2) after it has been dipped out of the galvanizing bath (28) by special rotational and / or steering movements in such a way as to avoid zinc drips. Plant according to claim 1, characterized in that the singulation of the components (2) from the carrier (7) via the singulation device (31) is provided following degreasing or following surface treatment, in particular pickling, or following flux application. Plant according to claim 1 or 2, characterized in that the singulation means (32) is arranged between the flux application device (21) and the hot-dip galvanizing device (25). Plant according to one of the preceding claims, characterized in that the singulation means (32) is designed such that all components (2) singulated from the carrier (7) are guided through the galvanizing bath (28) in an identical manner, in particular with identical movement, in identical arrangement and / or with identical time. A system according to one of the preceding claims, characterized in that a stripping device is provided downstream of the dipping area of ​​the galvanizing bath (28), in particular wherein the singulation means (32) is designed such that all components (2) separated from the workpiece carrier (7) are guided past the stripping device for stripping in an identical manner after dipping; and / or that the singulation means (32) is designed such that all components separated from the workpiece carrier (7) are moved in an identical manner after dipping in such a way that drips are removed, in particular drip off and / or are distributed evenly on the component surfaces. A system according to one of the preceding claims, characterized in that at least one rinsing device (12, 18), in particular with at least one rinsing stage, is provided, in particular wherein the rinsing device (12, 18) is provided downstream of the degreasing device (9) and / or downstream of the surface treatment device, preferably a rinsing device (12, 18) is provided downstream of the degreasing device (9) and downstream of the surface treatment device; and / or that a drying device (24) is provided downstream of the flux application device (21); and / or that a cooling device (29), in particular a quenching device, is provided downstream of the hot-dip galvanizing device (25); and / or that a post-treatment device (30) is provided downstream of the hot-dip galvanizing device (25) and optionally downstream of the optional cooling device (29). A system according to one of the preceding claims, characterized in that the components (2) are iron-based and / or iron-containing components (2), in particular steel-based and / or steel-containing components (2), preferably automotive components or components (2) for the automotive sector; and / or that the galvanizing bath (28) contains zinc and aluminum in a zinc-aluminium weight ratio in the range of 55-99.999 : 0.001-45, preferably in the range of 55-99.97 : 0.03-45, in particular in the range of 60-98 : 2-40, preferably in the range of 70-96 : 4-30; and / or that the galvanizing bath (28) has the following composition, wherein the weights are based on the galvanizing bath (28) and the sum of all components of the composition results in 100 wt.%: (i) zinc, in particular in amounts in the range of 55 to 99.999 wt.%, preferably 60 to 98 wt.%; (ii) aluminium, in particular in amounts from 0.001 wt.%, preferably from 0.005 wt.%.-%, further preferably in the range of 0.03 to 45 wt.%, further preferably in the range of 0.1 to 45 wt.%, preferably 2 to 40 wt.%, (iii) optionally silicon, in particular in amounts in the range of 0.0001 to 5 wt.%, preferably 0.001 to 2 wt.%; (iv) optionally at least one further ingredient and / or impurity, in particular from the group consisting of alkali metals such as sodium and / or potassium, alkaline earth metals such as calcium and / or magnesium and / or heavy metals such as cadmium, lead, antimony, bismuth, in particular in total amounts in the range of 0.0001 to 10 wt.%, preferably 0.001 to 5 wt.%; and / or that a flux (23) of the flux application device (21) has the following composition, wherein the weights are based on the flux (23) and the sum of all components of the composition results in 100 wt.%: (i) zinc chloride ZnCl2, in particular in amounts in the range of 50 to 95 wt.%, preferably 58 to 80 wt.%.-%; (ii) Ammonium chloride NH4Cl, in particular in amounts in the range of 5 to 50 wt.%, preferably 7 to 42 wt.%; (iii) optionally at least one alkali and / or alkaline earth salt, preferably sodium chloride and / or potassium chloride, in particular in total amounts in the range of 1 to 30 wt.%, preferably 2 to 20 wt.%; (iv) optionally at least one metal chloride, preferably heavy metal chloride, preferably selected from the group consisting of nickel chloride NiCl2, manganese chloride MnCl2, lead chloride PbCl2, cobalt chloride CoCl2, tin chloride SnCl2, antimony chloride SbCl3 and / or bismuth chloride BiCl3, in particular in total amounts in the range of 0.0001 to 20 wt.%, preferably 0.001 to 10 wt.%; (v) optionally at least one further additive, preferably a wetting agent and / or surfactant, in particular in amounts in the range of 0.001 to 10 wt.%, preferably 0.01 to 5 wt.%.-%, and / or that the flux application device (21), in particular the flux reservoir (22) of the flux application device (21), contains the flux (23) in a preferably aqueous solution, in particular in amounts and / or concentrations of the flux (23) in the range of 200 to 700 g / l, in particular 350 to 550 g / l, preferably 500 to 550 g / l, and / or that the flux is used as a preferably aqueous solution, in particular with amounts and / or concentrations of the flux in the range of 200 to 700 g / l, in particular 350 to 550 g / l, preferably 500 to 550 g / l. Plant according to one of the preceding claims, characterized in that the plant (1) is designed for the large-scale hot-dip galvanizing of a large number of identical or similar components (2), in particular in discontinuous operation, preferably for batch galvanizing. A system according to one of the preceding claims, characterized in that the surface treatment device is designed as a pickling device (15), preferably for chemical, in particular wet-chemical, and / or mechanical surface treatment of the components (2), preferably for pickling the surfaces of the components (2), and / or that the degreasing device (9) is decentralized and / or that the singulation device (31) is provided for the automated feeding, immersion and extraction of a component (2) singulated from the workpiece carrier (7) into the galvanizing bath (28) of the hot-dip galvanizing device (27). Method for hot-dip galvanizing components (2) using a molten zinc-aluminium alloy, wherein the components (2) are attached to a carrier (7) for grouped conveying prior to hot-dip galvanizing, subsequently the components (2) are subjected to a surface treatment, then the components (2) are provided with a flux (23) on their surface, and then the components (2) provided with the flux (23) on their surface are subjected to hot-dip galvanizing in a galvanizing bath (28) containing a molten zinc-aluminium alloy, wherein during hot-dip galvanizing the components (2) are fed from the carrier (7) separately and / or in a separated state to the galvanizing bath (28), immersed therein, and subsequently removed from it, wherein a separated component (2) is immersed in an immersion area of ​​the galvanizing bath (28).then moved from the immersion area to an adjacent exchange area and subsequently exchanged in the exchange area, wherein during singulation each component (2) is moved by special rotational and steering movements when withdrawing it from the exchange area in such a way that dripping lines of the liquid zinc-aluminum alloy are avoided. Method according to claim 10, characterized in that the components (2) are separated from the carrier (7) after surface treatment, in particular pickling, or after flux application. Method according to claim 10 or 11, characterized in that the isolated component (2) is moved from the immersion area to the exchange area only after completion of the reaction time of the flux (23) with the zinc-aluminium alloy. A method according to one of the preceding claims, characterized in that all components (2) separated from the workpiece carrier (7) are guided through the galvanizing bath (28) in an identical manner, in particular with identical movement in an identical arrangement and / or for an identical time; and / or that all components (2) separated from the workpiece carrier (7) are guided past a scraper device for removing the liquid zinc-aluminium alloy in an identical manner after immersion; and / or that all components (2) separated from the workpiece carrier (7) are moved in an identical manner after immersion such that drips of the liquid zinc-aluminium alloy are removed, in particular drip off and / or are distributed evenly on the component surface. A method according to one of the preceding method claims, characterized in that the components (2) are rinsed after degreasing and / or after surface treatment, in particular pickling, in particular rinsed once or several times, preferably wherein the components (2) are rinsed after degreasing and after surface treatment, in particular pickling, in particular rinsed once or several times; and / or that the flux (23) is dried after application to the surface of the components (2) and / or that the components (2) are dried after application of the flux (23) and / or that the component (2) is cooled, in particular quenched, after hot-dip galvanizing and / or that the component (2) is post-treated after hot-dip galvanizing, in particular after any cooling that may be provided. A method according to any one of claims 10 to 14, characterized in that the components (2) are iron-based and / or iron-containing components (2), in particular steel-based and / or steel-containing components (2), preferably automotive components or components (2) for the automotive sector; and / or that the galvanizing bath (28) contains zinc and aluminum in a zinc-aluminium weight ratio in the range of 55-99.999 : 0.001-45, preferably in the range of 55-99.97 : 0.03-45, in particular in the range of 60-98 : 2-40, preferably in the range of 70-96 : 4-30; and / or that the galvanizing bath (28) has the following composition, wherein the weights are based on the galvanizing bath (28) and the sum of all components of the composition results in 100 wt.%: (i) zinc, in particular in amounts in the range of 55 to 99.999 wt.%, preferably 60 to 98 wt.%; (ii) aluminium, in particular in amounts from 0.001 wt.%, preferably from 0.005 wt.%.-%, further preferably in the range of 0.03 to 45 wt.%, further preferably in the range of 0.1 to 45 wt.%, preferably 2 to 40 wt.%, (iii) optionally silicon, in particular in amounts in the range of 0.0001 to 5 wt.%, preferably 0.001 to 2 wt.%; (iv) optionally at least one further ingredient and / or impurity, in particular from the group consisting of alkali metals such as sodium and / or potassium, alkaline earth metals such as calcium and / or magnesium and / or heavy metals such as cadmium, lead, antimony, bismuth, in particular in total amounts in the range of 0.0001 to 10 wt.%, preferably 0.001 to 5 wt.%; and / or that the flux (23) has the following composition, wherein the weights are based on the flux (23) and the sum of all components of the composition results in 100 wt.%: (i) zinc chloride ZnCl2, in particular in amounts in the range of 50 to 95 wt.%, preferably 58 to 80 wt.%.-%; (ii) Ammonium chloride NH4Cl, in particular in amounts in the range of 5 to 50 wt.%, preferably 7 to 42 wt.%; (iii) optionally at least one alkali and / or alkaline earth salt, preferably sodium chloride and / or potassium chloride, in particular in total amounts in the range of 1 to 30 wt.%, preferably 2 to 20 wt.%; (iv) optionally at least one metal chloride, preferably a heavy metal chloride, preferably selected from the group consisting of nickel chloride NiCl2, manganese chloride MnCl2, lead chloride PbCl2, cobalt chloride CoCl2, tin chloride SnCl2, antimony chloride SbCl3 and / or bismuth chloride BiCl3, in particular in total amounts in the range of 0.0001 to 20 wt.%, preferably 0.001 to 10 wt.%; (v) optionally at least one further additive, preferably a wetting agent and / or surfactant, in particular in amounts in the range of 0.001 to 10 wt.%, preferably 0.01 to 5 wt.%.-%, and / or that the flux application device (21), in particular the flux reservoir (22) of the flux application device (21), contains the flux (23) in a preferably aqueous solution, in particular in amounts and / or concentrations of the flux (23) in the range of 200 to 700 g / l, in particular 350 to 550 g / l, preferably 500 to 550 g / l, and / or that the flux is used as a preferably aqueous solution, in particular with amounts and / or concentrations of the flux in the range of 200 to 700 g / l, in particular 350 to 550 g / l, preferably 500 to 550 g / l. Method according to one of the preceding method claims, characterized in that the method is provided for the large-scale hot-dip galvanizing of a plurality of identical or similar components (2), in particular in discontinuous operation, preferably for batch galvanizing. Method according to one of the preceding method claims, characterized in that the components (2) are subjected to a chemical, in particular wet-chemical, and / or mechanical surface treatment, in particular pickling, and / or that the components (2) are separated from the carrier (7) and / or automatically fed in the separated state to the galvanizing bath (28), immersed therein and subsequently removed from it.

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