In the field of copper electrolysis production, automatic cathode stripping system is becoming the core equipment to
promote the transformation and upgrading of the industry. By integrating mechanical automation, intelligent sensing
and data algorithms, this system not only solves the efficiency bottleneck of traditional manual stripping, but also
realizes the precise control and full traceability of the production process, which provides the key technical support
for copper smelting enterprises to build a modernized production line with high efficiency and low energy consumption.
System Composition and Operation Logic
The automatic cathode stripping system consists of three major functional modules that work together to form a
complete closed loop:
1. Intelligent positioning and transportation unit
Adopting laser ranging and visual positioning technology to capture the spatial coordinates of cathode plates in real
time, with positioning accuracy of ±0.3mm.
Equipped with bidirectional conveying rail, supporting parallel operation of multiple workstations, with a single-hour
handling capacity of 60-80 cathode plates.
Integrated anti-deviation and error correction mechanism, dynamically adjusting the clamping force through pressure
sensors to avoid deformation of copper sheets during transportation.
2. Fully automatic stripping actuator
Innovative three-axis linkage stripping technology, according to the copper layer crystallization thickness
(usually 0.5-1.2mm) automatically adjust the cutting angle
The tool is made of tungsten carbide-based composite material with ultrasonic vibration assisting device, which
reduces the peeling resistance by more than 30%.
Real-time monitoring of the pressure curve during the stripping process, emergency stop protection is activated
when abnormal fluctuations exceed the threshold, and the breakage rate is controlled within 0.15%.
3. Intelligent quality control and sorting system
Equipped with hyperspectral imager to detect surface defects (e.g. air holes, inclusions, etc.) of copper sheet
within 0.2 seconds.
Based on machine learning algorithm to establish quality grading model, automatically classify A/B/C finished
products and generate quality inspection report.
Data interoperability with MES system, realizing the traceability of process parameters of each copper sheet to
meet the quality certification needs of high-end customers.
Technology breakthroughs bring value upgrading
Compared with the traditional semi-automated equipment, the new generation system achieves breakthrough
improvement in four dimensions:
1. Optimization of energy consumption and economy
Adopting servo motor direct drive technology, saving 40%-50% energy compared with traditional hydraulic system.
Heat recovery device can convert the heat generated by stripping friction into auxiliary energy in the drying area,
saving about 200 tons of steam consumption per year.
Automatically switching to low power mode during the night time when the electricity price is low, reducing the
comprehensive electricity cost by 18%.
2. Expansion of process adaptability
Development of multi-specification cathode plate compatibility kit, supporting rapid switching from
1020mm×1080mm to 1580mm×1800mm.
Built-in electrolyte composition compensation algorithm automatically optimizes stripping parameters for
different copper sulfate concentrations (180-220g/L).
Optional acid corrosion-resistant version, adapting to the complex working conditions of recycled copper
smelting scenarios where the concentration of chloride ≤ 50ppm.
3. Intelligent transformation of operation and maintenance
Through vibration spectrum analysis and temperature monitoring, it can provide 14-day advance warning of
abnormalities in key components such as bearings and guide rails.
Remote operation and maintenance platform provides equipment OEE (overall efficiency) Kanban, real-time display
of capacity utilization, fault response and other 12 indicators.
Adopting modularized design, the replacement time of core components is shortened from 6 hours to 1.5 hours,
which reduces the loss of production downtime.
4. Enhanced safety performance
Totally enclosed protective cabin with negative pressure dust removal system, the concentration of copper powder
in the operation area is ≤1mg/m³ (the national standard requirement is ≤3mg/m³).
Emergency braking device response time ≤ 0.05 seconds, 4 times higher than the industry standard.
The operation interface is equipped with three levels of authority management, eliminating the risk of parameter
mis-modification.
Selection strategy and efficiency practice
Enterprises need to focus on the following technical indicators when planning automation upgrades:
Capacity matching verification
Estimation of stripping beat demand based on average daily copper cathode production (e.g. 300 tons/day)
Reserve 20%-30% capacity flexibility to cope with the efficiency loss caused by fluctuation of electrode plate thickness (±0.3mm).
Data interface standardization
The system is required to support OPC UA, MODBUS and other industrial communication protocols to ensure seamless
connection with existing DCS/PLC systems.
Confirmation of data sampling frequency ≥ 100Hz, to meet the needs of process optimization modeling
Full life cycle costing
Comparison of equipment energy consumption, spare parts replacement cycle (recommended major components ≥ 20,000
hours) and intelligent operation and maintenance premiums
Referring to industry cases, automation transformation usually reduces the cost of copper processing by $120-150 per ton,
with a payback period of about 2.5 years.
The practice of a medium-sized smelter shows that after the introduction of the automatic stripping system, the copper
cathode grade rate has increased from 92% to 98.6%, and the number of operators has been reduced from 6 to 2
per shift, with an annual direct economic benefit of more than 6 million yuan.
Future direction of technology evolution
Industry technology iteration presents three major trends:
1. Digital twin depth application
Construct a three-dimensional virtual model to simulate the stripping process, and optimize the parameters to
increase the yield by another 0.5 percentage points.
Combined with AR technology to realize three-dimensional labeling of fault points, maintenance efficiency increased by 40%.
2. Integration of green manufacturing technology
Developed hydrogen fuel cell-powered mobile stripping equipment to meet the demand for distributed recycled
copper processing.
Tested bio-based lubricants to replace mineral oil, reducing hazardous waste generation.
3. Upgrading autonomous decision-making capability
Introduced reinforcement learning algorithms, enabling the system to adjust 200+ process parameters according to
raw material fluctuations.
Developed cross-process cooperative control system to realize unmanned operation in the whole process of
electrolysis-stripping-baling.
Conclusion
The popularization of automatic cathode stripping system signifies that copper electrolysis production has formally
stepped into a new stage of intelligent manufacturing. It brings not only efficiency improvement, but also a
comprehensive innovation of product quality, energy utilization and safety management system. With the
continuous penetration of 5G, AI and other technologies, this system will play a more central role in the copper
industry chain, helping enterprises seize the competitive high ground in the new industrial revolution.