In the non-ferrous industry production scene, high temperature
melting, toxic gases, heavy lifting and other operational aspects
of the long-term threat to the safety of practitioners. With the
breakthrough of industrial robotics technology, this kind of “hard,
dirty, tired and dangerous” positions are experiencing subversive
changes. In this paper, the depth of analysis of industrial robots
through technological innovation, for the non-ferrous industry
to build a safer and more efficient production system.
First, the non-ferrous industry high
temperature and high risk positions
of the three core pain points
1. Extreme environmental threats to personal safety
The temperature in front of the smelting furnace can reach more
than 1200 ℃, the electrolysis workshop continues to emit
corrosive gases, the traditional manual operation faces the risk of burns,
poisoning and so on. According to statistics, more than 60%
of workplace accidents in the non-ferrous industry are directly
related to high temperature and high-risk environment.
2. High labor intensity leads to efficiency bottleneck
Metal ingot handling, rolling line inspection and other processes
need to repeat the weight-bearing operations, workers are
prone to fatigue resulting in operational errors, directly
affecting the production continuity.
3. Talent loss aggravates labor shortage
The young generation of high-risk jobs is increasingly
obvious, enterprises are facing the double pressure of
“difficult to recruit, difficult to retain”, the traditional
manpower model is unsustainable.
Second, the four major breakthrough advantages
of industrial robotics technology
1. High-temperature resistant special materials + intelligent protection system
Material breakthrough: the use of ceramic-based composite materials,
corrosion-resistant alloys, etc., so that the robot can work continuously
in a high-temperature environment at 1500 ℃;
Adaptive protection: real-time monitoring of the environment
temperature through infrared sensors, automatically triggering
the cooling module, to ensure the stable operation of the core
components.
2. Precise execution of high-risk processes
Melting automation: the robot is equipped with high-precision
gripper to realize precise pouring of metal liquid, with the error
controlled within ±0.5mm;
Unmanned electrolyzer management: robotic arm equipped with
visual recognition system can autonomously complete high-risk
tasks such as pole plate replacement and residue cleaning.
3. 7×24 hours high-intensity operation capability
The industrial robot has a single endurance of 48 hours, and with
the automatic charging pile, it can replace 3 shifts of manpower
and increase the production capacity of the melting and casting
workshop by more than 30%.
4. Data-driven process optimization
Through the Internet of Things (IoT) real-time collection of
production data, AI algorithms dynamically adjust the melting
temperature, pouring speed and other parameters to reduce
energy consumption by 10%-15%.
Third, the non-ferrous industry four
scenes of robot landing practice
Scene 1: melting workshop full process automation
Application links: raw material feeding → furnace monitoring →
metal liquid transfer → ingot molding
Effectiveness: reduce 80% of the high temperature area of artificial
exposure, product qualification rate increased to 99.2%.
Scenario 2: unmanned operation and maintenance of electrolysis workshop
Technical solution: rail-type inspection robot + lifting robotic arm
work together to realize full automation of tank voltage detection
and anode replacement.
Scenario 3: Hazardous chemical storage and transportation
Innovation point: explosion-proof AGV (automatic guided vehicle)
equipped with 3D obstacle avoidance system, accurately transporting
acid, molten salt and other dangerous materials.
Scene 4: Predictive maintenance of equipment
AI Early Warning Model: Through vibration sensors + machine learning,
the smelting furnace lining breakage risk is warned 48 hours in
advance, reducing the loss of unplanned downtime.
Future Trend: From “Replacement of
Manpower” to “Reconstruction of
Production Mode”
With the integration of 5G, digital twin and other technologies,
industrial robots are promoting the upgrading of the non-ferrous
industry to a higher dimension:
Digital twin factory: virtual simulation system to preview the
production process, robot execution efficiency by another 20%;
New mode of human-robot collaboration: workers remotely
manipulate robots to complete fine adjustments, completely
avoiding front-line risks;
Green Manufacturing Transformation: Robot precision control
reduces carbon emissions, helping enterprises reach the
“double carbon” goal.
Conclusion: Intelligent is the way to
crack the industry pain points
Industrial robots not only solve the urgent need for safety and
efficiency in the non-ferrous industry, but also through the data
precipitation to provide the underlying support for process
innovation. According to authoritative institutions, the global
non-ferrous industry robot penetration rate will exceed 45% in
2025, the first to complete the intelligent transformation of the
enterprise, will occupy the commanding heights in the new
round of industrial competition.
For enterprises still relying on traditional models, actively
embracing robotics is not only an inevitable choice to
fulfill social responsibility and safeguard the well-being
of employees, but also a strategic opportunity to realize
high-quality development.