In the copper electrolysis refining process, copper cathode stripper
is the key equipment connecting electrolysis and finished product
processing, and its performance directly determines the production
efficiency and product quality. As the global demand for high-purity
copper continues to grow, the traditional manual stripping method
can no longer meet the modern production requirements, automation,
intelligent copper cathode stripping machine has become the core
driving force for the industry upgrade. In this paper, we will analyse
the working principle, technical advantages and selection points of
copper cathode stripping machine to provide decision-making
reference for copper smelting enterprises.
First, the role of copper cathode stripping
machine in copper electrolysis
Copper electrolysis refining is the core process of purifying crude copper
into high purity copper cathode through electrolysis. In the electrolysis
tank, the crude copper anode plate gradually dissolves, and copper ions
are deposited on the cathode plate to form high-purity copper cathode
sheet. However, traditional manual stripping has problems such as low
efficiency, high labour intensity and easy damage of finished products.
Copper cathode stripping machine can accurately strip copper sheets
from cathode plates through automated mechanical operation, which
significantly improves production continuity and safety.
Core functions include:
Efficient stripping: non-destructive separation of copper cathode and
mother board by mechanical arm or vibration device, stripping speed
up to several pieces per minute.
Accurate Sorting: Integrated visual inspection system automatically
identifies and sorts copper sheets of different thicknesses, reducing
manual intervention.
Data feedback: real-time recording of stripping efficiency, energy
consumption and other parameters to optimise the electrolysis process.
Second, the technical advantages of copper
cathode stripping machine
1. Enhance production efficiency and reduce operating costs
Traditional manual stripping requires multiple workers to operate, while
the automated stripping machine can achieve 24-hour continuous operation,
and the daily handling capacity of a single machine can reach dozens of
tonnes. Taking a copper electrolysis plant with an annual production
capacity of 100,000 tonnes as an example, the use of automated
stripping machines can reduce labour costs by more than 30%, while
avoiding the loss of copper sheets caused by operational errors.
2. Ensure product consistency and improve purity grade
Manual stripping is prone to uneven strength, resulting in scratches on the
surface of the copper sheet or residual electrolyte, which affects the purity.
Through constant pressure control and flexible clamping technology, the
copper cathode stripping machine ensures the integrity of the copper
sheet and surface finish, so that the purity of the finished product can
reach more than 99.99% (in accordance with ASTM B115 standard).
3. Adaptable to complex production environment and enhance safety
High temperature, high humidity, acidic gas and other harsh conditions
exist in the electrolysis workshop all year round. The high-quality stripper
is made of corrosion-resistant stainless steel with IP65 protection level
design, and the key components are equipped with explosion-proof
motors to ensure stable operation of the equipment in strong corrosive
environments and reduce the risk of safety accidents.
4. Promote green manufacturing and reduce resource waste
The equipment integrates electrolyte recycling system, which can
automatically collect the residual electrolyte during the stripping
process and return it to the electrolysis tank, reducing the waste of
raw materials. At the same time, the low-power motor and intelligent
start-stop function can reduce energy consumption by 20%~30%,
helping enterprises achieve the goal of carbon neutrality.
The core structure and selection of copper
cathode stripping machine
1. Equipment structure analysis
Stripping unit: including manipulator, vibrator or pneumatic device,
responsible for the separation of copper sheet and mother board.
Conveyor system: chain or belt conveyor is used to connect the
electrolysis tank with the stripping station.
Control system: PLC or industrial computer to automate the whole
process and support remote monitoring and fault diagnosis.
Auxiliary modules: electrolyte recycling device, copper sheet palletiser,
etc. to enhance the integration of the production line.
2. Selection of key indicators
Processing capacity: Select the appropriate capacity (e.g. 5~50 wafers/minute)
according to the number of electrolysis tanks and production beat.
Compatibility: Support different sizes of motherboard (e.g. 1.0m×1.2m) and
copper thickness (6~15mm).
Reliability: Mean Time Between Failure (MTBF) needs to be higher than 8,000
hours, and the maintenance cycle is not less than 6 months.
Intelligence level: whether it has AI defect detection, energy consumption
optimisation algorithms and other advanced features.
Fourth, industry application scenarios and
maintenance recommendations
1. Typical application areas
Large-scale copper smelter: used for large-scale electrolytic copper
production, matching continuous casting, rolling and other downstream processes.
Recycled copper processing: handling cathode plates after electrolysis
of waste copper to enhance the resource recovery rate.
High-end copper foil manufacturing: to match the demand for precision
stripping of ultra-thin copper foil (6~12μm).
2. Equipment maintenance and upkeep
Daily inspection: Regular cleaning of electrolyte crystals, lubrication of
transmission parts, calibration of sensor precision.
Preventive maintenance: Quarterly inspection of motor insulation, replacement
of worn-out clamping jaws and conveyor belts.
Troubleshooting: If there is incomplete stripping or copper sheet tearing, it is
necessary to troubleshoot the stability of air pressure or the positioning
accuracy of the robotic arm.
V. Future Trend: Intelligent and Sustainable
Development
With the penetration of Industry 4.0 technology, copper cathode stripping
machine is evolving in the following directions:
Digital Twin and Predictive Maintenance: Simulate the operating state of the
equipment through virtual models to warn of potential failures in advance.
AI vision optimisation: deep learning algorithms automatically identify copper
defects and classify qualified products and returned products.
Green process upgrade: Hydrogen energy drive, waterless stripping technology
to further reduce carbon footprint.
Conclusion
As the ‘last mile’ equipment of copper electrolysis process, the automation and
intelligence level of copper cathode stripping machine directly determines the
production capacity and competitiveness of enterprises. Under the dual background
of strong demand for copper resources and tightened environmental protection
policies, investing in efficient and reliable stripping machines is not only an inevitable
choice for technological upgrading, but also a core path to achieve cost reduction and
efficiency and sustainable development. Enterprises need to combine their own
production capacity and process characteristics, choose the appropriate equipment,
and continue to pay attention to the industry's technological developments, in
order to cope with future market challenges.