In the field of non-ferrous metal smelting, the intelligent upgrading of electrolytic copper production
process is triggering changes in the industry. As the core link of copper electrolysis production line,
copper cathode stripping process has long relied on manual operation, with low efficiency, high cost,
and big safety hazards and other pain points. With the breakthrough of industrial robot technology,
copper cathode stripping robot is taking revolutionary technical advantages to promote this traditional
process to automation, intelligent direction.
Technical principle: the integration of multi-disciplinary
intelligent system
Copper cathode stripping robot is a composite intelligent equipment based on industrial robot technology,
machine vision recognition system and intelligent control algorithm. Its core design principle centers
around the electrolytic copper production process: after 72 hours of deposition of the cathode plate in the
electrolysis tank, a copper layer with a thickness of about 5-8mm is formed on the surface, and the traditional
manual stripping requires the use of tools such as crowbars to carry out physical separation, while the
robotic system realizes the full-process automation through multi-dimensional technological innovation.
The system integrates high-precision 3D visual positioning technology and adopts a dual-spectrum imaging
system (visible light + thermal imaging) to capture the surface morphology of the cathode plate in real time,
which can accurately identify the interface between the copper layer and the titanium plate substrate. The
end of the robotic arm is equipped with a customized stripping actuator, which completes the stripping action
with 0.01mm positioning accuracy by means of force-position hybrid control algorithm. The whole process
combines material mechanics analysis, motion trajectory optimization, dynamic pressure compensation and
other key technologies to ensure that the integrity of the copper sheet peeling rate of more than 99.8%.
Workflow: five steps to build standardized operations
Intelligent identification and positioning
The vision system carried by the robot conducts 3D scanning of the cathode plate hoisted to the workstation,
builds a copper layer thickness distribution map, and automatically calculates the best stripping entry point.
The system can be adapted to different sizes of cathode plates (common size 3100×1060mm), and the
recognition accuracy reaches ±0.5mm.
Flexible gripping and fixing
Dual robotic arms work together, using vacuum suction cups and electromagnetic composite fixtures to realize
stable gripping under the premise of avoiding copper sheet deformation. The pressure sensor monitors the
contact force in real time to ensure that the gripping force is controlled in the safe range of 25-35N.
Dynamic stripping operation
The main robot arm performs stripping action along the preset trajectory, and the stripping tool adopts progressive
cutting design, combined with high-frequency vibration (80-120Hz) to reduce stripping resistance. The system
automatically adjusts the knife angle (15°-45° adjustable) and travel speed (0.5-1.2m/s) according to the
real-time feedback to cope with copper layers of different crystallization patterns.
Material Sorting and Transportation
The stripped copper sheet enters the automatic weighing system through the conveyor belt, and the abnormal
sheet with weight deviation more than ±1.5kg enters the re-inspection channel. Qualified copper sheet is
transferred to packing station through AGV, and empty cathode plate returns to electrolysis process after
automatic cleaning.
Process quality monitoring
The integrated data platform collects 28 process parameters in real time such as current, vibration frequency,
pressure value, etc., and continuously optimizes the operation parameters through machine learning model. A
quality analysis report is automatically generated for every 1,000 plates, realizing traceability of the
production process.
Technical Advantage: Reconstructing the new standard of
production efficiency
1. Exponential increase in production efficiency
The cycle time of single peeling operation of the robot system is controlled within 45 seconds, which is 300% higher
than the efficiency of manual operation. Supporting 24-hour continuous operation, the annual processing capacity
can reach more than 250,000 pieces, which is perfectly suited to the high-intensity production rhythm of modern smelters.
2. Revolutionary reduction of safety risks
Eliminate the risk of manual exposure to harsh environments such as high temperature (60-80℃), high humidity (85%RH)
and strong acid mist (pH 1-2). Dual safety protection system (LIDAR+emergency stop device) realizes 200ms level
response speed, and the equipment failure rate is less than 0.5‰.
3. Stripping quality leapfrog progress
The deviation of copper sheet surface flatness is controlled within ±0.3mm, and the edge burr rate is reduced to 0.05%,
which significantly improves the proportion of A-grade copper output. Adaptive algorithms can handle complex crystallization
patterns, and the success rate of coping with abnormal situations such as “copper thorns” and “copper tumors” reaches 98.6%.
4. Production management digitalization upgrade
The equipment networking rate is 100%, supporting seamless connection with MES and ERP systems. The energy
consumption monitoring module reduces the power consumption of single-ton copper stripping to 1.8kW-h, saving
40% energy compared with the traditional mode. Spare parts life prediction system reduces maintenance cost by 35%.
5. Significant increase in system flexibility
Modularized design supports quick changeover, and the production line switchover of cathode plates of different
specifications (from 2m2 to 4.5m2) can be completed within 2 hours. 5G communication interface is reserved, laying
the foundation for subsequent access to the digital twin system.
Application Scenario: Building the Core Node of Intelligent Factory
In the electrolytic copper project with an annual production capacity of 300,000 tons, the deployment of 10 stripping
robots can replace 120 laborers, reducing the direct cost of the stripping process by 62%. The application practice of a
mega smelter shows that the payback period of equipment investment is shortened to 14 months, the copper loss rate
is reduced from 0.35% to 0.08%, and the annual economic benefit is increased by more than 30 million yuan.
The system is particularly suitable for three major scenarios: automation layout of newly built smart factories, intelligent
transformation of old production lines, and standardized output of overseas projects. Its environmental adaptability
(operating temperature -10℃ to 50℃) meets the needs of major copper-producing regions around the world, and is
becoming a new benchmark for intelligent manufacturing in the electrolytic copper industry.
Future Outlook
With the convergence and application of technologies such as digital twin and 5G edge computing, the next generation
of flaking robots will realize higher levels of autonomous decision-making capabilities. The predictive maintenance system
can warn of equipment abnormalities 72 hours in advance, the visual recognition accuracy will break through the 0.1mm
level, and the energy consumption index is expected to drop by another 15%. This continuous technological evolution is
redefining the efficiency boundaries of electrolytic copper production, injecting strong kinetic energy for the high-quality
development of the non-ferrous metals industry.
Driven by the wave of intelligent manufacturing, copper cathode stripping robot not only solves the industry's pain points,
but also opens up the path of process innovation. Its technical value has exceeded the scope of a single device, and it is
building a whole-chain intelligent production system covering “identification-execution-optimization”, providing a
replicable and successful model for the digital transformation of the traditional metallurgical industry.