A full-automatic casting method of anode carbon blocks

Abstract

The present application relates to metal casting technology field, more specifically, it relates to a kind of full-automatic pouring method of anode carbon block, including molten iron melting treatment, molten iron transfer, molten iron weighing and heat preservation, troubleshooting before pouring and the steps of pouring, in the process of molten iron weighing and heat preservation, weighing system monitors the molten iron weight in capacity bin, utilize the heating and heat preservation of the molten iron in capacity bin by intermediate frequency induction coil, and according to the molten iron temperature feedback of temperature monitoring system adjusts heat preservation power, in the process of pouring, the position of chute mechanism and anode carbon block is confirmed using visual system, and air pressure sensor and liquid level position sensor are integrated, so that the molten iron liquid level in soup tank is always kept in the set height range, finally, whether the pouring liquid level reaches the set requirement value is detected using visual system, a kind of full-automatic pouring method of anode carbon block of the present application is high in degree of automation, good in stability, can effectively improve the quality and production efficiency of anode carbon block and anode claw connection.

Description

Technical Field

[0001] This invention relates to the field of metal casting technology, and in particular to a fully automated casting method for anode carbon blocks. Background Technology

[0002] The anode carbon block is a key component in the electrolytic aluminum production process, primarily used for conducting current and participating in electrochemical reactions. It is typically made from carbonaceous materials such as petroleum coke and pitch coke through processes like molding and calcination, possessing excellent electrical conductivity, high-temperature resistance, and chemical stability. In the electrolytic cell, the anode carbon block is connected to the power source via anode claws, forming a complete current path. The anode claws are usually made of cast iron or steel, and their function is to conduct current from the power source to the anode carbon block.

[0003] In electrolytic aluminum production, the connection between the anode carbon block and the anode claw is typically achieved through a molten iron casting process. The specific process involves pre-fixing the anode claw in a mold, then pouring molten iron into the gap between the anode claw and the anode carbon block. After the molten iron cools and solidifies, a strong connection is formed. This connection method not only ensures stable current conduction but also withstands the high temperatures and mechanical stresses generated during electrolysis.

[0004] However, current molten iron casting processes still suffer from insufficient automation. Traditional casting techniques rely heavily on manual operation, with key parameters such as molten iron temperature control, casting speed, and cooling time requiring manual intervention. This leads to low production efficiency and a tendency for quality problems such as uneven casting and insufficient connection strength. Furthermore, manual operation increases the labor intensity and safety risks for workers. Therefore, developing a highly automated and stable molten iron casting method is of great significance for improving the quality and production efficiency of the connection between the anode carbon block and the anode claw. Summary of the Invention

[0005] To address the problems existing in the prior art, this application provides a fully automated casting method for anode carbon blocks.

[0006] The fully automated casting method for anode carbon blocks provided by this invention adopts the following technical solution:

[0007] A fully automated casting method for anode carbon blocks includes the following steps:

[0008] S1, molten iron melting treatment:

[0009] Electromagnets are used to attract and transfer metal materials from the material pool to a feeding cart, which moves along a transfer track to a medium-frequency electric furnace, where the metal materials are poured into the furnace for melting.

[0010] S2, Molten Iron Transfer:

[0011] After being melted in the medium-frequency electric furnace, the molten iron is poured onto a molten iron transfer car. The molten iron transfer car moves along the molten iron transfer track to the pneumatic casting machine, where it pours the molten iron into the capacity chamber of the pneumatic casting machine.

[0012] S3, Weighing and heat preservation of molten iron:

[0013] The weighing system at the bottom of the pneumatic casting machine monitors the weight of the molten iron in the capacity chamber. The medium frequency power supply cabinet of the casting machine supplies power to the medium frequency induction coil of the pneumatic casting machine to heat and keep the molten iron in the capacity chamber warm. The power of the medium frequency induction coil is adjusted according to the molten iron temperature fed back by the temperature monitoring system.

[0014] S4, Troubleshooting before pouring:

[0015] Confirm that the pneumatic casting machine has no fault alarms, the pressurization device has the normal required air pressure, and the stopper mechanism, chute mechanism, and vision system are ready.

[0016] S5, proceed with pouring:

[0017] The casting station sends a signal indicating that the anode carbon block has arrived. Upon receiving this signal, the casting system of the pneumatic casting machine controls the chute mechanism and the intelligent casting camera of the vision system to perform positioning. The intelligent casting camera of the vision system confirms the positions of the chute mechanism and the anode carbon block. After confirming the position information, the vision system outputs a signal to start casting to the pneumatic casting machine. The pressurizing device pressurizes the capacity chamber, causing the molten iron to flow into the outlet trough. The casting system integrates a pressure sensor and a liquid level sensor to maintain the molten iron level in the outlet trough within a set height range. Then, the servo adjusts the lifting degree of the stop rod mechanism to control the opening of the pouring spout. The molten iron flows from the outlet trough into the chute mechanism and then into the mold opening of the anode carbon block. During casting, the vision system monitors the casting liquid level in real time. When the casting liquid level reaches the set requirement value, the casting system receives a signal and stops casting.

[0018] Preferably, in S5, the inner edge of the top of the carbon bowl of the anode carbon block is provided with a stepped surface, and the vision system calculates and judges whether the pouring amount has reached the set value by detecting the proportion of the area of ​​the pouring liquid surface to the area of ​​the stepped surface of the carbon bowl.

[0019] Preferably, in S5, a protrusion is formed at the center of the bottom of the carbon bowl of the anode carbon block, and the anode claw is pressed against the protrusion at the bottom of the carbon bowl, so that there is a gap between the bottom of the anode claw and the carbon bowl.

[0020] Preferably, in S5, the anode carbon block has four mold openings. When the casting system receives a signal indicating that the anode carbon block has reached its position, the casting system controls the casting station to prevent the anode carbon block from being pushed. Simultaneously, the system begins to lift the stopper rod mechanism to pour through mold openings 1 and 2. The molten iron flows precisely from the chute mechanism to the anode carbon block pouring opening. The vision system monitors the liquid level at the pouring opening in real time. When the current liquid level reaches the set full-fill level, the stopper rod mechanism returns to the blocking position, and the chute mechanism moves to molds 3 and 4. After the chute mechanism moves to its position, it begins to lift the stopper rod mechanism to pour through mold openings 3 and 4. The molten iron flows precisely from the chute mechanism to the anode carbon block pouring opening. The vision system monitors the liquid level at the pouring opening in real time. When the current liquid level reaches the set full-fill level, the stopper rod mechanism returns to the blocking position, and the chute mechanism moves back to the positions of molds 1 and 2, allowing the casting station to push the anode carbon block. This cycle repeats continuously.

[0021] Preferably, in S1, the electromagnet adopts a three-level gradient magnetic field design, and the attraction force increases sequentially from the center to the edge.

[0022] Preferably, in S2, the molten iron transfer track adopts an embedded heat-conducting pipe design, and a circulating coolant is introduced into the heat-conducting pipe. The circulating coolant is an ethylene glycol solution with a flow rate of 2L / min.

[0023] Preferably, in S2, the molten iron ladle of the molten iron transfer car adopts a double-layer structure, with the inner layer being an aluminum silicate ceramic fiber insulation layer and the outer layer being a high-alumina mullite low-cement-content high-temperature composite castable.

[0024] Preferably, in S3, the weighing system employs four sets of piezoelectric sensors to form a redundant measurement network.

[0025] Preferably, in S3, the temperature monitoring system integrates multiple type B thermocouples, which are arranged at different heights of the capacity chamber. When a temperature gradient exceeding 20°C / m is detected, the electromagnetic stirring device is activated.

[0026] Preferably, in S5, the anode claw needs to be preheated before casting.

[0027] The beneficial effects of this invention are as follows:

[0028] The fully automated casting method for anode carbon blocks of the present invention reduces the degree of manual intervention in processes such as molten iron heat preservation and casting speed control, thereby improving production efficiency. The casting speed is increased from 80s / set to 40s / set, improving production efficiency by 200%. It also improves casting uniformity and connection strength, effectively reducing the labor intensity and safety risks of workers. The method has the effects of high automation and good stability, and plays a positive role in improving the quality and production efficiency of the connection between anode carbon blocks and anode claws. Attached Figure Description

[0029] Figure 1 This is a flowchart of the fully automated casting method for anode carbon blocks in the embodiments of this application;

[0030] Figure 2 This is a side view of molten iron being poured into a pneumatic casting machine in an embodiment of this application;

[0031] Figure 3 This is a perspective view of a pneumatic casting machine pouring molten iron into an anode carbon block in an embodiment of this application;

[0032] Figure 4 This is a top view of the molten iron transfer car, the pneumatic casting machine, and the casting station in the embodiments of this application;

[0033] Figure 5 This is a schematic diagram of the connection between the anode carbon block and the anode claw in an embodiment of this application.

[0034] Explanation of reference numerals in the attached drawings: 1. Molten iron transfer car; 2. Molten iron ladle; 3. Pneumatic casting machine; 4. Discharge trough; 5. Sluice gate mechanism; 6. Casting station; 7. Anode claw; 8. Anode carbon block; 9. Carbon bowl. Detailed Implementation

[0035] The following will combine Figures 1-5 The present invention will be further illustrated by the embodiments.

[0036] This embodiment discloses a fully automated casting method for anode carbon blocks.

[0037] The fully automated casting method for anode carbon blocks includes the following steps:

[0038] S1, molten iron melting treatment:

[0039] Electromagnets are used to attract and transfer metal materials from the material pool to the feeding trolley. This electromagnetic attraction method avoids mechanical damage to the metal surface and reduces oxide layer shedding and contamination. The feeding trolley then moves along a transfer track to the medium-frequency furnace. Tracked transport improves positioning accuracy and significantly increases efficiency compared to manual handling. The charging cart pours metal materials into the medium-frequency electric furnace for melting. The medium-frequency electric furnace is a smelting equipment that uses the principle of electromagnetic induction to heat metal. Its operating frequency range is usually stable between 300Hz and 320Hz. The industrial frequency AC power is converted into medium-frequency current through a medium-frequency power supply, which is input into the induction coil to generate an alternating magnetic field, causing eddy currents to form inside the metal material and rapidly heating and melting it. Compared with traditional smelting equipment such as coal-fired / gas-fired furnaces, the medium-frequency electric furnace can more accurately control the melting speed and temperature by adjusting the frequency and power. It is easy to seamlessly integrate with intelligent systems to achieve integrated control of smelting, transfer and casting. Furthermore, since there is no combustion process, it can avoid the generation of pollutants such as CO2 and SO2, meet green manufacturing standards, reduce fire risk and improve the workshop environment.

[0040] S2, Molten Iron Transfer:

[0041] After being melted in an induction furnace, the molten iron is poured onto the molten iron transfer car 1. The molten iron transfer car 1 moves along the molten iron transfer track to the pneumatic casting machine 3. Similarly, the use of track-based transportation can significantly improve efficiency compared to manual labor and reduce the temperature drop of the molten iron. Then, the molten iron transfer car 1 pours the molten iron into the capacity chamber of the pneumatic casting machine 3. The pneumatic casting machine 3 is a precision casting equipment that controls the flow rate and volume of molten iron through a pressurization device. It uses air pressure to drive the casting instead of traditional gravity casting. Through a closed-loop air pressure control system, it can achieve millimeter-level precision adjustment of the molten iron flow rate. It can be combined with multi-sensor fusion technology (such as weight, pressure, liquid level, vision) to dynamically optimize the casting trajectory, eliminate problems such as molten iron splashing and oxide inclusions in traditional casting, greatly improve casting efficiency, and effectively reduce the error of single casting volume, significantly improving the precision and surface quality of the casting part of the anode carbon block 8.

[0042] S3, Weighing and heat preservation of molten iron:

[0043] The weighing system at the bottom of the pneumatic casting machine 3 monitors the weight of the molten iron in the capacity chamber. The medium-frequency power supply cabinet of the casting machine supplies power to the medium-frequency induction coil of the pneumatic casting machine 3, heating and maintaining the molten iron in the capacity chamber. The power of the medium-frequency induction coil is adjusted based on the molten iron temperature feedback from the temperature monitoring system. In this step, by integrating weighing monitoring, induction heating, and temperature feedback adjustment technologies, the heat preservation power can be dynamically adjusted to maintain the molten iron temperature stably within the process range, significantly reducing iron oxidation and component segregation. Furthermore, through precise energy supply, energy consumption can be reduced by 30% compared to traditional heat preservation methods. Ultimately, this solves the problems of large temperature fluctuations, serious energy waste, and high reliance on manual labor during molten iron heat preservation.

[0044] S4, Troubleshooting before pouring:

[0045] After confirming that the pneumatic casting machine 3 has no fault alarms, the air pressure of the pressurizing device is at the normal required value, and the stopper rod mechanism, chute mechanism 5, and vision system are ready, the systematic pre-inspection and multi-mechanism collaborative preparation before casting significantly improve the stability and reliability of the casting process, effectively eliminate the problems of missed inspections and misjudgments in traditional manual inspection, and greatly reduce the failure rate in the process preparation stage, providing a standardized and intelligent foundation for continuous and high-precision casting.

[0046] S5, proceed with pouring:

[0047] The casting station 6 sends a signal indicating that the anode carbon block 8 has arrived. After receiving the signal, the casting system of the pneumatic casting machine 3 controls the chute mechanism 5 and the intelligent casting camera of the vision system to perform positioning. The intelligent casting camera of the vision system confirms the position of the chute mechanism 5 and the anode carbon block 8. The vision system can ensure precise alignment between the chute mechanism 5 and the anode carbon block 8, making the casting positioning process fully automated, eliminating human operation errors, improving the consistency of the casting trajectory, effectively avoiding molten iron splashing or casting problems, and significantly improving the casting qualification rate and production efficiency of the anode carbon block 8. After the vision system confirms the position information of the chute mechanism 5 and the anode carbon block 8, it outputs a signal to start pouring to the pneumatic pouring machine 3. The pressurizing device pressurizes the capacity chamber, causing the molten iron to flow into the outlet trough 4. The pouring system integrates a pressure sensor and a liquid level sensor to keep the molten iron level in the outlet trough 4 within the set height range. Then, the servo-adjusted stopper mechanism lifts to control the opening of the pouring gate. The molten iron flows from the outlet trough 4 into the chute mechanism 5 and then into the mold of the anode carbon block 8. This pouring system achieves high-precision and stable output in the molten iron pouring process through multi-sensor collaborative control and closed-loop adjustment technology. The integrated pressure sensor monitors the pressurization value in real time, and the liquid level sensor dynamically detects the molten iron level height. The pressurization amount is adjusted through a PID algorithm to control the liquid level fluctuation within the set range of ±3mm. Simultaneously, the servo motor precisely adjusts the lifting height of the stopper mechanism and linearly controls the opening of the pouring gate to ensure that the molten iron flow rate matches the pouring speed. Finally, when the molten iron passes through the chute mechanism 5 and the anode carbon block 8 mold opening, it forms a continuous and stable laminar flow state. This technology greatly improves the accuracy of pouring flow control and the stability of the liquid surface, effectively eliminates problems such as pouring interruption and molten iron spillage, improves the casting qualification rate, and reduces molten iron oxidation loss, realizing fully automated precision pouring. During the pouring process, the vision system monitors the pouring liquid level in real time. When the pouring liquid level reaches the set requirement value, the pouring system receives a signal and stops pouring. This allows the pouring system to achieve precise termination of the pouring volume through visual monitoring and closed-loop control technology. In this embodiment, the vision system captures the pouring liquid level in real time at a frequency of 30 frames per second. It dynamically compares the liquid level with a preset threshold using an image recognition algorithm. When the liquid level reaches the set requirement value, the system immediately outputs a stop signal, simultaneously shuts down the pressurizing device and resets the stopper mechanism, achieving a millisecond-level response to the pouring action. This process can eliminate the lag and subjective error of manual visual judgment, avoid material waste caused by excessive pouring of molten iron or structural defects caused by under-pouring, effectively improve the dimensional consistency after pouring and shorten the pouring cycle. Ultimately, under the fully automatic closed-loop control process, the level of production standardization is significantly improved.

[0048] In summary, the fully automated casting method for anode carbon blocks provided by this invention is a highly automated and stable method for casting molten iron, which can effectively improve the quality and production efficiency of the connection between the anode carbon block 8 and the anode claw 7.

[0049] In S5, the pouring sequence can be set in the pouring system according to actual process requirements. For example, when pouring four molds, it can be set to pour molds 1 and 2 of the anode carbon block 8 first, and then pour molds 3 and 4, or it can be set to pour molds 1 and 3 first, and then pour molds 2 and 4. The specific process of pouring molds 1 and 2 first and then molds 3 and 4 is as follows: When the pouring system receives the anode carbon block 8 arrival signal, the pouring system controls the pouring station 6 to stop pushing the anode carbon block 8, and at the same time starts to lift the stopper rod to pour molds 1 and 2. Molten iron is precisely poured from the chute mechanism 5. The molten iron flows to the pouring port of anode carbon block 8. The vision system monitors the liquid level at the pouring port in real time. When the current liquid level is detected to have reached the set full-filling level, the stopper rod returns to the blocking position, and the chute moves to molds 3 and 4. After the chute moves into position, the stopper rod is raised to pour into molds 3 and 4. Molten iron flows precisely from the chute to the pouring port of anode carbon block 8. The vision system monitors the liquid level at the pouring port in real time. When the current liquid level is detected to have reached the set full-filling level, the stopper rod returns to the blocking position, and the chute mechanism 5 moves back to the position of molds 1 and 2, allowing the pouring station 6 to push the anode carbon block 8, and the cycle repeats.

[0050] In S1, the electromagnet employs a three-level gradient magnetic field design, with the attraction force increasing progressively from the center to the edge. In this embodiment, the central magnetic field strength is 0.8T, and the edge magnetic field strength is 1.2T. The increased edge attraction strength effectively prevents metal materials from slipping off the electromagnet's edge due to inertia during transport. Furthermore, the weak central magnetic field allows for slight displacement of the metal material in the adsorption area, which, combined with the strong edge magnetic field, forms a centripetal constraint force, automatically aligning the stacked metal materials with the central axis, resulting in more orderly transport of the metal materials via the electromagnet.

[0051] In S2, the molten iron transfer track adopts an embedded heat pipe design, and a circulating coolant (such as ethylene glycol solution, flow rate 2L / min) is introduced into the heat pipe to prevent iron filings from sticking to the molten iron transfer track at high temperatures. It also continuously removes surface heat load from the molten iron transfer track, avoiding metal fatigue caused by high-temperature oxidation, reducing the wear rate of the molten iron transfer track, and extending maintenance intervals. Furthermore, the embedded design makes the working platform flat and easy to clean. In addition, if the molten iron transfer car 1 unexpectedly stops, the heat pipe can continuously conduct heat away from the contact area, preventing deformation or lubrication failure caused by localized overheating of the molten iron transfer track, thereby reducing the failure rate. A laser positioning system is also equipped between the molten iron transfer track and the pneumatic casting machine 3 to achieve millimeter-level docking.

[0052] In S2, the ladle 2 of the molten iron transfer car 1 adopts a double-layer structure. In this embodiment, the inner layer of the ladle 2 is an aluminosilicate ceramic fiber insulation layer, and the outer layer is a high-alumina mullite low-cement content high-temperature composite castable. The double-layer composite structure design of the ladle 2 significantly improves the safety and efficiency of high-temperature molten iron transfer through the complementary properties of materials. Among them, the aluminosilicate ceramic fiber insulation layer extends the melting loss resistance life of the inner wall of the ladle 2 to more than 5 times that of traditional refractory bricks. The anti-slag sticking property of the aluminosilicate ceramic fiber insulation layer can also improve the automatic peeling rate of the slag shell after the molten iron solidifies, achieving the effect of easy cleaning. In addition, the double-layer structure can improve the heat insulation effect and effectively reduce the temperature drop during the molten iron transfer process.

[0053] In the S3 system, the weighing system employs four sets of piezoelectric sensors to form a redundant measurement network. The three-point support structure automatically balances the weight distribution of the molten iron. Even if the molten iron surface is tilted or the center of gravity of the ladle shifts, the overall measurement deviation can still be controlled within a reasonable range through a vector synthesis algorithm. This significantly improves accuracy compared to single-point sensor solutions. Furthermore, if one sensor fails due to high-temperature drift or mechanical impact, the remaining two sets of sensors reconstruct the weight data using a triangulation model, allowing the system to continuously output valid values ​​and avoid interruptions in the pouring process. This enables accurate weight detection from the front, back, left, and right sides of the ladle, with a measurement error within 0.2 kg.

[0054] In S3, the temperature monitoring system integrates multiple Type B thermocouples consisting of temperature-sensing optical fibers surrounding the casting furnace and a measuring host. The temperature measurement range is 0-1600℃, and these thermocouples are deployed at different heights within the capacity chamber. When a temperature gradient exceeding 20℃ / m is detected, an electromagnetic stirring device is activated to quickly eliminate the temperature difference. Furthermore, by constructing a thermal field model using gradient data, the system can intelligently match the power distribution across different sections of the coil, avoiding energy redundancy caused by uniform heating and reducing energy consumption during the heat preservation stage.

[0055] In S5, a stepped surface is provided on the inner edge of the top of the carbon bowl of the anode carbon block 8. The vision system calculates whether the pouring volume has reached the set value by detecting the proportion of the area of ​​the pouring liquid surface to the area of ​​the stepped surface of the carbon bowl. Furthermore, a protrusion is formed at the center of the bottom of the carbon bowl of the anode carbon block 8. The anode claw 7 is pressed against the protrusion at the bottom of the carbon bowl, so that there is a gap between the bottom of the anode claw 7 and the carbon bowl 9, which increases the pouring space and improves the connection stability between the anode claw 7 and the anode carbon block 8.

[0056] In step S5, before casting, the anode claw 7 needs to be preheated. In this embodiment, preheating raises the surface temperature of the anode carbon block 8 to 300-400°C, reducing the temperature difference impact at the moment of contact with molten iron and preventing micro-cracks caused by uneven thermal expansion of the anode carbon block 8. Preheating also removes moisture and volatiles adsorbed in the pores of the anode carbon block 8, preventing the violent precipitation of gas during molten iron casting and the formation of pores or bubbles. After preheating the anode claw 7, the bonding strength between the molten iron and the anode claw 7 can be effectively improved.

[0057] The above are all preferred embodiments of the present invention and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A fully automated casting method for anode carbon blocks, characterized in that, Includes the following steps: S1, molten iron melting treatment: Electromagnets are used to attract and transfer metal materials in the material pool to a feeding cart, which moves along a transfer track to an intermediate frequency electric furnace, where the metal materials are poured into the furnace for melting. S2, Molten Iron Transfer: After being melted in the medium-frequency electric furnace, the molten iron is poured into the molten iron transfer car (1). The molten iron transfer car (1) moves along the molten iron transfer track to the pneumatic casting machine (3). The molten iron transfer car (1) pours the molten iron into the capacity hopper of the pneumatic casting machine (3). S3, Weighing and heat preservation of molten iron: The weighing system at the bottom of the pneumatic casting machine (3) monitors the weight of the molten iron in the capacity chamber. The medium frequency power supply cabinet of the casting machine supplies power to the medium frequency induction coil of the pneumatic casting machine (3) to heat and keep the molten iron in the capacity chamber. The power of the medium frequency induction coil is adjusted according to the molten iron temperature fed back by the temperature monitoring system. S4, Troubleshooting before pouring: Confirm that the pneumatic casting machine (3) has no fault alarm, the air pressure of the pressurizing device is at the normal required value, and the stopper rod mechanism, chute mechanism (5) and vision system are ready; S5, proceed with pouring: The casting station (6) sends a signal indicating that the anode carbon block (8) has arrived. After receiving the signal, the casting system of the pneumatic casting machine (3) controls the chute mechanism (5) and the intelligent casting camera of the vision system to perform positioning. The intelligent casting camera of the vision system confirms the position of the chute mechanism (5) and the anode carbon block (8). After the vision system confirms the position information of the chute mechanism (5) and the anode carbon block (8), it outputs a signal to start casting to the pneumatic casting machine (3). The pressurizing device pressurizes the capacity chamber. The molten iron flows into the outlet trough (4). The casting system integrates a pressure sensor and a liquid level sensor to keep the molten iron level in the outlet trough (4) within a set height range. Then, the servo adjusts the lifting degree of the stop rod mechanism to control the opening of the pouring gate. The molten iron flows from the outlet trough (4) into the chute mechanism (5) and then into the mold of the anode carbon block (8) through the chute mechanism (5). During the casting process, the vision system monitors the casting liquid level in real time. When the casting liquid level reaches the set requirement value, the casting system receives the signal and stops casting.

2. The fully automated casting method for anode carbon blocks according to claim 1, characterized in that: In S5, a stepped surface is provided on the inner edge of the top of the carbon bowl of the anode carbon block (8). The vision system calculates and judges whether the pouring amount has reached the set value by detecting the ratio of the area of ​​the pouring liquid surface to the area of ​​the stepped surface of the carbon bowl.

3. The fully automated casting method for anode carbon blocks according to claim 2, characterized in that: In S5, a protrusion is formed at the center of the bottom of the carbon bowl of the anode carbon block (8), and the anode claw (7) is pressed against the protrusion at the bottom of the carbon bowl, so that there is a gap between the bottom of the anode claw (7) and the carbon bowl (9).

4. The fully automated casting method for anode carbon blocks according to claim 1, characterized in that: In S5, the anode carbon block (8) has four mold openings. When the casting system receives the signal that the anode carbon block (8) is in place, the casting system controls the casting station (6) to stop pushing the anode carbon block (8) and simultaneously begins to lift the stopper mechanism to pour molds 1 and 2. The molten iron flows precisely from the chute mechanism (5) to the pouring opening of the anode carbon block (8). The vision system detects the liquid level at the pouring opening in real time. When it detects that the current liquid level has reached the set full-fill level, the stopper mechanism returns to the blocking position, and the chute... The trough mechanism (5) moves to the 3rd and 4th mold openings. After the trough mechanism (5) moves into place, it begins to lift the stopper mechanism to pour the 3rd and 4th mold openings. The molten iron flows precisely from the trough mechanism (5) to the pouring port of the anode carbon block (8). The vision system detects the liquid level at the pouring port in real time. When it detects that the current liquid level has reached the set full liquid level, the stopper mechanism returns to the blocking position, and the trough mechanism (5) moves back to the 1st and 2nd mold positions, allowing the pouring station (6) to push the anode carbon block (8) in a cyclical motion.

5. The fully automated casting method for anode carbon blocks according to claim 1, characterized in that: In S1, the electromagnet adopts a three-level gradient magnetic field design, and the attraction force increases sequentially from the center to the edge.

6. The fully automated casting method for anode carbon blocks according to claim 1, characterized in that: In S2, the molten iron transfer track adopts an embedded heat pipe design, and circulating coolant is introduced into the heat pipe. The circulating coolant is an ethylene glycol solution with a flow rate of 2L / min.

7. The fully automated casting method for anode carbon blocks according to claim 1, characterized in that: In S2, the molten iron ladle (2) of the molten iron transfer car (1) adopts a double-layer structure, with the inner layer being an aluminum silicate ceramic fiber insulation layer and the outer layer being a high-alumina mullite low-cement content high-temperature composite castable.

8. The fully automated casting method for anode carbon blocks according to claim 1, characterized in that: In S3, the weighing system uses four sets of piezoelectric sensors to form a redundant measurement network.

9. The fully automated casting method for anode carbon blocks according to claim 1, characterized in that: In S3, the temperature monitoring system integrates multiple Type B thermocouples, which are arranged at different heights in the capacity compartment. When a temperature gradient exceeding 20°C / m is detected, the electromagnetic stirring device is activated.

10. The fully automated casting method for anode carbon blocks according to claim 3, characterized in that: In S5, the anode claw (7) needs to be preheated before casting.

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