Intelligent double-station demolding system for electrolytic cell sealing gasket

Abstract

The application relates to the field of powder metallurgy and special material forming technology, in particular to an intelligent double-station demolding system for electrolytic cell sealing gaskets. The intelligent double-station demolding system comprises a hydraulic machine, a movable cross beam arranged in the hydraulic machine in a sliding mode, demolding mechanisms arranged on the two sides of the movable cross beam, a central controller, a moving workbench arranged on the movable cross beam in a sliding mode, a translation mechanism, a rotating mechanism arranged below the translation mechanism and a rotating ejector rod, a demolding workbench frame, an ejector rod, a translation mechanism and an ejecting mechanism arranged below the translation mechanism. The intelligent double-station demolding system can improve production efficiency, reduce the product failure rate in the demolding process, automatically check the appearance of the sealing gasket green body, avoid the die pressing accidents caused by the residual sealing gasket green body and reduce the maintenance cost.

Description

Technical Field

[0001] This invention relates to the field of powder metallurgy and special material forming technology, and in particular to an intelligent dual-station demolding system for electrolytic cell sealing gaskets. Background Technology

[0002] PTFE gaskets are core sealing components in alkaline water electrolysis hydrogen production equipment, and their quality directly affects the hydrogen sealing performance, operational safety, and service life of the electrolyzer. These gaskets are typically formed from PTFE powder using a mold.

[0003] Current production processes face two major pain points:

[0004] 1. Efficiency bottleneck: Traditional single-station presses involve sequential processes of filling, pressing, holding pressure, and demolding, resulting in slow production cycle and low efficiency.

[0005] 2. Quality risks:

[0006] Demolding damage: The green gasket (unsintered compact) has low strength and poor toughness. If the force is uneven or the ejection force is too large during demolding, micro-cracks or surface scratches are easily generated inside. These micro-defects can become channels for hydrogen leakage during subsequent sintering and use, thus becoming the primary cause of hydrogen leakage problems.

[0007] Quality depends on manual labor: Whether the demolding is complete and whether the gasket blank is intact both depend on manual experience, resulting in poor consistency and making it impossible to prevent defective gasket blanks from flowing into subsequent processes.

[0008] Therefore, this invention proposes an intelligent dual-station demolding system for electrolytic cell sealing gaskets, which can balance high efficiency and ultra-high yield while eliminating hidden damage to the sealing gaskets. This demolding system overcomes efficiency bottlenecks through a dual-station asynchronous parallel operation mode, and achieves "non-destructive" demolding of the sealing gasket blanks through force-sensing adaptive control, rotation-assisted demolding, and online machine vision detection. This significantly improves the sealing reliability of the gaskets from the manufacturing stage and solves the problem of hydrogen leakage. Summary of the Invention

[0009] The purpose of this invention is to solve the problems existing in the prior art and to propose an intelligent dual-station demolding system for electrolytic cell sealing gaskets.

[0010] To achieve the above objectives, the present invention adopts the following technical solution:

[0011] An intelligent dual-station demolding system for an electrolytic cell sealing gasket includes a hydraulic press and a movable crossbeam that slides vertically inside the hydraulic press. Demolding mechanisms are respectively provided on both sides of the movable crossbeam. Each demolding mechanism includes a demolding worktable fixed to one side of the movable crossbeam and a movable worktable that slides on the top surface of the movable crossbeam and the demolding worktable. The system also includes a central controller.

[0012] The movable worktable includes a translation mechanism, a rotation mechanism disposed below the translation mechanism, and a rotation top rod;

[0013] The demolding workbench includes a demolding workbench frame, an ejector rod, a translation mechanism, and an ejector mechanism disposed below the translation mechanism;

[0014] The central controller is electrically connected to the translation mechanism, the rotation mechanism, and the ejection mechanism;

[0015] The central controller is configured to include real-time monitoring of the ejection force of the ejection mechanism, executing a "pause-retract-re-eject" strategy and / or a "micro-vibration" strategy based on the ejection force, and determining the demolding quality of the gasket blank.

[0016] Furthermore, the translation mechanism includes a guide plate and a linear module. There are multiple translation mechanisms, which are arranged diagonally on the top plates of the moving worktable and the demolding worktable, respectively.

[0017] The ejection mechanism includes multiple guide columns, a movable plate slidably disposed on the multiple guide columns, and multiple electric cylinders disposed below the movable plate;

[0018] The rotating mechanism includes a motor fixed to the bottom surface of the slider of the linear module, a second gear fixedly connected to the end of the motor output shaft, a first gear meshing with the second gear, and a rotating push rod slidably disposed in the shaft hole of the first gear.

[0019] Furthermore, the guide plate is fixed diagonally to the top plate of the movable worktable and the demolding worktable, and the guide plate is a strip-shaped through-hole plate;

[0020] The linear module is disposed on one side of the guide plate and is fixed to the bottom surface of the top plate of the movable worktable and the demolding worktable, respectively.

[0021] Furthermore, the rotating push rod is slidably disposed on one side of the linear module slider on the movable worktable and inside the strip-shaped through hole of the guide plate;

[0022] The ejector pin is slidably disposed on one side of the linear module slider on the demolding worktable and in the strip-shaped through hole of the guide plate;

[0023] The guide pillars pass through the sides of the movable plate and their bottoms are fixed on the demolding worktable frame. The cylinder body of the electric cylinder is fixed on the demolding worktable frame, and the end of the ejector screw of the electric cylinder is fixed on the movable plate.

[0024] Furthermore, the ejection mechanism also includes a force sensor integrated into the end of the electric cylinder ejection screw or the movable plate; the force sensor is electrically connected to the central controller, which is configured to: monitor the ejection force in real time during the ejection process and plot the ejection force-stroke curve; if the ejection force exceeds the preset safety threshold in the demolding system within the preset stroke, and the ejection force-stroke curve shows a peak or jitter, then control the ejection mechanism to cyclically execute the "pause-retreat-re-eject" strategy;

[0025] The number of times the "pause-retreat-re-push" strategy is executed is the first maximum number of cycles N1 preset in the demolding system. If the ejection force still exceeds the safety threshold after the number of cycles reaches N1, the central controller will start the "micro-vibration" strategy.

[0026] Furthermore, the "pause-revert-re-top" strategy includes the following steps:

[0027] A1. Emergency Stop: Immediately stop the electric cylinder's ejection action;

[0028] A2. Intelligent reversal: Controls the electric cylinder to move in the reverse direction;

[0029] A3. Push out again: Control the electric cylinder to push out again;

[0030] A4. Cycle and upgrade judgment: When ejecting again, if the ejection force returns to normal, continue to complete the demolding; if the ejection force exceeds the safety threshold again, repeat steps A1-A3.

[0031] Furthermore, the rotating mechanism also includes an encoder for detecting the rotation angle of the rotating push rod; the encoder is electrically connected to the central controller, which is configured to: during the push-out process, if the push-out force exceeds the safety threshold and the push-out force-stroke curve appears at a sustained high level, or if the push-out force still exceeds the safety threshold after the "pause-retreat-push-out" strategy has been executed N1 times, the central controller controls the rotating push rod and the push-out push rod to cyclically execute the "micro-amplitude vibration" strategy based on the feedback from the encoder;

[0032] The "micro-amplitude vibration" strategy is executed cyclically for the second maximum number of cycles N2 preset in the demolding system. If the ejection force still exceeds the safety threshold after the number of cycles reaches N2, the demolding system will stop in an emergency and issue an audible and visual alarm.

[0033] Furthermore, the "micro-vibration" strategy includes the following steps:

[0034] B1. Pause ejection and positioning: The central controller immediately pauses the electric cylinder;

[0035] B2. Perform micro-amplitude reciprocating vibration: The central controller sends a command to the motor of the rotating mechanism to drive the rotating top rod to perform micro-amplitude reciprocating rotation;

[0036] B3. Combining the "retract-repush" compound action: While or after micro-amplitude reciprocating vibration, the demolding system can simultaneously execute the "retract-repush" action in the "pause-retract-repush" strategy.

[0037] B4. Attempt to eject and final judgment: After the micro-amplitude reciprocating vibration ends, the central controller restarts the electric cylinder of the ejection mechanism to attempt ejection;

[0038] B5. If the ejection force returns to below the safety threshold, continue demolding; if the ejection force still exceeds the safety threshold, repeat steps B2-B4.

[0039] Furthermore, the demolding workbench is also equipped with a visual inspection device for visually inspecting the mold cavity and the gasket blank after demolding. The visual inspection device is electrically connected to the central controller, which is configured to: analyze the captured images to determine whether the gasket blank has been completely demolded or whether there are defects. If it has not been completely demolded or has defects, an alarm is issued, data is recorded, and the machine is stopped.

[0040] Furthermore, the demolding mechanism comprises a first station and a second station, with the molds at the first station and the second station being the first mold and the second mold, respectively. The central controller is configured to perform asynchronous parallel operation at both stations, including the following steps:

[0041] S1. Control the moving worktable of the first station to move the first mold to the demolding worktable of the first station, and at the same time control the moving worktable of the second station to move the second mold to the top of the movable crossbeam.

[0042] S2. Control the translation mechanism, ejection mechanism and rotation mechanism of the first station to coordinate their actions to perform the demolding operation of the first mold;

[0043] S3. While S2 is in progress, control the hydraulic press to press the second mold.

[0044] S4. After the first mold demolding operation is completed, the filling operation is carried out. The first station and the second station exchange roles and run S1-S4 in a cycle.

[0045] S2 also includes:

[0046] S21. The rotating ejector pin and the ejector pin move radially to align with the ejection point at the bottom of the first mold and clamp them together.

[0047] S22, Intelligent demolding: The ejection mechanism ejects the material, and the central controller monitors the ejection force in real time, executing a "pause-retract-re-eject" strategy or / and a "micro-vibration" strategy until demolding is complete;

[0048] S23. Visual inspection after demolding: After demolding, the central controller judges the demolding quality of the sealing gasket blank. If it is qualified, it is transferred to the next process; if it is not qualified, the demolding system immediately issues an alarm, records data and stops the machine, waiting for manual handling.

[0049] Compared with existing technologies, the intelligent dual-station demolding system for electrolytic cell sealing gaskets provided by this invention has the following advantages:

[0050] 1. Through a unique dual-station asynchronous parallel operation design, the most time-consuming "pressing / holding" process is completely overlapped with the "demolding + filling" process in terms of time, eliminating equipment waiting time and improving production efficiency;

[0051] 2. Breakthrough guarantee of product quality:

[0052] Force-sensing adaptive control: Through real-time feedback from force sensors, the ejection strategy is intelligently adjusted to achieve flexible demolding, fundamentally eliminating internal damage to the sealing gasket blank caused by excessive ejection force.

[0053] Micro-vibration assistance: In response to the characteristic of PTFE material being prone to sticking to the mold, the sealing gasket blank is loosened by micro-rotation vibration, avoiding the tearing caused by forced ejection;

[0054] The combination of these two technologies reduces the product defect rate caused by the demolding process;

[0055] 3. Integrated visual inspection: 100% automated visual inspection of each sealing gasket blank ensures no residue, no burrs, and no damage, achieving zero omissions and objectivity in quality inspection, and completely avoiding costly molding accidents caused by gasket residue.

[0056] 4. The demolding system will automatically alarm and stop when it encounters abnormal resistance, protecting the mold and the machine itself, and reducing maintenance costs and downtime. Attached Figure Description

[0057] Figure 1 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 1 (with foundation);

[0058] Figure 2 This is a schematic diagram of the three-dimensional structure of the present invention. Figure 2 (Without foundation);

[0059] Figure 3 This is a three-dimensional structural diagram of the translation mechanism, rotation mechanism, ejection mechanism, rotating ejector rod, and ejection ejector rod of the present invention;

[0060] Figure 4 This is a flowchart of the demolding process of the present invention;

[0061] In the diagram: 1. Hydraulic press, 2. Moving worktable, 3. Demolding worktable, 31. Demolding worktable frame, 4. Mold, 5. Translation mechanism, 51. Guide plate, 52. Linear module, 6. Ejection mechanism, 61. Electric cylinder, 62. Movable plate, 63. Guide column, 7. Movable crossbeam, 8. Rotation mechanism, 81. Motor, 82. Gear II, 83. Gear I, 9. Rotating ejector rod, 10. Ejector rod. Detailed Implementation

[0062] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0063] In the description of this invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0064] Example 1, such as Figures 1-3 As shown, an intelligent dual-station demolding system for an electrolytic cell sealing gasket includes a hydraulic press 1 and a movable crossbeam 7 that slides vertically inside the hydraulic press 1. Demolding mechanisms are respectively provided on both sides of the movable crossbeam 7. The demolding mechanism includes a demolding worktable 3 that is fixed to one side of the movable crossbeam 7 and a movable worktable 2 that slides on the top surface of the movable crossbeam 7 and the demolding worktable 3. It also includes a central controller.

[0065] The mobile worktable 2 includes a translation mechanism 5, a rotation mechanism 8 disposed below the translation mechanism 5, and a rotation top rod 9;

[0066] The demolding workbench 3 includes a demolding workbench frame 31, an ejector rod 10, a translation mechanism 5, and an ejector mechanism 6 disposed below the translation mechanism 5;

[0067] The central controller is electrically connected to the translation mechanism 5, the rotation mechanism 8, and the ejection mechanism 6;

[0068] The central controller is configured to include real-time monitoring of the ejection force of the ejection mechanism 6, executing a "pause-retreat-re-eject" strategy and / or a "micro-vibration" strategy based on the ejection force, and determining the demolding quality of the sealing gasket blank.

[0069] This invention constructs a highly integrated automated demolding system. Its core framework is a hydraulic press 1, which provides the pressure required for the pressing operation. Inside the hydraulic press 1, there is a movable crossbeam 7 that can slide precisely up and down along four guide side beams. In this invention, the hydraulic press 1 is an upward-pressing type; therefore, the main innovative element of this invention is mounted on the movable crossbeam 7. If the hydraulic press 1 is a downward-pressing type, the main innovative element of this invention can be mounted on the lower crossbeam of the hydraulic press 1.

[0070] On the left and right sides of the movable crossbeam 7, two sets of fully functional demolding mechanisms are arranged symmetrically, which are defined as the first station and the second station, respectively.

[0071] The specific mechanical components of each demolding mechanism are as follows:

[0072] Mobile workbench 2:

[0073] Function: As a transport platform for mold 4, it realizes the reciprocating motion between the "pressing station" of mold 4 on the movable crossbeam 7 and the "demolding station" of the demolding workbench 3 on the outside of the movable crossbeam 7.

[0074] Structure: It is a rigid cast iron or steel plate welded platform. Its bottom is connected to the upper plane of the movable crossbeam 7 and the demolding table 3 via a high-precision linear guide pair (standard configuration, not shown in the figure). This linear guide pair ensures that the movable table 2 can slide smoothly and accurately in a direction parallel to the length of the movable crossbeam 7;

[0075] Drive: Driven by a servo motor in conjunction with a ball screw or rack and pinion (standard setting, not shown in the figure) to ensure positioning accuracy;

[0076] Mold fixing: The table surface is equipped with standard T-slots or positioning pin holes for quick installation and positioning of the mold 4.

[0077] The demolding worktable 3 remains stationary, while the movable worktable 2 moves onto it to perform the demolding operation. The demolding worktable 3, in conjunction with the movable worktable 2, is responsible for executing precise demolding actions. The demolding worktable 3 is supported by a robust demolding worktable frame 31, which is securely fixed to one side of the movable crossbeam 7 via foundation support and bolts. Its position is directly opposite the end point of the travel of the movable worktable 2, i.e., the demolding station.

[0078] To facilitate filling, demolding, and other post-demolding operations, this invention is placed in a sunken foundation, with the top surface of the foundation approximately at the height of the demolding station. The foundation is equipped with steps and passageways for easy maintenance, filling, and material removal.

[0079] Example 2, as Figures 2-3 As shown, the translation mechanism 5 includes a guide plate 51 and a linear module 52. There are multiple translation mechanisms 5, which are arranged diagonally on the top plates of the moving worktable 2 and the demolding worktable 3.

[0080] The guide plate 51 is fixed diagonally on the top plate of the movable worktable 2 and the demolding worktable 3 respectively, and the guide plate 51 is a strip-shaped through-hole plate;

[0081] The linear module 52 is disposed on one side of the guide plate 51 and is fixed to the bottom surface of the top plate of the movable worktable 2 and the demolding worktable 3 respectively.

[0082] The rotating push rod 9 is slidably disposed on one side of the slider of the linear module 52 on the movable worktable 2 and in the strip-shaped through hole of the guide plate 51;

[0083] The ejector rod 10 is slidably disposed on one side of the slider of the linear module 52 on the demolding worktable 3 and in the strip-shaped through hole of the guide plate 51.

[0084] In this embodiment, refer to Figure 3 The translation mechanism 5 is key to achieving radial adjustment of the rotating ejector rod 9 and the ejector rod 10. Four sets of translation mechanisms 5 are installed diagonally on the top plates of both the moving worktable 2 and the demolding worktable 3 to ensure the force balance of the mold 4. Simultaneously, the mold 4 has ejection points corresponding to the rotating ejector rod 9; in this embodiment, there are four ejection points.

[0085] The guide plate 51 is a steel plate with a long, narrow through hole at its center, and the guide plates are fixed to the top plates of the moving worktable 2 and the demolding worktable 3 in a diagonal arrangement. The linear module 52 is a standardized linear motion unit that integrates a servo motor, an ejector screw, and a slider. It is installed on the bottom surface of the moving worktable 2 and the demolding worktable 3, and the movement direction of its slider is consistent with the length direction of the through hole in the guide plate 51.

[0086] A connecting block 1 is fixedly connected to the side of the slider of the linear module 52 of the movable worktable 2, and a connecting block 2 is fixedly connected to the side of the slider of the linear module 52 of the demolding worktable 3. The rotating ejector rod 9 passes through the connecting block 1 and is placed in the strip-shaped through hole of the guide plate 51 of the movable worktable 2; the ejector rod 10 passes through the connecting block 2 and is placed in the strip-shaped through hole of the guide plate 51 of the demolding worktable 3.

[0087] When the linear module 52 receives a control signal, its slider drives the rotating ejector rod 9 and the ejector rod 10 to move precisely radially along the guide plate 51 of the moving worktable 2 and the demolding worktable 3, respectively, to adapt to the ejection point position of molds 4 of different sizes.

[0088] Example 3, as Figure 3 As shown, based on the above embodiment, the ejection mechanism 6 includes a plurality of guide posts 63, a movable plate 62 slidably disposed on the plurality of guide posts 63, and a plurality of electric cylinders 61 disposed below the movable plate 62;

[0089] The guide pillars 63 pass through the sides of the movable plate 62, and their bottoms are fixed on the demolding workbench frame 31. The cylinder body of the electric cylinder 61 is fixed on the demolding workbench frame 31, and the end of the ejector screw is fixed on the movable plate 62.

[0090] The ejection mechanism 6 also includes a force sensor integrated on the end of the ejection screw of the electric cylinder 61 or on the movable plate 62; the force sensor is electrically connected to the central controller, which is configured to: monitor the ejection force in real time during the ejection process and plot the ejection force-stroke curve; if the ejection force exceeds the preset safety threshold in the demolding system within the preset stroke, and the ejection force-stroke curve shows a peak or jitter, then control the ejection mechanism 6 to cyclically execute the "pause-retreat-re-eject" strategy;

[0091] The number of times the "pause-retreat-re-push" strategy is executed is the first maximum number of cycles N1 preset in the demolding system. If the ejection force still exceeds the safety threshold after the number of cycles reaches N1, the central controller will start the "micro-vibration" strategy.

[0092] In this embodiment, a force sensor (such as a strain gauge or piezoelectric sensor) is integrated at the end of the ejector screw of the electric cylinder 61 to monitor force changes during the ejection process in real time. Multiple guide pillars 63 are evenly distributed and vertically fixed to the demolding table frame 31 at their bottom. A movable plate 62 is fitted onto the guide pillars 63 via linear bearings and can slide precisely up and down along the guide pillars 63. Four electric cylinders 61 are evenly distributed below the movable plate 62. The cylinder bodies of the electric cylinders 61 are fixed to the demolding table frame 31, and the ends of their ejector screws are rigidly connected to the movable plate 62. An ejector rod 10 is positioned above the movable plate 62. When the electric cylinder 61 pushes the movable plate 62 upward, the ejection force is transmitted to the mold 4 through the ejector rod 10 and the rotating rod 9, completing the demolding process.

[0093] In this embodiment, during the ejection process, the central controller reads data from the force sensor at a high-frequency sampling rate (e.g., 1kHz) and plots a real-time ejection force-stroke curve. Ideally, the ejection force-stroke curve rises smoothly to its peak and then quickly falls back. When the gasket blank sticks to the mold, the ejection force will climb at a certain stroke point, and the ejection force-stroke curve will show a brief, steep peak, or high-frequency, low-amplitude jitter. This usually indicates that there is soft sticking or slight local mechanical jamming between the gasket blank and the mold. For example, the gasket blank shrinks due to cooling and wraps tightly around the mold core 4 over a large area, but has not yet formed a hard lock.

[0094] Once the central controller detects that the ejection force exceeds the preset safety threshold (this safety threshold can be set on the HMI according to the characteristics of the gasket blank and the mold) or that the ejection force-stroke curve shows high-frequency, low-amplitude jitter, it immediately executes the following "pause-retreat-re-eject" strategy:

[0095] A1. Emergency Stop: Immediately stop the ejection action of electric cylinder 61;

[0096] A2. Intelligent Reverse Movement: Controls the electric cylinder 61 to move in the reverse direction by a small distance (e.g., 0.5mm to 2mm). This operation can instantly release accumulated stress, causing slight loosening at the adhesion interface between the gasket blank and the mold, thus relieving the "vacuum adsorption" or "mechanical jamming" state between the gasket blank and the mold.

[0097] A3. Re-ejection: Pause briefly (e.g., 0.1s) to allow stress redistribution in the demolding system. Then, control the electric cylinder 61 again to eject at the same or slightly slower speed;

[0098] A4. Cycle and upgrade judgment: When ejecting again, if the ejection force returns to normal, continue to complete the demolding; if the ejection force exceeds the safety threshold again, repeat steps A1-A3.

[0099] Cycle Limitation: The demolding system presets a first maximum number of cycles N1 (e.g., 3 times). If the ejection force still cannot return to normal after N1 cycles, the demolding system determines that this strategy is invalid and the problem is more serious, and will automatically upgrade to the "micro-vibration" strategy.

[0100] Technical benefits: This "pause-retreat-re-push" strategy gives the machine "tactile feedback," enabling it to perceive and handle anomalies like an experienced operator. It significantly reduces the risk of breakage of the rotating ejector rod 9 and the ejector rod 10, as well as damage to the green gasket, improving production yield and equipment reliability. It is a key technology for achieving unmanned operation.

[0101] Example 4, based on the above examples, such as Figure 3As shown, the rotating mechanism 8 includes a motor 81 fixed to the bottom surface of the slider of the linear module 52, a gear 82 fixedly connected to the end of the output shaft of the motor 81, a gear 83 meshing with the gear 82, and a rotating push rod 9 slidably disposed in the shaft hole of the gear 83. A connecting block 3 fixedly connected to the motor 81 is disposed above the gear 83, and multiple L-shaped fixing blocks (not fully shown in the figure) are fixedly connected below the connecting block 3. The long sides of the L-shaped fixing blocks abut against the bottom surface of the gear 83. Therefore, the gear 83 can be fixed in height by the connecting block 3 and the fixing blocks. Based on the above embodiment, the lower half of the rotating push rod 9 is provided with a key that mates with the shaft hole of the gear 83. The rotating push rod 9 passes through the shaft hole of the gear 83, the connecting block 3, and the connecting block 1 sequentially from bottom to top, and is placed in the strip-shaped through hole of the guide plate 51 of the movable worktable 2.

[0102] The rotating mechanism 8 also includes an encoder for detecting the angle of the rotating push rod 9; the encoder is electrically connected to the central controller, which is configured to: during the push-out process, if the push-out force exceeds the safety threshold and the push-out force-stroke curve appears at a sustained high level, or if the push-out force still exceeds the safety threshold after the "pause-retreat-push-out" strategy has been executed N1 times, the central controller controls the rotating push rod 9 and the push-out push rod 10 to cyclically execute the "micro-amplitude vibration" strategy based on the feedback from the encoder;

[0103] The "micro-amplitude vibration" strategy is executed cyclically for the second maximum number of cycles N2 preset in the demolding system. If the ejection force still exceeds the safety threshold after the number of cycles reaches N2, the demolding system will stop in an emergency and issue an audible and visual alarm.

[0104] The entire rotating mechanism 8 is fixed to the slider of the linear module 52 of the translation mechanism 5 by the motor 81, so it has the ability to follow the radial movement of the translation mechanism 5.

[0105] The transmission chain of rotating mechanism 8 is as follows:

[0106] Power source: A motor 81 with an encoder. Motor 81 is a servo motor that provides controllable rotational motion and precise angle feedback.

[0107] First-stage reduction and transmission: Gear 2 82 is fixed on the output shaft of motor 81. Gear 1 83 meshes with gear 2 82. This gear pair not only transmits torque, but also determines the final output speed and direction.

[0108] Output: The rotating ejector rod 9 is keyed into the central shaft hole of gear 83. The upper end of the rotating ejector rod 9 passes through the guide plate 51 of the movable worktable 2 and can press against the bottom of the mold. When the motor 81 rotates, the power is ultimately converted into the rotation of the rotating ejector rod 9 through the gear pair.

[0109] The main function of the rotating mechanism 8 is to provide rotating jacking force or "micro-vibration".

[0110] Rotary ejection force: For specific structural gaskets requiring rotary demolding, the central controller, based on encoder feedback, precisely controls the motor 81 to drive the rotary ejector rod 9 at a preset speed and direction while the ejector mechanism 6 is operating, preventing excessive rotation that could damage the gasket blank. This allows the gasket blank to rotate simultaneously during ejection, achieving a complex spiral demolding action.

[0111] Triggering conditions for the "micro-vibration" strategy:

[0112] Direct trigger: When the ejection force not only exceeds the safety threshold during the ejection process, but also the ejection force-stroke curve shows a sharp rise and remains at a high level, the demolding system directly judges it as hard sticking to the mold, skips the "pause-retreat-re-eject" strategy, and directly starts the "micro-vibration" strategy.

[0113] Upgrade Trigger: As described in the above embodiments, if the problem is still not resolved after the "pause-revert-repush" strategy has been cycled N1 times, the demolding system will automatically upgrade to the central controller to start the "micro-vibration" strategy.

[0114] "Micro-vibration" strategy:

[0115] B1. Pause Ejection and Positioning: The central controller immediately pauses the electric cylinder 61 of the ejection mechanism 6. At the same time, it ensures that the rotating ejector rod 9 on the moving worktable 2 has been positioned by the translation mechanism 5 in the previous embodiment, with its top abutting against the corresponding ejection point at the bottom of the mold;

[0116] B2. Perform micro-amplitude reciprocating vibration: The central controller sends a command to the motor 81 of the rotating mechanism 8 to drive the rotating top rod 9 to perform micro-amplitude reciprocating rotation;

[0117] Specific parameters:

[0118] Rotation angle: typically between ±10° and ±30° (controlled by precise feedback from the encoder);

[0119] Rotation frequency: relatively high, usually between 5Hz and 15Hz (i.e., alternating forward and backward 5-15 times per second).

[0120] Duration: Vibrate continuously for a preset time t, for example, 3 seconds;

[0121] High-frequency micro-vibration can transform the enormous static friction between the gasket green and the mold into smaller dynamic friction. Micro-vibration applies alternating shear stress to the bonding interface, effectively breaking up the microscopic mechanical engagement points between the gasket green and mold 4. The vibration energy helps overcome van der Waals forces and causes slight loosening of the gasket green as a whole.

[0122] B3. Combining the "retract-repush" compound action: This is a more powerful combination strategy. Simultaneously with or after micro-amplitude reciprocating vibration, the demolding system can synchronously execute the "retract-repush" action from the "pause-retract-repush" strategy.

[0123] "Micro-amplitude reciprocating vibration" is responsible for "loosening" in the rotational direction, while "retracting-re-pushing" is responsible for "unfastening" in the axial direction. The combination of the two can handle more complex sticking failures.

[0124] B4. Attempt to eject and final judgment: After the micro-amplitude reciprocating vibration ends, the central controller restarts the electric cylinder 61 of the ejection mechanism 6 to attempt ejection;

[0125] B5. If the ejection force returns to below the safety threshold, continue demolding; if the ejection force still exceeds the safety threshold, repeat steps B2-B4.

[0126] Cycle Limit: The demolding system has a preset second maximum number of cycles N2 (e.g., 3 times). If demolding still fails after N2 cycles, it is determined to be a non-automatic recovery fault (such as severe mold damage or abnormal clamping), and the machine will immediately stop in an emergency, issuing an audible and visual alarm and requesting manual intervention.

[0127] The "pause-retreat-re-push" strategy and the "micro-vibration" strategy constitute an intelligent response system that progresses from simple to complex and is strengthened step by step. The safety threshold is the start switch for the entire system, while the ejection force-stroke curve is the diagnostic report. Through this system, the demolding system perfectly simulates the thought process and behavior of an experienced operator when dealing with mold sticking problems, but it is faster, more accurate, and more reliable, thus achieving non-destructive and efficient demolding of the sealing gasket blank.

[0128] In Example 5, the demolding workbench 3 is also equipped with a visual inspection device (not shown in the figure) for visually inspecting the cavity of the mold 4 and the green gasket after demolding. The visual inspection device is electrically connected to the central controller, which is configured to visually inspect the cavity of the mold 4 and the green gasket after demolding. The central controller is also electrically connected to the visual inspection device and configured to analyze the captured images to determine whether the green gasket has been completely demolded or whether there are defects. If it has not been completely demolded or has defects, an alarm is issued, data is recorded, and the machine is stopped.

[0129] In this embodiment, the visual inspection device includes a high-resolution industrial camera and a ring-shaped LED light source. It is securely mounted on the demolding worktable frame 31, with its field of view centered on the mold cavity 4 and the sealing gasket blank, and performs visual inspection after demolding.

[0130] The specific operation steps and working principle of visual detection in this embodiment are as follows:

[0131] C1. Image Acquisition: When a certain workstation completes the demolding operation, before the moving worktable 2 is moved away, the central controller triggers the vision inspection device to take pictures of the mold cavity and the gasket blank: the ring LED light source is lit up instantly, and the entire mold cavity and gasket blank are uniformly illuminated in the form of coaxial light or low-angle diffused light to highlight the outline and surface defects of the gasket blank. The industrial camera completes a high-definition shot in a very short exposure time (to prevent motion blur).

[0132] C2. Image Preprocessing: The captured images are transmitted to the central controller, which performs preprocessing to improve analysis accuracy, including:

[0133] Noise reduction filtering: Use Gaussian filtering or median filtering algorithms to eliminate inherent noise and dust interference from the image sensor;

[0134] Contrast enhancement: Stretches the grayscale range of the image, making the contrast between the gasket blank, mold cavity and background more distinct;

[0135] C3. Feature Extraction and Recognition Analysis:

[0136] This is the core of the algorithm, which executes multiple analysis tasks in parallel:

[0137] a. Integrity inspection (presence or absence of residue):

[0138] Methods: Blob analysis (connected component analysis) or template matching;

[0139] Process: The preprocessed image is binarized, converting it into an image with only black and white pixels. The demodulation system calculates the number, area, and position of white (or black) connected regions. This is then compared with a pre-stored cavity image template in the central controller.

[0140] Judgment: If the area and shape of a connected region within the cavity are found to match the outline height of a standard sealing gasket, it is judged as "the sealing gasket blank has not been removed and there is residue";

[0141] b. Defect detection (burrs, chipped corners, cracks):

[0142] Method: Edge detection (such as the Canny algorithm) combined with morphological operations;

[0143] process:

[0144] Flash: Extra, irregular, fine edges are detected outside the edge of the gasket profile;

[0145] Missing corners / cracks: Indentations, breaks, or burrs were detected within the edge of the gasket profile. Morphological "opening operations" help highlight these minor defects;

[0146] Judgment: If abnormal edges outside the contour or serious defects inside the contour are detected, it is judged as "gasket green defect".

[0147] C4. Decision-making and execution:

[0148] Qualified: If all the above analysis items pass, it is judged as qualified. The central controller determines that the mold is OK, the demolding system continues to run, and the qualified sealing gasket blank is transferred to the next process.

[0149] Non-compliant: If any of the above analysis items fails (residue or defect detected), it is judged as non-compliant, and the central controller immediately:

[0150] a. Issue an alarm: Trigger the audible and visual alarm to notify the operator;

[0151] b. Record data: Save abnormal images, occurrence time, workstation number, and mold number to the database for traceability analysis;

[0152] c. Execute a shutdown: Immediately suspend the entire demolding system. This ensures that defective gasket preforms are not transferred to the next process, provides accurate data support for mold 4 maintenance, and prevents mold 4 with residue from entering the next mold closing cycle, thereby completely avoiding costly mold-pressing accidents;

[0153] The visual inspection device enables online automated inspection of demolding quality, replacing manual inspection which is prone to fatigue and errors. It not only eliminates molding accidents caused by residual gaskets, but also filters out defective products with appearance flaws, ensuring the consistency and high reliability of the gasket blanks.

[0154] Example 6: The demolding mechanism consists of a first station and a second station, with molds 4 at the first and second stations being the first mold and the second mold, respectively. The central controller is configured to perform asynchronous parallel operations at both stations, including the following steps:

[0155] S1. Control the moving worktable 2 of the first station to move the first mold to the demolding worktable 3 of the first station, and at the same time control the moving worktable 2 of the second station to move the second mold to the top of the movable crossbeam 7.

[0156] S2. The translation mechanism 5, ejection mechanism 6 and rotation mechanism 8 of the first station work together to perform the demolding operation of the first mold.

[0157] S3. While demolding at the first station, control the hydraulic press 1 to press the second mold.

[0158] S4. After the first mold demolding operation is completed, the filling operation is carried out. The first station and the second station exchange roles and run S1-S4 in a cycle.

[0159] Based on the above embodiments, in this embodiment, the central controller (such as an industrial PLC) is the brain of the entire demolding system. Figure 4 As shown, the specific control flow is as follows:

[0160] Initial state: The moving worktable 2 of the first station is located at the pressing station of the movable crossbeam 7, and the moving worktable 2 of the second station is located at the demolding station of the second station.

[0161] S1, Synchronous workstation repositioning:

[0162] The central controller controls the moving worktable 2 of the first station to move the first mold (containing a pre-pressed sealing gasket blank) to the demolding station of the first station;

[0163] At the same time, the central controller controls the moving worktable 2 of the second station to move the second mold (with the filling completed) to the pressing station inside the hydraulic press 1;

[0164] S2. The translation mechanism 5, ejection mechanism 6, and rotation mechanism 8 of the first station work together to perform the demolding operation of the first mold, specifically including the following steps:

[0165] S21. The central controller synchronously adjusts the translation mechanism 5 on the moving worktable 2 and demolding worktable 3 of the first station, driving the rotating ejector rod 9 and the ejector rod 10 to move radially, accurately aligning with the ejection point at the bottom of the first mold and clamping it.

[0166] S22, Intelligent Demolding: The electric cylinder 61 of the ejection mechanism 6 is activated to eject the material. The force sensor monitors the ejection force in real time and plots the ejection force-stroke curve. If the ejection force-stroke curve is normal, the material is ejected smoothly; if the ejection force-stroke curve is abnormal, the central controller controls the ejection mechanism 6 to execute a "pause-retract-re-eject" strategy or / and activates the rotary mechanism 8 to execute a "micro-vibration" strategy until demolding is complete.

[0167] S23. Post-demolding visual inspection: After demolding, the central controller judges the demolding quality of the gasket blank: Before the moving worktable 2 at the first station is removed, the central controller triggers the visual inspection device to take pictures of the mold cavity and the gasket blank, and performs integrity and defect detection on the gasket blank. If the visual inspection is qualified, it is transferred to the next process; if the visual inspection is unqualified and residues or defects are found, the demolding system immediately issues an alarm, records data, and stops the machine, awaiting manual handling.

[0168] S3, operating in parallel with S2, involves controlling hydraulic press 1 to press the second mold while demolding at the first station. This includes the following steps:

[0169] During the entire execution of step S2, the central controller controls the moving beam 7 of the hydraulic press 1 to move upward, performing pressing and pressure holding operations on the second mold;

[0170] S4. Filler and role exchange:

[0171] After demolding and visual inspection at the first station, the first mold is filled by an automatic filling machine or manually. The roles of the first and second stations are switched, and steps S1-S4 are repeated to achieve uninterrupted continuous production.

[0172] The above description is only a preferred embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any equivalent substitutions or modifications made by those skilled in the art within the scope of the technology disclosed in the present invention, based on the technical solution and inventive concept of the present invention, should be covered within the scope of protection of the present invention.

Claims

1. An intelligent dual-station demolding device for an electrolytic cell sealing gasket, comprising a hydraulic press (1) and a movable crossbeam (7) slidably disposed inside the hydraulic press (1), characterized in that: The movable crossbeam (7) is provided with demolding mechanisms on both sides. The demolding mechanisms include demolding worktables (3) fixed on one side of the movable crossbeam (7) and movable worktables (2) slidably disposed on the top surfaces of the movable crossbeam (7) and the demolding worktables (3), and also include a central controller. The mobile worktable (2) includes a translation mechanism (5), a rotation mechanism (8) disposed below the translation mechanism (5), and a rotation top rod (9). The demolding workbench (3) includes a demolding workbench frame (31), an ejector rod (10), a translation mechanism (5), and an ejector mechanism (6) located below the translation mechanism (5). The central controller is electrically connected to the translation mechanism (5), the rotation mechanism (8), and the ejection mechanism (6); The central controller is configured to include real-time monitoring of the ejection force of the ejection mechanism (6), executing a "pause-retreat-re-eject" strategy and a "micro-vibration" strategy based on the ejection force; and determining the demolding quality of the gasket blank. The ejection mechanism (6) also includes a force sensor; the force sensor is electrically connected to the central controller, which is configured to: monitor the ejection force in real time during the ejection process and plot the ejection force-stroke curve; if the ejection force exceeds the preset safety threshold in the demolding system within the preset stroke, and the ejection force-stroke curve shows a peak or jitter, then control the ejection mechanism (6) to cyclically execute the "pause-retreat-re-eject" strategy; The number of times the "pause-retreat-re-push" strategy is executed is the first maximum number of cycles N1 preset in the demolding system. If the ejection force still exceeds the safety threshold after the number of cycles reaches N1, the central controller will start the "micro-vibration" strategy. The "micro-vibration" strategy includes the following steps: B1. Pause ejection and positioning: The central controller immediately pauses the electric cylinder (61). B2. Perform micro-amplitude reciprocating vibration: The central controller sends a command to the motor (81) of the rotating mechanism (8) to drive the rotating top rod (9) to perform micro-amplitude reciprocating rotation; B3. Combining the "retract-repush" compound action: While or after the micro-amplitude reciprocating vibration is in progress, the demolding system simultaneously executes the "retract-repush" action in the "pause-retract-repush" strategy. B4. Attempt to eject and final judgment: After the micro-amplitude reciprocating vibration ends, the central controller restarts the electric cylinder (61) of the ejection mechanism (6) to attempt ejection; B5. If the ejection force returns to below the safety threshold, continue demolding; if the ejection force still exceeds the safety threshold, repeat steps B2-B4.

2. The intelligent dual-station demolding device for an electrolytic cell sealing gasket according to claim 1, characterized in that: The translation mechanism (5) includes a guide plate (51) and a linear module (52). There are multiple translation mechanisms (5), which are arranged diagonally on the top plates of the moving worktable (2) and the demolding worktable (3). The ejection mechanism (6) includes multiple guide posts (63), a movable plate (62) slidably disposed on the multiple guide posts (63), and multiple electric cylinders (61) disposed below the movable plate (62). The rotating mechanism (8) includes a motor (81) fixed on the bottom surface of the slider of the linear module (52), a gear two (82) fixedly connected to the end of the output shaft of the motor (81), a gear one (83) meshing with the gear two (82), and a rotating push rod (9) slidably disposed in the shaft hole of the gear one (83).

3. The intelligent dual-station demolding device for an electrolytic cell sealing gasket according to claim 2, characterized in that: The guide plate (51) is fixed diagonally on the top plate of the movable worktable (2) and the demolding worktable (3), and the guide plate (51) is a strip-shaped through-hole plate; The linear module (52) is disposed on one side of the guide hole plate (51) and fixed to the bottom surface of the top plate of the movable worktable (2) and the demolding worktable (3).

4. The intelligent dual-station demolding device for an electrolytic cell sealing gasket according to claim 2, characterized in that: The rotating top rod (9) is slidably disposed on one side of the slider of the linear module (52) on the movable worktable (2) and in the strip-shaped through hole of the guide plate (51); The ejector rod (10) is slidably disposed on one side of the slider of the linear module (52) on the demolding worktable (3) and in the strip-shaped through hole of the guide plate (51); The guide pillars (63) pass through the side of the movable plate (62) respectively, and their bottoms are fixed on the demolding workbench frame (31). The cylinder body of the electric cylinder (61) is fixed on the demolding workbench frame (31), and the end of the ejector screw of the electric cylinder (61) is fixed on the movable plate (62).

5. The intelligent dual-station demolding device for an electrolytic cell sealing gasket according to claim 1, characterized in that: The "pause-revert-re-re-push" strategy includes the following steps: A1. Emergency stop: Immediately stop the ejection action of the electric cylinder (61); A2. Intelligent reversal: Controls the electric cylinder (61) to move in the reverse direction; A3. Push out again: Control the electric cylinder (61) to push out again; A4. Cycle and upgrade judgment: When ejecting again, if the ejection force returns to normal, continue to complete the demolding; if the ejection force exceeds the safety threshold again, repeat steps A1-A3.

6. The intelligent dual-station demolding device for an electrolytic cell sealing gasket according to claim 1, characterized in that: The rotating mechanism (8) also includes an encoder for detecting the rotation angle of the rotating top rod (9); the encoder is electrically connected to the central controller, which controls the rotating top rod (9) and the ejector top rod (10) to cyclically execute the "micro-amplitude vibration" strategy based on the feedback from the encoder. The "micro-amplitude vibration" strategy is executed cyclically for the second maximum number of cycles N2 preset in the demolding system. If the ejection force still exceeds the safety threshold after the number of cycles reaches N2, the demolding system will stop in an emergency and issue an audible and visual alarm.

7. The intelligent dual-station demolding device for an electrolytic cell sealing gasket according to claim 1, characterized in that: The demolding workbench (3) is also equipped with a visual inspection device, which is used to visually inspect the cavity of the mold (4) and the green gasket after demolding. The visual inspection device is electrically connected to the central controller, which is configured to: analyze the captured images to determine whether the green gasket has been completely removed or whether there are defects. If it has not been completely removed or has defects, an alarm is issued, data is recorded and the machine is stopped.

8. The intelligent dual-station demolding device for an electrolytic cell sealing gasket according to claim 5, characterized in that: The demolding mechanisms are a first station and a second station, and the molds (4) on the first station and the second station are the first mold and the second mold, respectively. The central controller is configured to perform asynchronous parallel operation of the two stations, including the following steps: S1. Control the moving worktable (2) of the first station to move the first mold to the demolding worktable (3) of the first station, and at the same time control the moving worktable (2) of the second station to move the second mold to the top of the movable crossbeam (7). S2. The translation mechanism (5), ejection mechanism (6) and rotation mechanism (8) of the first station work together to perform the demolding operation of the first mold; S3. While S2 is being performed, control the hydraulic press (1) to press the second mold. S4. After the first mold demolding operation is completed, the filling operation is carried out. The first station and the second station exchange roles and run S1-S4 in a cycle. S2 also includes: S21, the rotating ejector pin (9) and the ejector pin (10) move radially, align with the ejection point at the bottom of the first mold and press against it; S22, Intelligent demolding: The ejection mechanism (6) ejects, and the central controller monitors the ejection force in real time, and executes the "pause-retreat-re-eject" strategy and the "micro-vibration" strategy until demolding is completed; S23. Visual inspection after demolding: After demolding, the central controller judges the demolding quality of the sealing gasket blank. If it is qualified, it is transferred to the next process; if it is not qualified, the demolding system immediately issues an alarm, records data and stops the machine, waiting for manual handling.

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