Multi-mechanism cooperative repair control method and system for stainless steel cathode plate

Abstract

The invention relates to the technical field of copper electrolysis production equipment, and discloses a multi-mechanism collaborative repair control method and system for a stainless steel cathode plate. The method sequentially comprises the following steps: acquiring surface deformation data of a negative plate through a detection unit; generating repair parameters containing leveling point positions and strength based on the data; controlling a leveling execution mechanism to repair according to the parameters; detecting and judging again after repairing, and if not, compensating and repairing based on new data generation parameters until the data are qualified. The system comprises a sensing layer, an execution layer comprising a leveling execution mechanism and a control layer configured with a collaborative scheduling module, and is used for executing the method. According to the invention, the automatic cooperation and closed-loop self-adaptive repair of multiple mechanisms such as edge strip clamping, overturning, polishing, leveling and detection are realized, the average single-chip repair time is shortened to about 165 seconds from about 900 seconds of a traditional method, and the percent of pass is increased to nearly 100 percent from 92 percent.

Description

Technical Field

[0001] This invention belongs to the technical field of copper electrolysis production equipment, specifically relating to a multi-mechanism collaborative repair control method and system for stainless steel cathode plates. Background Technology

[0002] As a core component in copper electrolysis production, the flatness and perpendicularity of stainless steel cathode plates directly affect the quality of electrolytic copper and the efficiency of production current. During long-term cyclic use, cathode plates inevitably develop defects such as warping, scratches, and deformation due to welding stress, mechanical impact, and electrolytic deposition. Therefore, periodic repair is necessary to restore their performance. Currently, there is an urgent need in the industry for efficient, high-precision, and automated cathode plate repair technology to replace traditional manual repair methods that rely on experience, are labor-intensive, and have inconsistent quality, thus achieving a continuous and intelligent repair process.

[0003] Existing technologies include several automated or semi-automated solutions for specific processes involving cathode plates. For example, some solutions involve visual inspection of cathode plate appearance defects (e.g., patent CN115343293A) or inspection of cathode plate surface flatness (e.g., patent CN223192315U); others focus on physical leveling of the cathode plate (e.g., patent CN120532897A) or trimming of the clamping strips (e.g., patent CN203393241U). However, these solutions generally have limitations: they are mostly isolated devices or methods for a single function or process, such as only performing inspection or only achieving leveling. In actual repair workshops, a complete repair process typically includes multiple steps such as removing clamping strips, flipping, polishing, leveling, and inspection. Existing technologies lack a unified, coordinated, and seamlessly integrated collaborative control scheme for these multiple devices or mechanisms with varying functions, operating times, and operating principles. This results in a fragmented and interrupted repair process, heavily reliant on manual transfer, positioning, and judgment between various independent devices. This not only leads to low overall repair efficiency but also makes it difficult to guarantee the consistency and stability of repair accuracy, failing to meet the needs of modern continuous production.

[0004] In view of this, the present invention aims to provide an improved technical solution to overcome the shortcomings of the prior art. Summary of the Invention

[0005] To address the aforementioned problems in existing technologies, this invention provides a multi-mechanism collaborative repair control method for stainless steel cathode plates, applied to a repair system including a detection unit and a leveling unit. The method sequentially includes:

[0006] Testing steps: Obtain the deformation data of the cathode plate to be repaired;

[0007] Decision-making steps: Based on the plate deformation data, generate repair parameters for controlling the leveling operation, the repair parameters including the location and intensity information of the leveling action;

[0008] Execution steps: According to the repair parameters, control the leveling actuator to level and repair the cathode plate.

[0009] Verification steps: Obtain the deformation data of the cathode plate surface after leveling and repair again;

[0010] Judgment steps: Based on the re-acquired panel deformation data, determine whether the repair result meets the preset qualification standards;

[0011] Compensation steps: If it is determined that the qualified standard is not met, new repair parameters are generated based on the current deformation data of the plate surface, and the leveling actuator is controlled to perform compensation and repair operations.

[0012] Furthermore, the repair parameters include at least one of the following: the location of the leveling rib, the stamping depth, the number of stampings, and the stamping sequence among multiple locations.

[0013] Furthermore, the detection step is performed by multiple laser rangefinders; the execution step is performed by a pneumatic stamping cylinder.

[0014] Furthermore, prior to the detection step, the method further includes a preprocessing step, which includes controlling the actuator to sequentially perform at least one of the following operations on the cathode plate: removing the clamping strip, flipping the plate surface, and polishing the plate surface.

[0015] This invention also provides a multi-mechanism collaborative control system for a stainless steel cathode plate repair device. The system executes the aforementioned control method and includes: a sensing layer for collecting cathode plate surface deformation data and system operating status information; an execution layer including a leveling execution mechanism; and a control layer communicatively connected to both the sensing layer and the execution layer. The control layer is equipped with a collaborative scheduling module. The collaborative scheduling module is used to: receive surface deformation data from the sensing layer; generate repair parameters for controlling the leveling execution mechanism based on the surface deformation data; and control the leveling execution mechanism to perform leveling repair on the cathode plate according to the repair parameters.

[0016] Furthermore, the collaborative scheduling module is also used to: after the leveling and repair is completed, determine whether the cathode plate meets the preset qualification standard based on the plate deformation data collected again by the sensing layer; if it is determined to be unqualified, generate new repair parameters based on the plate deformation data collected again and control the leveling execution mechanism to perform at least one compensation repair.

[0017] Furthermore, the repair parameters include at least one of the following: the location of the leveling rib, the stamping depth, the number of stampings, and the stamping sequence among multiple locations.

[0018] Furthermore, the sensing layer includes multiple laser rangefinders for non-contact measurement to obtain the deformation data of the plate surface; the leveling actuator includes at least one pneumatic stamping cylinder.

[0019] Furthermore, the execution layer also includes a mechanism for performing edge strip clamping, flipping, and polishing operations; the collaborative scheduling module is also used to: control the cathode plate to sequentially pass through the edge strip clamping, flipping, polishing, leveling, and inspection stations according to the preset repair process flow and the system operation status information collected by the sensing layer.

[0020] Compared with the prior art, the present invention has the following advantages:

[0021] (1) Achieve multi-station collaboration and efficient continuous operation for cathode plate repair. Through the collaborative scheduling module, multiple heterogeneous stations such as strip clamping, flipping, polishing, leveling, and inspection are integrated into a seamless automated production line, realizing the automatic flow and strict interlocking of cathode plates between stations. This changes the traditional discrete operation mode that relies on manual transfer and greatly improves production efficiency.

[0022] (2) Achieve adaptive high-precision repair based on closed-loop feedback. Through the closed-loop control logic of "detection-decision-execution-verification", the system can dynamically generate personalized repair parameters containing information such as position, sequence and depth based on the real-time obtained board deformation data, and drive the actuator to perform precise leveling; automatic re-inspection after repair, and non-conforming parts can trigger compensation repair, which significantly improves the first-time repair pass rate and final repair accuracy.

[0023] (3) Improve the stability of repair quality and the intelligence level of the system. The adaptive closed-loop mechanism reduces the reliance on human experience, making the repair process standardized and traceable; the system has automatic rework capability, forming a complete quality assurance cycle, ensuring the high quality and consistency of the cathode plates leaving the factory, thus providing a reliable guarantee for the stable and efficient operation of subsequent electrolysis processes. Attached Figure Description

[0024] Figure 1 This is a schematic diagram of a multi-mechanism collaborative repair control method for a stainless steel cathode plate according to an embodiment of the present invention. Detailed Implementation

[0025] To make the objectives, technical solutions, and advantages of this invention clearer, the technical solutions of this invention will be clearly and completely described below in conjunction with the embodiments of this invention. Obviously, the described embodiments are only some, not all, of the embodiments of this invention. All other embodiments obtained by those skilled in the art based on the embodiments of this invention without creative effort are within the scope of protection of this invention.

[0026] Example 1

[0027] This embodiment details the implementation process of the core closed-loop adaptive repair control method of this invention at the detection and calibration station. The system hardware architecture involved in this embodiment mainly consists of a perception layer, an execution layer, and a control layer.

[0028] The sensing layer comprises five high-precision laser rangefinders (e.g., Keyence LK-G5001 models) installed at the inspection station, which scan the cathode plate surface non-contactly to acquire dense 3D point cloud data. The execution layer includes a set (e.g., three) of independently controlled pneumatic ramming cylinders at the leveling station, each with a displacement sensor mounted on the piston rod end. The control layer is centered around an industrial programmable logic controller (PLC, such as a Siemens S7-1515), which connects to all laser rangefinders, servo valves of the pneumatic ramming cylinders, and displacement sensors via an industrial Ethernet network. The PLC integrates a collaborative scheduling module.

[0029] The specific repair control process is as follows:

[0030] First, inspection is performed. After the transfer robot (such as a six-axis robot) precisely positions and clamps the cathode plate at the inspection / leveling station, the PLC controls five laser rangefinders to simultaneously measure the plate surface. After receiving the raw distance data, the PLC calculates the height deviation of each measurement point on the plate surface relative to the ideal fitted plane through coordinate transformation and a least squares plane fitting algorithm, i.e., the plate surface deformation data. The system can identify the point with the largest deformation, for example, its coordinates are (x1, y1), and the deformation is -3.5mm, indicating that there is a depression with a depth of 3.5mm at that location.

[0031] Next, a decision is made. The collaborative scheduling module invokes the built-in leveling algorithm. This algorithm takes the acquired board deformation data and the known thickness of the board (e.g., 3mm) as input, and dynamically generates a set of executable repair parameters based on preset empirical formulas and material mechanics models. For the aforementioned -3.5mm dent, the algorithm simulates manual screeding experience, adopting a strategy of first the core and then the periphery. The generated parameter instruction set is, for example: First instruction, perform a single screed to a depth of 1.8mm at the maximum deformation point (x1, y1); Second instruction, perform a single screed to a depth of 0.8mm at the adjacent point (x1-50, y1); Third instruction, perform a single screed to a depth of 0.8mm at another adjacent point (x1+50, y1). This set of parameters clearly specifies the location, sequence, and screed depth of the screeding.

[0032] Then, the operation is carried out. Based on the generated repair parameter sequence, the PLC sends action commands to the corresponding pneumatic stamping cylinders in sequence. When each stamping cylinder performs stamping, its displacement sensor provides real-time, high-frequency feedback on the actual displacement of the piston rod. The PLC compares this feedback value with the command depth value and performs real-time pressure fine-tuning through a proportional valve, forming a closed-loop control of the stamping depth. This ensures that each stamping accurately reaches the target depth, thereby completing this leveling repair.

[0033] Finally, verification and compensation are performed. After one leveling cycle is completed, the laser rangefinder immediately performs a comprehensive inspection of the board surface again. If the maximum deformation measured is ≤0.5mm (this is the preset pass standard), the collaborative scheduling module determines that the board is repaired and passes, the control process ends, and the transfer robot is notified to send the board out. If residual deformation is found, for example, the maximum deformation is -1.1mm (>0.5mm), it is determined to be unqualified. At this time, the collaborative scheduling module automatically starts the compensation and repair cycle: using the new residual deformation data (-1.1mm) and its position as input, the leveling algorithm is rerun to generate a set of targeted compensation and repair parameters (for example, performing a single fine stamping with a depth of 0.6mm at the residual deformation point (x2, y2), and the stamping cylinder is controlled to execute again. This "verification-compensation" process can be automatically iterated until the board passes or the maximum number of cycles set by the system (e.g., 3 times) is reached.

[0034] This embodiment achieves data-driven, adaptive, and high-precision repair of cathode plate deformation through a complete closed loop of "detection-decision-execution-verification-compensation," significantly reducing reliance on operator experience.

[0035] Example 2

[0036] Based on Example 1, this embodiment further elaborates on the collaborative scheduling implementation of integrating closed-loop repair control into a fully automated system containing multiple heterogeneous workstations.

[0037] In this embodiment, the stainless steel cathode plate repair device is a complete automated production line, which sequentially includes a strip-grabbing station, a first flipping station, a double-sided polishing station, the inspection / leveling station described in Example 1, a second flipping station, a strip-grabbing installation station, and loading / unloading stations. The execution layer is correspondingly expanded to include dedicated pneumatic clamps for strip-grabbing and installation, a servo-driven turntable for 180° rotation and 90° flipping of the plate surface, a double-head polishing machine, the pneumatic stamping cylinder group from Example 1, and a six-axis robot responsible for transfer between stations. The perception layer network is also more complex, with position detection sensors and gripper status sensors installed at each station, a pressure sensor added at the polishing station, and an angle encoder added at the flipping station.

[0038] The entire process of collaborative control is managed uniformly by the collaborative scheduling module in the PLC:

[0039] After the system starts, the collaborative scheduling module operates according to the preset repair process logic (loading → removing clamping strips → first flip → polishing → inspection / leveling → second flip → installing clamping strips → unloading). When the cathode plate to be repaired arrives from the loading conveyor, the scheduling module first instructs the six-axis robot to grab the plate and, based on the real-time "idle" or "busy" status feedback from each station, moves it to the first available station—the clamping strip removal station. After the arrival sensor at this station is triggered, the scheduling module controls the special pneumatic clamp to automatically remove the old plastic clamping strips on both sides of the plate. After completion, the clamp sensor sends a feedback signal.

[0040] Subsequently, the scheduling module instructs the robot to move the board according to the process logic and the status of the next station (the first flip station). After receiving the board arrival signal, the servo turntable of the flip station executes the preset flipping action to adjust the board surface to a suitable angle for polishing, and the encoder confirms that the angle is in place.

[0041] Next, the board is sent to the double-sided polishing station. The scheduling module starts the polishing machine and dynamically adjusts the cylinder pressure based on real-time feedback from the pressure sensor, keeping the polishing pressure closed-loop controlled within the set range of 0.2±0.05 MPa to ensure uniform polishing effect without damaging the board surface. After the polishing time is up, a completion signal is issued.

[0042] Afterward, the board is sent to the core inspection / leveling station to perform the closed-loop adaptive repair process as described in Example 1. Once the repair is successful, the scheduling module will instruct the robot to send the board sequentially to the subsequent second flipping station (to adjust it back to its original posture) and the edge strip installation station (to install new edge strips), and finally to the unloading area.

[0043] Throughout the process, the collaborative scheduling module acts like an "intelligent traffic command center." It continuously monitors the sensor status of all workstations and makes scheduling decisions based on strict state interlocking logic and preset cycle times. For example, the upstream polishing workstation is only allowed to release completed parts when the inspection / leveling workstation is in an "idle" state. This effectively avoids material accumulation at bottleneck workstations and ensures that multiple mechanisms with different functions, principles, and cycle times can seamlessly connect and work collaboratively as a whole, forming an efficient, continuous, and stable automated repair production line.

[0044] Example 3

[0045] This embodiment demonstrates the actual effect of applying the method and system described in this invention through specific repair experimental data, and compares it with traditional repair methods.

[0046] One hundred stainless steel cathode plates with varying degrees of warping and scratches due to long-term use were selected as the repair targets. The initial maximum deformation of the plate surface ranged from 2.0 mm to 7.0 mm. The automated plate repair device and control system constructed as in Examples 1 and 2 were used for the entire repair process.

[0047] Experimental Process and Results: All 100 cathode plates underwent automated repair. The repair process strictly followed the workflow of "pre-treatment → closed-loop leveling → automatic verification." Of these, 78 cathode plates achieved a flatness of ≤0.5mm after one closed-loop repair cycle at the inspection / leveling station, resulting in a first-time repair pass rate of 78%. The remaining 22 plates, due to complex initial deformation, did not meet the standard after one repair. The system automatically triggered a compensation repair cycle, and after a maximum of two compensation repairs, all 22 plates also met the pass standard. Therefore, the final pass rate reached 100%. The repair time for all 100 plates (from entering the clamping strip station to completing the clamping strip installation and leaving) was approximately 165 seconds per plate. The average maximum residual deformation of all qualified plates after repair was 0.32mm, indicating high quality consistency.

[0048] Comparative Example

[0049] Another 100 cathode plates with similar defect levels were selected and repaired using traditional methods: workers operated a crane to transport the plates to an independent hydraulic leveling machine, where deformed areas were visually inspected and leveled using a ruler. The hydraulic press was then manually operated for point pressure leveling. After leveling, the plates were hoisted to an inspection platform for manual inspection with feeler gauges. If a plate failed to meet the requirements, it had to be hoisted back and re-leveled. Statistical results showed that repairing these 100 plates took approximately 25 hours, with an average repair time of approximately 900 seconds (15 minutes) per plate. Ultimately, only 92 plates achieved a flatness of ≤0.5mm, a pass rate of 92%. Eight other plates were scrapped due to over-repair causing new damage or poor results. The average maximum residual deformation of the passable plates was 0.45mm, with a large dispersion.

[0050] The comparative data shows that the present invention, through a multi-mechanism collaborative control system and a closed-loop adaptive repair method, improves the cathode plate repair efficiency by several times (from about 900 seconds / piece to about 165 seconds / piece) and significantly increases the repair qualification rate from 92% to nearly 100%. At the same time, it greatly improves the uniformity and stability of the repair quality, fully verifying the beneficial technical effects achieved by the present invention.

[0051] The above embodiments are merely specific implementations of the present invention, and their descriptions are quite specific and detailed, but they should not be construed as limiting the scope of the present invention. It should be noted that those skilled in the art can make several modifications and improvements without departing from the concept of the present invention, such as adjusting the number and arrangement of laser rangefinders, replacing different models of PLCs or robots, and optimizing the specific formula of the leveling algorithm, etc., all of which fall within the protection scope of the present invention.

Claims

1. A multi-mechanism collaborative repair control method for stainless steel cathode plates, characterized in that, Applied to a repair system comprising a detection unit and a leveling unit, the method comprises, in sequence: Testing steps: Obtain the deformation data of the cathode plate to be repaired; Decision-making steps: Based on the plate deformation data, generate repair parameters for controlling the leveling operation, the repair parameters including the location and intensity information of the leveling action; Execution steps: According to the repair parameters, control the leveling actuator to level and repair the cathode plate.

2. Verification steps: Obtain the deformation data of the cathode plate surface again after leveling and repair; Judgment steps: Based on the re-acquired panel deformation data, determine whether the repair result meets the preset qualification standards; Compensation steps: If it is determined that the qualified standard is not met, new repair parameters are generated based on the current deformation data of the plate surface, and the leveling actuator is controlled to perform compensation and repair operations.

3. The multi-mechanism collaborative repair control method for stainless steel cathode plates according to claim 1, characterized in that, The repair parameters include at least one of the following: the location of the leveling rib, the stamping depth, the number of stampings, and the stamping sequence between multiple locations.

4. The multi-mechanism collaborative repair control method for stainless steel cathode plates according to claim 1, characterized in that, The detection step is performed by multiple laser rangefinders; the execution step is performed by a pneumatic stamping cylinder.

5. The multi-mechanism collaborative repair control method for stainless steel cathode plates according to claim 1, characterized in that, Prior to the detection step, the method further includes a preprocessing step, which includes controlling the actuator to sequentially perform at least one of the following operations on the cathode plate: removing the clamping strip, flipping the plate surface, and polishing the plate surface.

6. A multi-mechanism collaborative control system for a stainless steel cathode plate repair device, characterized in that, The system is used to perform the control method as described in any one of claims 1 to 4, the system comprising: The sensing layer is used to collect data on the deformation of the cathode plate and the system operating status. The execution layer includes the calibration execution mechanism; The control layer is communicatively connected to both the perception layer and the execution layer, and the control layer is configured with a collaborative scheduling module. The collaborative scheduling module is used for: Receive plate surface deformation data from the sensing layer; Based on the plate deformation data, repair parameters are generated to control the leveling actuator; Based on the repair parameters, the leveling actuator is controlled to perform leveling and repair on the cathode plate.

7. The multi-mechanism collaborative control system of the stainless steel cathode plate repair device according to claim 5, characterized in that, The collaborative scheduling module is also used to: after the leveling and repair is completed, determine whether the cathode plate meets the preset qualification standard based on the plate deformation data collected again by the sensing layer; if it is determined to be unqualified, generate new repair parameters based on the plate deformation data collected again and control the leveling actuator to perform at least one compensation repair.

8. The multi-mechanism collaborative control system of the stainless steel cathode plate repair device according to claim 5 or 6, characterized in that, The repair parameters include at least one of the following: the location of the leveling rib, the stamping depth, the number of stampings, and the stamping sequence between multiple locations.

9. The multi-mechanism collaborative control system of the stainless steel cathode plate repair device according to claim 5, characterized in that, The sensing layer includes multiple laser rangefinders for non-contact measurement to obtain deformation data of the plate surface; the leveling actuator includes at least one pneumatic stamping cylinder.

10. The multi-mechanism collaborative control system of the stainless steel cathode plate repair device according to claim 5, characterized in that, The execution layer also includes a mechanism for performing edge strip clamping, flipping, and polishing operations; the collaborative scheduling module is also used to control the cathode plate to sequentially pass through the edge strip clamping, flipping, polishing, leveling, and inspection stations according to the preset repair process flow and the system operation status information collected by the sensing layer.

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