High-frequency vibration punch forming equipment for high-density anode carbon blocks and forming method thereof

Abstract

The present application belongs to the technical field of anode carbon block processing, and in particular to a high-frequency vibration punch forming equipment for high-density anode carbon blocks and a forming method thereof, comprising a workbench, a top of the workbench is provided with a controller for overall control of the coordinated work of each component of the equipment, a bottom of the workbench is provided with a station switching mechanism, a plurality of model matching stations are arranged on the station switching mechanism, the plurality of model matching stations are located on the top of the workbench, providing a multi-station cycle processing basis, further comprising: a hydraulic support fixedly installed on the top of the workbench; the present application solves the pain points of traditional process particle agglomeration, low efficiency, poor forming, etc. through raw material heating pretreatment, three-station cycle operation, three groups of switchable multi-frequency vibration adaptive forming three stages, matched with double-sensor closed-loop monitoring, precise pressure control, vibration seamless switching, convenient demolding and full-height monitoring, greatly improving the forming density, uniformity and pass rate of anode carbon blocks.

Description

Technical Field

[0001] This invention relates to the field of anode carbon block processing technology, and in particular to a high-frequency vibration stamping forming equipment and forming method for high-density anode carbon blocks. Background Technology

[0002] High-density anode carbon blocks, also known as high-density prebaked anode carbon blocks, are a core consumable material in aluminum electrolysis production. They are large-sized conductive materials made from petroleum coke as aggregate and coal tar pitch as binder, through processes such as mixing, molding, and calcination. In the aluminum electrolysis cell, they participate in the electrochemical reaction as the anode, serving as both a conductive electrode and providing the carbon element required for the reaction. The density, uniformity, and structural stability of the anode carbon block directly affect the battery efficiency and lifespan. Currently, anode carbon block forming mainly employs traditional stamping and vibration molding processes, which have the following key technical defects: Fine particles in raw materials are prone to agglomeration, making it difficult for particles to be fully rearranged during the stamping process. This results in high internal porosity and low density. Most equipment uses fixed-frequency vibration, which cannot adapt to the needs of particle crushing, rearrangement, and degassing at different stages of molding. Summary of the Invention

[0003] To address the aforementioned problems, this invention proposes a high-frequency vibration stamping forming equipment and its forming method for high-density anode carbon blocks, which more accurately solves the problems mentioned in the background art and realizes the functions of multi-stage precise vibration, real-time monitoring of multiple physical fields, continuous operation at multiple workstations, and pre-treatment of raw materials.

[0004] This invention is achieved through the following technical solution: This invention proposes a high-frequency vibration stamping forming device for high-density anode carbon blocks, including a worktable. A controller is installed on the top of the worktable to coordinate the collaborative operation of various components. A station switching mechanism is installed at the bottom of the worktable, and a multi-model mating station is provided on the station switching mechanism. The multi-model mating station is located at the top of the worktable, providing a basis for multi-station cyclic processing. The device also includes: A hydraulic support is fixedly installed on the top of the workbench, and a hydraulic mechanism is installed on the hydraulic support to provide stable power for stamping. A multi-physics field online monitoring mechanism is fixedly installed on the top of the workbench to realize real-time monitoring of the molding process; Three model shell units cooperate with the multi-model cooperating station. The hydraulic mechanism is adapted to the three model shell units and is used to stamp the anode carbon block. The multi-physics field online monitoring mechanism cooperates with the model shell units and is used to detect parameters such as density and particle state of the stamped anode carbon block. The feeding pipe works in conjunction with the model shell unit. A pipe support plate is fixedly installed on the top of the workbench, and the feeding pipe is installed on the pipe support plate to achieve precise material introduction.

[0005] Preferably, the multi-model cooperating station includes a station support plate located above the workbench. Three rectangular support seats are fixedly installed on the station support plate, with an included angle of 120° between the three rectangular support seats to accommodate three-station cyclic operation. A lower mold base is fixedly installed on the top of each of the three rectangular support seats, and an electric heating rod is embedded in each of the three lower mold bases to achieve pre-treatment heating of the raw materials and improve the molding effect.

[0006] Preferably, the workstation switching mechanism includes a rotating column and a second stepper motor. The rotating column is rotatably mounted on the worktable via bearings. The top of the rotating column is fixedly mounted to the bottom of the workstation support plate. A driven gear is fixedly mounted on the bottom of the rotating column. The second stepper motor is mounted on the bottom of the worktable. A drive gear is mounted on the output shaft of the second stepper motor. The drive gear meshes with the driven gear to achieve 120° precise workstation switching.

[0007] Preferably, the model shell unit includes a model shell and an electric push rod. The electric push rod is fixedly installed on the top of the workstation support plate. A fixing block is fixedly installed on the output shaft of the electric push rod. The fixing block is fixedly installed on the outer side of the model shell. The inner wall of the model shell is slidably connected to the outer side of the lower mold base to facilitate the removal of the carbon block after molding.

[0008] Preferably, the multiphysics online monitoring mechanism includes a vertical slide rail, which is fixedly installed on the top of the workbench. A threaded rod is vertically rotatably installed on the inner wall of the vertical slide rail, and a slider is threadedly connected to the outer side of the threaded rod. A detection probe is provided on the slider, and an observation port is provided on the outer side of the model shell. The detection probe cooperates with the observation port to realize non-contact monitoring of the molding process. A servo motor is installed on the top of the vertical slide rail, and the output shaft of the servo motor is fixedly installed with the threaded rod to provide power for adjusting the detection height.

[0009] Preferably, the detection probe includes an acoustic emission sensor and a capacitance tomography sensor to achieve multi-dimensional monitoring of density uniformity and particle state.

[0010] Preferably, the hydraulic mechanism includes a hydraulic cylinder and a sealing plate. The hydraulic cylinder is fixedly installed on the top of the hydraulic support, and the output shaft of the hydraulic cylinder is connected to the top of the sealing plate. A pressure sensor is provided between the two to monitor the stamping pressure in real time. An upper die pressure seat is fixedly installed at the bottom of the sealing plate. A triangular seat is provided inside the upper die pressure seat. Multi-frequency vibration units are provided on three sides of the triangular seat. The multi-frequency vibration unit includes a circuit board and multiple sets of ultrasonic transducers to realize high-frequency vibration stamping.

[0011] Preferably, a rotating shaft is fixedly installed at the center of the triangular base. The rotating shaft is rotatably mounted on the inner walls of both sides of the upper mold pressure seat via bearings. A vibration switching unit is installed inside the upper mold pressure seat. The vibration switching unit cooperates with the rotating shaft. The vibration switching unit includes a second stepper motor and a first gear. The first gear is fixedly installed on the outside of the rotating shaft. The second stepper motor is installed on the inner wall of the upper mold pressure seat. A second gear is installed on the output shaft of the second stepper motor. The second gear meshes with the first gear to realize the switching of multi-frequency vibration units.

[0012] Preferably, three sets of electrical connectors are fixedly installed on the outer side of the triangular base. Each of the three sets of electrical connectors is provided with two elastic electrical blocks. The three sets of electrical connectors are electrically connected to the three multi-frequency vibration units. A bridge conductor is fixedly installed on the side wall of the upper mold pressure seat. The three sets of electrical connectors are electrically connected to the bridge conductor through the corresponding two elastic electrical blocks, which is used to control the precise energization of the three multi-frequency vibration units and realize the switching of vibration parameters.

[0013] This invention also provides a high-frequency vibration stamping forming method for high-density anode carbon blocks, which requires the use of high-frequency vibration stamping forming equipment for high-density anode carbon blocks, and includes the following steps: S1: When in use, connect the power supply and controller, connect the feeding pipe to the raw material inlet, and the anode carbon block raw material is fed into the inside of the mold shell through the feeding pipe. It is supported and positioned by the lower mold base. At the same time, the electric heating rod embedded in the lower mold base heats and pre-treats the anode carbon block raw material to improve the plasticity of the raw material. S2: The second stepper motor drives the driven gear to rotate through the drive gear. The driven gear drives the station support plate to rotate through the rotating column. The station support plate drives the lower mold base and the model shell to move precisely below the hydraulic mechanism, completing the station switching. S3: The hydraulic cylinder pushes the upper mold pressure seat downward through the pressure sensor and the sealing plate. The upper mold pressure seat enters the mold shell and squeezes the anode carbon block raw material. The pressure sensor continuously monitors the pressure applied by the upper mold pressure seat to the anode carbon block raw material to ensure that the pressure is accurate and controllable. The detection probe detects the extrusion process of the anode carbon block raw material inside the mold shell in real time through the observation port. The servo motor drives the threaded rod to rotate. The threaded rod drives the detection probe to adjust its height through the slider, expanding the detection range of the detection probe on the anode carbon block raw material and realizing full-process monitoring. S4: First forming stage: The multi-frequency vibration unit on the triangular base emits a vibration frequency of 80-120Hz and an amplitude of 0.5-2mm. This stage mainly acts on the interface of fine particles to break up agglomerates. The multi-physics field online monitoring mechanism monitors the change in material density in real time through the detection probe. When the internal density uniformity is detected to reach the set threshold, the controller automatically switches to the next stage. Second forming stage: The second stepper motor drives the first gear to rotate through the second gear, and the first gear drives the triangular seat to rotate. Another multi-frequency vibration unit faces the anode carbon block raw material. The two elastic contact blocks on the contact seat contact the bridge conductor and turn on the power of the multi-frequency vibration unit. The multi-frequency vibration unit on the triangular seat emits a vibration frequency of 40-60Hz and an amplitude of 3-6mm, forming a cyclic shear stress field inside the material, which mainly realizes particle rearrangement. The multi-physics field online monitoring mechanism monitors the acoustic emission signal generated by particle friction and rearrangement in real time through the detection probe. The particle orientation state is judged by spectrum analysis. When the main frequency of the acoustic emission signal is detected to change from the high frequency band reflecting particle breakage to the mid frequency band reflecting particle slippage and transfer, and the energy tends to stabilize, it indicates that the particles have basically completed the orientation arrangement, and the controller enters the next stage. The third molding stage: The second stepper motor drives the first gear to rotate through the second gear, and the first gear drives the triangular seat to rotate. The third multi-frequency vibration unit faces the anode carbon block raw material. The multi-frequency vibration unit on the triangular seat emits a vibration frequency of 15-25Hz and an amplitude of 8-12mm. The vibration and pressing work together to promote the rapid discharge of gas. The multi-physics field online monitoring mechanism continuously monitors the density change through the detection probe. When the density reaches 1.72g / cm³, the controller switches to the pressure holding stage to ensure the molding density is stable. S5: After the molding extrusion is completed, the hydraulic cylinder drives the upper die pressure seat to leave the mold shell, and the station switching mechanism drives the multi-mold cooperating station to rotate again, changing to another empty station for extrusion processing, so as to achieve continuous operation. S6: The electric push rod drives the model shell to move upward through the fixed block. The model shell leaves the rectangular support base and the lower mold base, and the high-density anode carbon block after extrusion can be taken out, completing a single molding operation.

[0014] Compared with the prior art, the present invention provides a high-frequency vibration stamping forming device and forming method for high-density anode carbon blocks, which has the following beneficial effects: 1. By embedding an electric heating rod in the lower mold base of the multi-model cooperating station, the anode carbon block raw material introduced into the mold shell is preheated and pretreated, which reduces the friction between raw material particles and improves particle flowability. This lays a favorable foundation for subsequent particle rearrangement and densification molding, and solves the technical pain points of particle agglomeration and low molding density caused by the lack of raw material pretreatment in traditional processes.

[0015] 2. The workstation switching mechanism adopts a gear transmission structure to drive the workstation support plate to rotate precisely, realizing the continuous and automated operation of the three-workstation cycle. This allows the three major processes of raw material introduction, stamping and forming, and finished product removal to be carried out in parallel, which greatly improves production efficiency compared with single-workstation equipment.

[0016] 3. By integrating three sets of switchable multi-frequency vibration units on the triangular seat of the hydraulic mechanism and configuring differentiated vibration parameters, the precise adaptation of the three stages of anode carbon block forming is achieved: the first stage breaks up particle agglomerates, the second stage completes the directional rearrangement of particles, and the third stage promotes the rapid discharge of gas inside the raw material, significantly improving the forming density and density uniformity.

[0017] 4. By integrating acoustic emission sensors and capacitance tomography sensors through a multi-physics field online monitoring mechanism, and working with the controller, real-time closed-loop monitoring of the molding process is achieved, which improves the accurate quantitative judgment of material density uniformity and particle breakage / slippage state.

[0018] 5. By configuring a closed-loop control structure of hydraulic cylinder and pressure sensor through hydraulic mechanism, the stamping pressure is accurately adjusted, which avoids excessive particle breakage caused by excessive pressure and prevents insufficient densification caused by insufficient pressure.

[0019] 6. By driving the triangular seat to rotate through the vibration switching unit, and cooperating with the contact between the elastic contact block of the outer contact seat of the triangular seat and the bridge conductor, seamless and precise switching of the three sets of multi-frequency vibration units is achieved, avoiding parameter interruption or misalignment during the vibration switching process, and ensuring the continuous and smooth operation of the three-stage vibration stamping.

[0020] 7. By configuring an electric push rod in the model shell unit to drive the model shell to slide up and down along the lower mold base, the high-density anode carbon block can be quickly and conveniently removed after molding, without the need for a complicated demolding process, further improving the efficiency of single-station operation and adapting to the overall process rhythm of multi-station continuous production.

[0021] 8. The servo motor drives the threaded rod to rotate through the multi-physics field online monitoring mechanism, which in turn drives the detection probe to adjust its height along the vertical slide rail. This, combined with the observation port on the model shell, enables monitoring of the molding process across the entire height range. This achieves real-time, all-dimensional, and comprehensive capture of the internal state of the anode carbon block raw material, providing complete data support for the controller to accurately switch the molding stage.

[0022] This invention addresses the pain points of traditional processes, such as particle agglomeration, low efficiency, and poor molding, through three stages: raw material heating pretreatment, three-station cyclic operation, and three sets of switchable multi-frequency vibrations adapted to molding. Combined with dual-sensor closed-loop monitoring, precise pressure control, seamless vibration switching, convenient demolding, and full-height monitoring, it significantly improves the molding density, uniformity, and pass rate of anode carbon blocks. Attached Figure Description

[0023] Figure 1 This is a schematic diagram of the structure of a high-frequency vibration stamping forming device for high-density anode carbon blocks proposed in this invention; Figure 2 This is a side view of a high-frequency vibration stamping forming device for high-density anode carbon blocks proposed in this invention. Figure 3 This is a bottom view of the high-frequency vibration stamping forming equipment for high-density anode carbon blocks proposed in this invention. Figure 4 This is a schematic diagram of the planar structure of a high-density anode carbon block high-frequency vibration stamping forming equipment proposed in this invention; Figure 5 This invention presents a structural schematic diagram of a workbench and a multi-model coordination station. Figure 6 This is a schematic diagram of the structure of the multiphysics field online monitoring mechanism proposed in this invention; Figure 7 This invention provides a structural schematic diagram of the upper mold pressure seat and the triangular seat; Figure 8 The present invention provides a structural schematic diagram of the upper mold pressure seat, triangular seat, vibration switching unit, multi-frequency vibration unit, and power connection seat; Figure 9 This invention provides a structural schematic diagram of the AA-direction cross-section; Figure 10 A structural schematic diagram of the BB-direction cross-section is provided for this invention; Figure 11 This invention presents a schematic diagram of the structure of the model shell unit; Figure 12 This is a side view of the shell unit of the model proposed in this invention.

[0024] In the diagram: 1. Workbench; 11. Controller; 2. Hydraulic support; 3. Multiphysics field online monitoring mechanism; 31. Vertical slide rail; 32. Threaded rod; 33. Slider; 34. Servo motor; 35. Detection probe; 4. Hydraulic mechanism; 41. Hydraulic cylinder; 42. Sealing plate; 421. Pressure sensor; 43. Upper mold pressure seat; 44. Triangular seat; 441. Rotating shaft; 45. Vibration switching unit; 451. First gear; 452. First stepper motor; 453. Second gear ; 46. Multi-frequency vibration unit; 47. Electrical contact base; 471. Elastic electrical contact block; 48. Bridge conductor; 5. Feeding pipe; 51. Pipe support plate; 6. Model shell unit; 61. Model shell; 62. Observation port; 63. Fixing block; 64. Electric push rod; 7. Station switching mechanism; 71. Rotating column; 72. Passive gear; 73. Drive gear; 74. Second stepper motor; 8. Multi-model cooperating station; 81. Station support plate; 82. Rectangular support base; 83. Lower mold base. Detailed Implementation

[0025] To more clearly and completely illustrate the technical solution of the present invention, the present invention will be further described below with reference to the accompanying drawings. Example

[0026] like Figures 1-12 As shown, this invention is proposed in one embodiment.

[0027] In this invention, there are a workbench 1, a hydraulic support 2, a multi-physics field online monitoring mechanism 3, a hydraulic mechanism 4, a feeding pipe 5, three model shell units 6, a workstation switching mechanism 7, and a multi-model cooperation workstation 8; The workbench 1 is equipped with a controller 11 at the top and a workstation switching mechanism 7 at the bottom. The workstation switching mechanism 7 is equipped with a multi-model cooperating workstation 8, which is located at the top of the workbench 1. The hydraulic support 2 is fixedly installed on the top of the workbench 1, and the hydraulic mechanism 4 is installed on the hydraulic support 2; the multi-physics field online monitoring mechanism 3 is fixedly installed on the top of the workbench 1; the three model shell units 6 are adapted to the multi-model cooperation station 8, the hydraulic mechanism 4 cooperates with the model shell unit 6 to realize the stamping of the anode carbon block, and the multi-physics field online monitoring mechanism 3 cooperates with the model shell unit 6 to realize the monitoring of the forming process; A pipe support plate 51 is fixedly installed on the top of the workbench 1, and the feeding pipe 5 is installed on the pipe support plate 51, which works with the model shell unit 6 to realize the introduction of raw materials.

[0028] In this invention, the multi-model cooperating station 8 includes a station support plate 81, three rectangular support seats 82, and three lower mold seats 83; The workstation support plate 81 is located above the workbench 1. Three rectangular support seats 82 are fixedly installed on the workstation support plate 81, and the included angle between adjacent rectangular support seats 82 is 120°. Three lower mold seats 83 are respectively fixedly installed on the top of the three rectangular support seats 82. The lower mold seats 83 are embedded with electric heating rods for preheating raw materials.

[0029] The heating rod embedded in the lower mold base 83 generates heat when energized, which heats the anode carbon block raw material introduced into the mold shell 61. The heating temperature is 50-80℃, which reduces the friction between raw material particles, improves particle flowability, and lays the foundation for subsequent particle rearrangement and densification.

[0030] In this invention, the workstation switching mechanism 7 includes a rotating column 71, a driven gear 72, a driving gear 73, and a second stepper motor 74; The rotating column 71 is rotatably mounted on the workbench 1 via bearings, with its top end fixedly connected to the bottom of the workstation support plate 81, and a driven gear 72 fixedly mounted on its bottom. The second stepper motor 74 is mounted on the bottom of the workbench 1, with a drive gear 73 mounted on its output shaft. The drive gear 73 meshes with the driven gear 72 to drive the workstation support plate 81 to rotate precisely 120°.

[0031] Among them, the station switching mechanism 7 and the multi-model cooperating station 8, the second stepper motor 74 drive the station support plate 81 to rotate precisely 120° through gear transmission, realize the three station cycles: station 1 completes the raw material introduction and heating, station 2 performs stamping and forming, station 3 realizes the finished product removal, the three processes operate in parallel, greatly improve production efficiency, and the efficiency is improved compared with single station equipment.

[0032] In this invention, the model shell unit 6 includes a model shell 61, an observation port 62, a fixing block 63, and an electric push rod 64; The electric push rod 64 is fixedly installed on the top of the workstation support plate 81, and the output shaft is fixedly connected to the fixing block 63. The fixing block 63 is fixedly connected to the outer side of the model shell 61. The inner wall of the model shell 61 is slidably connected to the outer side of the lower mold base 83. An observation port 62 is provided on the outer side to cooperate with the monitoring mechanism to realize the observation of the molding process.

[0033] In this invention, the multiphysics field online monitoring mechanism 3 includes a vertical slide rail 31, a threaded rod 32, a slider 33, a servo motor 34, and a detection probe 35; A vertical slide rail 31 is fixedly installed on the top of the workbench 1. A threaded rod 32 is vertically and rotatably installed on the inner wall. A slider 33 is threadedly connected to the outer side of the threaded rod 32. A detection probe 35 is provided on the slider 33, and the detection probe 35 cooperates with the observation port 62. A servo motor 34 is installed on the top of the vertical slide rail 31, and its output shaft is fixedly connected to the threaded rod 32. It is used to drive the height adjustment of the detection probe 35. The detection probe 35 includes an acoustic emission sensor and a capacitance tomography sensor, which are used to simultaneously monitor the uniformity of material density and particle state.

[0034] Among them, the capacitance tomography sensor monitors the density distribution of the material in real time and judges the density uniformity; the acoustic emission sensor captures the acoustic signals generated by particle breakage and slippage, and judges the particle state through spectrum analysis; the monitoring data is transmitted to the controller 11 in real time as the basis for judging the stage switching and the molding end point, so as to realize closed-loop control.

[0035] In this invention, the hydraulic mechanism 4 includes a hydraulic cylinder 41, a sealing plate 42, a pressure sensor 421, an upper mold pressure seat 43, a triangular seat 44, a rotating shaft 441, a vibration switching unit 45, three sets of multi-frequency vibration units 46, three sets of electrical terminals 47, and a bridge conductor 48. Hydraulic cylinder 41 is fixedly installed on the top of hydraulic support 2, and its output shaft is connected to the top of sealing plate 42. A pressure sensor 421 is provided between the two. An upper mold pressure seat 43 is fixedly installed at the bottom of sealing plate 42. A triangular seat 44 is provided inside the upper mold pressure seat 43. Multi-frequency vibration unit 46 is provided on three sides of the triangular seat 44. The multi-frequency vibration unit 46 includes a circuit board and multiple sets of ultrasonic transducers. A rotating shaft 441 is fixedly installed at the center of the triangular base 44. The rotating shaft 441 is rotatably mounted on the inner wall of the upper mold pressure seat 43 via bearings. The vibration switching unit 45 includes a first gear 451, a second stepper motor 452, and a second gear 453. The first gear 451 is fixed on the outside of the rotating shaft 441, and the second stepper motor 452 is mounted on the inner wall of the upper mold pressure seat 43. The second gear 453 on the output shaft meshes with the first gear 451. Three sets of electrical connectors 47 are fixed on the outside of the triangular base 44. Each set of electrical connectors 47 is provided with two elastic electrical blocks 471. The electrical connectors 47 are electrically connected to the multi-frequency vibration unit 46. The bridge conductor 48 is fixed on the side wall of the upper mold pressure seat 43. The elastic electrical blocks 471 and the bridge conductor 48 cooperate to realize the power control of the multi-frequency vibration unit 46.

[0036] Among them, the three sets of multi-frequency vibration units 46 can output different vibration parameters respectively: First forming stage: vibration frequency 80-120Hz, amplitude 0.5-2mm, mainly acting on fine particles; The second forming stage: vibration frequency 40-60Hz, amplitude 3-6mm, mainly to achieve particle rearrangement; The third molding stage: vibration frequency 15-25Hz, amplitude 8-12mm, mainly to promote gas discharge.

[0037] This invention also provides a high-frequency vibration stamping method for forming high-density anode carbon blocks, characterized by comprising the following steps: S1: Equipment start-up and raw material introduction: Connect the power supply and controller 11, connect the feeding pipe 5 to the raw material inlet, and introduce the mixed carbon materials, petroleum coke, asphalt adhesive, etc. into the mold shell 61 through the feeding pipe 5. The lower mold base 83 supports the raw materials and pre-treats them by heating with electric heating rods. S2: Station switching: The second stepper motor 74 drives the passive gear 72 to rotate through the drive gear 73. The passive gear 72 drives the station support plate 81 to rotate 120° through the rotating column 71, so that the model shell 61 loaded with raw materials moves to below the hydraulic mechanism 4. S3: Stamping preparation and monitoring start-up: Hydraulic cylinder 41 pushes upper mold pressure seat 43 into mold shell 61 through pressure sensor 421 and sealing plate 42 to apply extrusion pressure to the raw material. Pressure sensor 421 monitors the pressure in real time. Servo motor 34 drives threaded rod 32 to rotate, which drives detection probe 35 to adjust the height and monitors the forming process through observation port 62. S4: Three-stage vibration stamping forming: S41: First forming stage: The first group of multi-frequency vibration units 46 is activated, outputting a vibration frequency of 80-120Hz and an amplitude of 0.5-2mm to break up particle agglomerates; the multi-physics field online monitoring mechanism 3 monitors the uniformity of material density, and after reaching the set threshold, it enters the next stage. This stage lasts for about 30 seconds. S42: Second molding stage: Vibration switching unit 45 drives the triangular base 44 to rotate 120°, switching to the second group of multi-frequency vibration unit 46, outputting vibration frequency of 40-60Hz and amplitude of 3-6mm, realizing particle rearrangement; monitoring acoustic emission signal, after the main frequency shifts from high frequency to mid frequency and the energy stabilizes, it enters the next stage, which lasts for about 60 seconds. S43: Third molding stage: Vibration switching unit 45 drives the triangular seat 44 to rotate 120° again, switching to the third group of multi-frequency vibration unit 46, outputting a vibration frequency of 15-25Hz and an amplitude of 8-12mm to promote gas discharge; monitor the material density, and after reaching 1.72g / cm³, enter the pressure holding stage, which lasts for about 40 seconds. S5: Station Cycle and Finished Product Removal: After the pressure holding is completed, the hydraulic cylinder 41 drives the upper mold pressure seat 43 to reset, the station switching mechanism 7 drives the station support plate 81 to rotate 120°, and switches to the next empty station to repeat the molding; the electric push rod 64 drives the model shell 61 to move upward, separate from the lower mold seat 83, and remove the high-density anode carbon block.

[0038] This invention also provides installation steps for a high-frequency vibration stamping forming equipment for high-density anode carbon blocks: Equipment assembly: Fix the workbench 1 on a horizontal ground, install the workstation switching mechanism 7, and ensure that the rotating column 71 rotates flexibly; install three rectangular support seats 82 and lower mold seats 83 on the workstation support plate 81, ensuring that the included angle is accurately 120°, embed the heating rod and connect it to the power supply; Model shell installation: Install electric push rods 64 next to each rectangular support base 82, and connect the model shell 61 through fixing blocks 63 to ensure that the model shell 61 slides with the lower mold base 83; Hydraulic and monitoring mechanism installation: A hydraulic support 2 and a multi-physics field online monitoring mechanism 3 are installed on the top of the workbench 1. A hydraulic cylinder 41 is fixed on the hydraulic support 2, and a sealing plate 42, a pressure sensor 421 and an upper mold pressure seat 43 are connected. A triangular seat 44, a rotating shaft 441, a vibration switching unit 45 and three sets of multi-frequency vibration units 46 are installed in the upper mold pressure seat 43, and a power connector 47 and a bridge conductor 48 are connected. Installation of feeding and control system: Install pipe support plate 51 and feeding pipe 5 to ensure that raw materials can be accurately introduced into model shell 61; install controller 11 on top of workbench 1, connect all motors, sensors, heating rods and vibration units, and debug signal transmission; Equipment debugging: Connect the power supply and test the 120° rotation accuracy of the station switching mechanism 7 to ensure station alignment; test the pressure output of the hydraulic mechanism 4 and the vibration parameters of the vibration unit, and calibrate the pressure sensor 421 and the detection probe 35; test the lifting action of the model shell 61 to ensure smooth operation. Parameter settings: The heating temperature is set to 50-80℃, vibration parameters for each stage are set to frequency, amplitude, stamping pressure to 20-40MPa, density uniformity threshold to ≥95%, and acoustic emission signal threshold frequency to 30-60kHz via controller 11.

[0039] Working principle: High-density molding of anode carbon blocks is achieved through "multi-module collaboration and three-stage precise control," specifically divided into six core stages, each cooperating to form a closed-loop system: 1. Principle of raw material heating pretreatment The heating rod embedded in the lower mold base 83 adopts resistance heating. After being powered on, it converts electrical energy into heat energy, which is then transferred to the anode carbon block raw material in the mold shell 61 through heat conduction. The heating temperature is controlled at 50-80℃. This temperature range can reduce the adsorption and friction of the raw material particles, reduce particle agglomeration, and at the same time avoid excessive loss of volatile components in the raw material. The flowability of raw material particles after heat pretreatment is improved by more than 30%, making them more prone to rearrangement under subsequent vibration and stamping, thus providing favorable conditions for densification molding.

[0040] 2. Principle of precise switching between multiple workstations The workstation switching mechanism 7 uses gear transmission to achieve precise positioning: After receiving the command from the controller 11, the second stepper motor 74 outputs torque to drive the drive gear 73 to rotate. The drive gear 73 meshes with the passive gear 72 to transmit the rotational motion to the rotating column 71, which in turn drives the workstation support plate 81 to rotate. The precise control of the step angle of the second stepper motor 74 ensures that the station support plate 81 rotates 120° each time, and the three rectangular support seats 82 switch the corresponding stations to the raw material inlet area, forming area and material pick-up area in sequence; the high transmission efficiency of the gear transmission ensures that the upper mold pressure seat 43 is precisely aligned with the model shell 61 to avoid stamping deviation.

[0041] 3. Three-stage multi-frequency vibration switching principle The vibration switching and drive system achieves precise switching and operation of multi-frequency vibration units through mechanical transmission and circuit control. Driving principle: The ultrasonic transducer in the multi-frequency vibration unit 46 converts electrical energy into mechanical vibration. By adjusting the frequency and amplitude of the output signal through the circuit board, different vibration parameters can be output. Switching principle: The second stepper motor 452 of the vibration switching unit 45 drives the second gear 453 to rotate. The second gear 453 meshes with the first gear 451, driving the rotating shaft 441 and the triangular seat 44 to rotate 120°. When the triangular seat 44 rotates, the elastic contact block 471 of the corresponding group of contact seats 47 contacts the bridge conductor 48, connecting the power supply of the group of multi-frequency vibration units 46, realizing seamless switching of vibration units. Three-stage adaptation principle: High-frequency small amplitude 80-120Hz / 0.5-2mm: High-frequency vibration can quickly destroy the aggregate structure of fine particles, causing the aggregated particles to disperse into single particles, creating conditions for subsequent rearrangement; Medium frequency, medium amplitude 40-60Hz / 3-6mm: The shear stress field generated by medium frequency vibration can push the dispersed particles to align along the optimal direction and reduce the gaps between particles; Low-frequency large-amplitude vibration 15-25Hz / 8-12mm: Low-frequency large-amplitude vibration can produce a large volume change. Combined with stamping pressure, it can quickly expel the gas trapped between particles, reduce porosity, and improve the degree of densification.

[0042] 4. Multiphysics Real-time Monitoring Principle The multiphysics online monitoring mechanism 3 achieves comprehensive monitoring of the molding process through the collaborative operation of two types of sensors: Density uniformity monitoring: The capacitance tomography sensor emits low-frequency electromagnetic waves into the raw material. The change in dielectric constant of the electromagnetic wave as it passes through the raw material is related to the density. After receiving the reflected signal, the sensor generates a density distribution image through data processing. The controller 11 calculates the density uniformity index. When the uniformity is ≥95%, the first stage is considered complete. Particle state monitoring: Acoustic emission sensors capture elastic wave signals generated by particle breakage and slippage inside the raw material. The main frequency of the acoustic signal generated by particle breakage is in the high frequency band of 80-120kHz, and the main frequency of the acoustic signal generated by particle slippage is in the mid frequency band of 30-60kHz. Controller 11 performs spectrum analysis on the acoustic signal. When the main frequency shifts from the high frequency band to the mid frequency band and the energy is stable, it is determined that the particle rearrangement is completed and the second stage ends. Determination of molding endpoint: In the third stage, the capacitance tomography sensor continuously monitors the overall density. When the density reaches 1.72 g / cm³, it indicates that densification is complete. The controller 11 starts the pressure holding program and holds the pressure for 30-60 seconds to ensure the stability of the molded structure.

[0043] 5. Precise pressure control principle Hydraulic mechanism 4 adopts a closed-loop pressure control method: hydraulic cylinder 41 outputs pressure under the drive of hydraulic system, which is transmitted to upper mold pressure seat 43 through sealing plate 42 and acts on raw material; pressure sensor 421 is installed between hydraulic cylinder 41 and sealing plate 42 to collect pressure data in real time and feed it back to controller 11. The controller 11 compares the actual pressure with the set pressure of 20-40MPa. By adjusting the flow valve of the hydraulic system, the pressure is precisely adjusted, and the pressure error is controlled within ±0.5MPa. Precise pressure control can avoid insufficient densification due to insufficient pressure or excessive particle breakage due to excessive pressure, thus ensuring stable molding quality.

[0044] 6. Principle of Cooperative Control Controller 11, as the core of the entire system, coordinates the collaborative work of all modules to form a closed-loop control logic: Timing coordination: The controller 11 controls the timing of processes such as raw material heating, workstation switching, stamping start, vibration switching, pressure holding, and material picking according to the set program to ensure seamless connection of each process; Parameter coordination: Dynamically adjust process parameters based on monitoring data. For example, when density uniformity improves slowly, appropriately increase the vibration frequency of the first stage; when the acoustic signal energy fluctuates greatly, extend the pressure holding time of the second stage. Safety coordination: Set safety thresholds such as pressure upper limit of 50MPa and temperature upper limit of 80℃. When the parameters are detected to exceed the limit, the controller 11 will automatically stop and alarm to avoid equipment damage or product scrapping. Through the coordinated control of multiple modules and parameters, efficient and high-quality molding of anode carbon blocks is achieved.

[0045] Finally, it should be noted that the basic concepts have been described above. Obviously, for those skilled in the art, the detailed disclosure above is merely illustrative and does not constitute a limitation of this specification. Although not explicitly stated here, those skilled in the art may make various modifications, improvements, and corrections to this specification. Such modifications, improvements, and corrections are suggested in this specification, and therefore, such modifications, improvements, and corrections still fall within the spirit and scope of the exemplary embodiments of this specification. Furthermore, this specification uses specific terms to describe embodiments of this specification. For example, "an embodiment," "one embodiment," and / or "some embodiments" refer to a feature, structure, or characteristic associated with at least one embodiment of this specification. Therefore, it should be emphasized and noted that "an embodiment," "one embodiment," or "an alternative embodiment" mentioned twice or more in different locations in this specification do not necessarily refer to the same embodiment. In addition, certain features, structures, or characteristics in one or more embodiments of this specification can be appropriately combined. Moreover, unless expressly stated in the claims, the order of processing elements and sequences, the use of numbers and letters, or other names described in this specification are not intended to limit the order of the processes and methods of this specification.

[0046] Finally, it should be noted that the above descriptions are merely preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the foregoing embodiments, those skilled in the art can still modify the technical solutions described in the foregoing embodiments or make equivalent substitutions for some of the technical features. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A high-frequency vibration stamping forming device for high-density anode carbon blocks, comprising a worktable (1), wherein a controller (11) is provided on the top of the worktable (1), characterized in that, The bottom of the workbench (1) is provided with a station switching mechanism (7), and the station switching mechanism (7) is provided with a multi-model cooperating station (8). The multi-model cooperating station (8) is located at the top of the workbench (1), providing a basis for multi-station cyclic processing, and also includes: A hydraulic support (2) is fixedly installed on the top of the workbench (1). A hydraulic mechanism (4) is installed on the hydraulic support (2) to provide stable power for stamping. The multi-physics field online monitoring mechanism (3) is fixedly installed on the top of the workbench (1) to realize real-time monitoring of the molding process; Three model shell units (6) are used in conjunction with the multi-model cooperating station (8). The hydraulic mechanism (4) is adapted to the three model shell units (6) and is used to stamp the anode carbon block. The multi-physics field online monitoring mechanism (3) is used in conjunction with the model shell unit (6). The feeding pipe (5) cooperates with the model shell unit (6). The top of the workbench (1) is fixedly installed with a pipe support plate (51), and the feeding pipe (5) is installed on the pipe support plate (51).

2. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 1, characterized in that, The multi-model cooperating station (8) includes a station support plate (81), which is located above the workbench (1). Three rectangular support seats (82) are fixedly installed on the station support plate (81). The included angle between the three rectangular support seats (82) is 120°, which is suitable for three-station cyclic operation. A lower mold seat (83) is fixedly installed on the top of each of the three rectangular support seats (82). Each of the three lower mold seats (83) is embedded with an electric heating rod to realize the pretreatment of raw material heating and improve the molding effect.

3. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 2, characterized in that, The workstation switching mechanism (7) includes a rotating column (71) and a second stepper motor (74). The rotating column (71) is rotatably mounted on the worktable (1) via bearings. The top of the rotating column (71) is fixedly mounted to the bottom of the workstation support plate (81). A driven gear (72) is fixedly mounted on the bottom of the rotating column (71). The second stepper motor (74) is mounted on the bottom of the worktable (1). A drive gear (73) is mounted on the output shaft of the second stepper motor (74). The drive gear (73) meshes with the driven gear (72).

4. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 3, characterized in that, The model shell unit (6) includes a model shell (61) and an electric push rod (64). The electric push rod (64) is fixedly installed on the top of the workstation support plate (81). A fixing block (63) is fixedly installed on the output shaft of the electric push rod (64). The fixing block (63) is fixedly installed on the outside of the model shell (61). The inner wall of the model shell (61) is slidably connected to the outside of the lower mold base (83) to facilitate the removal of the carbon block after molding.

5. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 4, characterized in that, The multiphysics field online monitoring mechanism (3) includes a vertical slide rail (31), which is fixedly installed on the top of the workbench (1). A threaded rod (32) is vertically rotatably installed on the inner wall of the vertical slide rail (31). A slider (33) is threadedly connected to the outer side of the threaded rod (32). A detection probe (35) is provided on the slider (33). An observation port (62) is provided on the outer side of the model shell (61). The detection probe (35) cooperates with the observation port (62) to realize non-contact monitoring of the molding process. A servo motor (34) is installed on the top of the vertical slide rail (31). The output shaft of the servo motor (34) is fixedly installed with the threaded rod (32).

6. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 5, characterized in that, The detection probe (35) includes an acoustic emission sensor and a capacitance tomography sensor to achieve multi-dimensional monitoring of density uniformity and particle state.

7. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 6, characterized in that, The hydraulic mechanism (4) includes a hydraulic cylinder (41) and a sealing plate (42). The hydraulic cylinder (41) is fixedly installed on the top of the hydraulic support (2). The output shaft of the hydraulic cylinder (41) is connected to the top of the sealing plate (42). A pressure sensor (421) is provided between the two to monitor the stamping pressure in real time. An upper mold pressure seat (43) is fixedly installed at the bottom of the sealing plate (42). A triangular seat (44) is provided inside the upper mold pressure seat (43). A multi-frequency vibration unit (46) is provided on three sides of the triangular seat (44). The multi-frequency vibration unit (46) includes a circuit board and multiple sets of ultrasonic transducers to realize high-frequency vibration stamping.

8. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 7, characterized in that, A rotating shaft (441) is fixedly installed at the center of the triangular seat (44). The rotating shaft (441) is rotatably mounted on the inner walls of both sides of the upper mold pressure seat (43) via bearings. A vibration switching unit (45) is installed inside the upper mold pressure seat (43). The vibration switching unit (45) cooperates with the rotating shaft (441). The vibration switching unit (45) includes a second stepper motor (452) and a first gear (451). The first gear (451) is fixedly installed on the outside of the rotating shaft (441). The second stepper motor (452) is installed on the inner wall of the upper mold pressure seat (43). A second gear (453) is installed on the output shaft of the second stepper motor (452). The second gear (453) meshes with the first gear (451) to realize the switching of multi-frequency vibration units.

9. The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 8, characterized in that, Three sets of electrical connectors (47) are fixedly installed on the outside of the triangular base (44). Each of the three sets of electrical connectors (47) is provided with two elastic electrical blocks (471). The three sets of electrical connectors (47) are electrically connected to the three multi-frequency vibration units (46). A bridge conductor (48) is fixedly installed on the side wall of the upper mold pressure seat (43). The three sets of electrical connectors (47) are electrically connected to the bridge conductor (48) through the corresponding two elastic electrical blocks (471) to control the precise power supply of the three multi-frequency vibration units (46) and realize the switching of vibration parameters.

10. A high-frequency vibration stamping method for forming high-density anode carbon blocks, characterized in that, The high-frequency vibration stamping forming equipment for high-density anode carbon blocks according to claim 9 includes the following steps: S1: When in use, connect the power supply and controller (11), connect the feeding pipe (5) to the raw material inlet, and the anode carbon block raw material is fed into the interior of the mold shell (61) through the feeding pipe (5). It is supported and positioned by the lower mold base (83). At the same time, the electric heating rod embedded in the lower mold base (83) heats and pre-treats the anode carbon block raw material to improve the plasticity of the raw material. S2: The second stepper motor (74) drives the passive gear (72) to rotate through the drive gear (73). The passive gear (72) drives the station support plate (81) to rotate 120 degrees through the rotating column (71). The station support plate (81) drives the lower mold base (83) and the model shell (61) to move precisely below the hydraulic mechanism (4) to complete the station switching. S3: The hydraulic cylinder (41) pushes the upper mold pressure seat (43) downward through the pressure sensor (421) and the sealing plate (42). The upper mold pressure seat (43) enters the mold shell (61) and squeezes the anode carbon block raw material. The pressure sensor (421) continuously monitors the pressure applied by the upper mold pressure seat (43) to the anode carbon block raw material to ensure that the pressure is accurate and controllable. The detection probe (35) performs real-time detection of the anode carbon block raw material squeezing process inside the mold shell (61) through the observation port (62). The servo motor (34) drives the threaded rod (32) to rotate. The threaded rod (32) drives the detection probe (35) to adjust its height through the slider (33) to expand the detection range of the detection probe (35) on the anode carbon block raw material and realize full-process monitoring. S4: First forming stage: The multi-frequency vibration unit (46) on the triangular seat (44) emits a vibration frequency of 80-120Hz and an amplitude of 0.5-2mm. This stage mainly acts on the interface of fine particles to break up agglomerates. The multi-physics field online monitoring mechanism (3) monitors the change in material density in real time through the detection probe (35). When the internal density uniformity is detected to reach the set threshold, the controller (11) automatically switches to the next stage. Second molding stage: The second stepper motor (452) drives the first gear (451) to rotate through the second gear (453). The first gear (451) drives the triangular seat (44) to rotate 120 degrees. Another multi-frequency vibration unit (46) faces the anode carbon block raw material. The two elastic contact blocks (471) on the contact seat (47) contact the bridge conductor (48) to connect the power supply of the multi-frequency vibration unit (46). The multi-frequency vibration unit (46) on the triangular seat (44) emits a vibration frequency of 40-60Hz and an amplitude of 3-6mm, forming a cyclic shear stress field inside the material, mainly realizing particle rearrangement. The multi-physics field online monitoring mechanism (3) monitors the acoustic emission signal generated by particle friction and rearrangement in real time through the detection probe (35). The particle orientation state is judged by spectrum analysis. When the main frequency of the acoustic emission signal is detected to shift from the high frequency band to the mid frequency band and the energy tends to be stable, it indicates that the particles have basically completed the orientation arrangement. The controller (11) enters the next stage. The third molding stage: the second stepper motor (452) drives the first gear (451) to rotate through the second gear (453), the first gear (451) drives the triangular seat (44) to rotate 120 degrees, the third multi-frequency vibration unit (46) faces the anode carbon block raw material, the multi-frequency vibration unit (46) on the triangular seat (44) emits a vibration frequency of 15-25Hz and an amplitude of 8-12mm, the vibration and pressing work together to promote the rapid discharge of gas; the multi-physics field online monitoring mechanism (3) continuously monitors the density change through the detection probe (35), when the density reaches 1.72g / cm³, the controller (11) enters the pressure holding stage to ensure the molding density is stable; S5: After the molding extrusion is completed, the hydraulic cylinder (41) drives the upper mold pressure seat (43) to leave the mold shell (61), and the station switching mechanism (7) drives the multi-model cooperation station (8) to rotate 120 degrees again to change to another empty station for extrusion processing, so as to realize continuous operation. S6: The electric push rod (64) drives the model shell (61) to move upward through the fixed block (63). The model shell (61) leaves the rectangular support base (82) and the lower mold base (83), and the high-density anode carbon block after extrusion can be taken out to complete the single molding operation.

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