An automatic polishing information full-process tracking system and method for copper electrolysis cathode plate

Abstract

The application discloses a kind of copper electrolysis cathode plate automatic polishing information whole-process tracking system and method, the system includes hardware architecture and software function module;The hardware architecture includes equipment communication adaptation unit, position identification unit, data transmission unit and background processing unit;The software function module includes whole-process real-time tracking module, cross-device data collaboration module and regionalization timeout early warning query module;The software function module is realized based on hardware architecture, with the whole groove information released by automatic polishing unit as core data source, in combination with position identification storage data, in combination with the data of program processing, vehicle, unit transfer component installation setting.The application does not need to install identification and acquisition hardware, and has low modification cost and strong adaptability;With polishing unit as the only data source, the data is accurate and reliable;Relying on exclusive storage unit to adapt to on-site flow logic, with timeout early warning, significantly improve the control efficiency, adapt to industry promotion, and ensure production stability.

Description

Technical Field

[0001] This invention relates to the field of automated control technology for copper electrolytic metallurgical equipment, and in particular to a full-process tracking system and method for automatic grinding information of copper electrolytic cathode plates. Background Technology

[0002] In the copper electrolysis production process, stainless steel cathode plates are the core tooling equipment, characterized by their reusability. The cleanliness and flatness of their surfaces directly affect the quality of copper deposition and the purity of the finished product. For example, in a conventional production process, stainless steel cathode plates with attached electrolytic copper need to be transported from the electrolytic cell to the stripping unit by a dedicated overhead crane to remove the copper from the cathode, in whole-cell units. After stripping, the plates are automatically arranged by the unit and then transferred by a dedicated overhead crane to the automatic grinding unit for edge stripping, liquid level line, and plate body grinding and maintenance. The ground cathode plates are then transported back to the electrolytic cell for production or stored in a storage rack for static storage, depending on production scheduling needs.

[0003] Currently, existing automated grinding units in the production system only have single-machine information recording functions, storing only local data such as processing time and grinding items, lacking cross-equipment linkage and data acquisition capabilities. Due to the frequent and dynamic transfer of stainless steel cathode plates between electrolytic cells, dedicated overhead cranes, process units, and storage racks, traditional management methods generally rely on manual ledger recording and independent statistics for each device. This not only involves significant manual intervention and low levels of automation but also easily leads to data lag, recording errors, and missing information, causing abnormal conditions such as excessive grinding time, missed grinding, and repeated grinding. Over time, this reduces plate flatness and affects electrolytic extraction results. Furthermore, the electrolytic cells, overhead cranes, stripping units, grinding units, and storage racks within the workshop are independent, with inconsistent communication protocols, resulting in severe data barriers. This makes it impossible to establish a data link throughout the entire process of cathode plate transfer, processing, and storage, hindering full-process information traceability, status monitoring, and centralized control, and failing to meet the needs of modern copper electrolysis industry for large-scale, continuous, and refined intelligent production management. Summary of the Invention

[0004] To address the shortcomings of existing technologies, this invention provides a full-process tracking system and method for automatic grinding information of copper electrolytic cathode plates, which is adapted to the dynamic reverse operation characteristics of stainless steel cathode plates and enables real-time tracking of stainless steel cathode plate information throughout the entire process and regional timeout warning queries.

[0005] This invention is achieved through the following technical solution:

[0006] A full-process tracking system for automatic grinding of copper electrolytic cathode plates includes a hardware architecture and software functional modules. The hardware architecture includes a device communication adapter unit, a location identification unit, a data transmission unit, and a background processing unit. The software functional modules include a real-time full-process tracking module, a cross-device data collaboration module, and a regional timeout warning query module. The software functional modules are implemented based on the hardware architecture, using the whole-slot information released by the automatic grinding unit as the core data source, combined with location identification storage data, and combined with the processed data of the crane and unit transport components for installation and settings.

[0007] The device communication adapter unit is installed on the overhead crane, automatic grinding unit, internal transfer components of the special unit, and related equipment of each tank. It obtains data through the original communication interface of the equipment to establish a communication link, adapts to the communication protocols of different devices, and realizes stable acquisition of real-time position and action data of the overhead crane and position and action data of the internal transfer components of the unit.

[0008] The location identification unit is installed at all locations along the entire electrolytic process of the stainless steel cathode plate and is assigned a unique location code and a dedicated storage unit. When the overhead crane transports the cathode plate (one set per slot) to the corresponding location, it obtains the real-time location and action data of each device through information interaction across the entire network, automatically associates it with the corresponding storage unit, and realizes the accurate binding and tracking of the position of the entire slot of stainless steel cathode plate. It does not participate in the collection of grinding information.

[0009] The back-end processing unit includes a data storage server and a back-end management terminal, and has a built-in back-end program processing module. This module receives and stores grinding information for the entire stainless steel cathode plate from the automatic grinding unit, as well as data from the crane and unit transport components transmitted by the equipment communication adapter unit. Through program control logic algorithms, it tracks the stainless steel cathode plate's movement trajectory and binds it to the grinding information, while simultaneously processing, analyzing, and interactively displaying the data. The program control logic algorithms include multi-dimensional condition value matching, hierarchical logic adjudication, and operating condition identification.

[0010] Furthermore, the data transmission unit adopts a dual-mode transmission protocol of industrial Ethernet and wireless communication to receive the position and action data obtained by the equipment communication adapter unit and the grinding information released by the automatic grinding unit, thereby solving the data stability problem in the complex environment of the entire copper electrolysis process and ensuring that all kinds of data are efficiently transmitted to the background processing unit.

[0011] Furthermore, the full-process real-time tracking module analyzes the position and movement data of the overhead crane through its internal program processing module, locating the entire path trajectory of the cathode plate from the original electrolytic cell, through its transfer to the automatic grinding unit, and then its lowering to the target position. Simultaneously, it receives information released by the automatic grinding unit, accurately recording the grinding time and detailed process items for the entire cell, including edge strips, liquid level lines, and the entire plate. All grinding data and flow trajectory data are automatically bound through the program control logic algorithm.

[0012] Furthermore, the cross-device data collaboration module incorporates a multi-device communication protocol adaptation algorithm and a data association program to solve the problem of inconsistent communication interfaces and data formats of different devices. It associates the position and action data of the crane and the unit with the grinding data of the tank group released by the automatic grinding unit to ensure the continuity and consistency of grinding information and flow trajectory, and avoid data gaps.

[0013] Furthermore, the regionalized timeout warning query module supports dividing the query range by workshop area, and has a built-in dynamic timeout threshold algorithm that can be adjusted in combination with the priority of grinding process; and based on grinding time and location tracking data, it automatically filters the tank groups and corresponding locations that have exceeded the timeout for grinding within the area, and generates warning prompts on the background management terminal; at the same time, it provides a historical data retrieval function, which can query grinding records, flow trajectory and timeout status by region and time period, and the data source can be traced back to the content published by the automatic grinding unit and the equipment communication data.

[0014] A method for tracking the entire process of automatic polishing information of copper electrolysis cathode plates includes the following steps:

[0015] S1. Equipment Communication Link Establishment: Establish communication links between the overhead crane, automatic grinding unit, internal transfer components of the special unit, and related equipment in the tank. Adapt different equipment communication protocols through the equipment communication adapter unit to realize the real-time acquisition and transmission of position and motion data of the overhead crane and unit transfer components. At the same time, assign a unique position code to all positions in the entire electrolysis process that the stainless steel cathode plate may reach through the position identification unit, configure a dedicated storage unit for each position and write the position information, and complete the position tracking hardware adaptation.

[0016] S2. Tracking of the Flow Trajectory of the Entire Stainless Steel Cathode Plate: When the overhead crane performs the lifting action of the entire stainless steel cathode plate, its position and action data are transmitted to the background processing unit via the communication link. The background program processing module records the initial electrolytic cell position of the stainless steel cathode plate. During the transfer process, the program analyzes the crane's position change data in real time and dynamically tracks the transfer trajectory. After the stainless steel cathode plate enters the dedicated unit, the action data of the unit's transfer components triggers the program association, recording that the stainless steel cathode plate has entered the processing state. After completion, the program tracks the entire process of the stainless steel cathode plate being lowered to the target position through the data of the overhead crane and the unit's transfer components.

[0017] S3. Position Code Recognition and Trajectory Tracking: During the transfer of the overhead crane, its real-time position information is linked with the original electrolytic cell position triggering device to automatically identify the original electrolytic cell position code and associate it with the corresponding storage unit; during the transfer process, the position code and the association relationship of the storage unit are dynamically updated to achieve trajectory tracking.

[0018] S4. Grinding Information Release and Binding: After the automatic grinding unit completes the preset grinding process for the whole-slot stainless steel cathode plate, the automatic grinding unit, as the sole information publisher, synchronously generates the grinding information of the whole-slot stainless steel cathode plate. The information is then pushed to the background processing unit via the data transmission unit. The background program processing module automatically binds and stores the grinding information with the corresponding flow trajectory data of the whole-slot stainless steel cathode plate.

[0019] S5. Cross-device data collaborative processing: The background program uses a multi-device data association algorithm to standardize and integrate grinding information, crane operation and unit transfer data, ensuring the continuity of data from different devices and forming a complete data chain for the entire process of grinding and transferring stainless steel cathode plates in the whole tank.

[0020] S6. Regionalized Timeout Warning and Query: Based on dynamically adjustable preset thresholds, the backend processing unit analyzes the grinding time of the entire stainless steel cathode plate published by the automatic grinding unit through the program. Combined with the tracked location data, it filters out the tank groups and corresponding locations in each region whose grinding time exceeds the threshold and generates warning prompts. At the same time, it responds to user query commands and, based on the stored end-to-end data chain, provides feedback on the grinding records, transfer trajectory and timeout status of the entire stainless steel cathode plate in the specified area and time period.

[0021] The threshold calculation is mainly based on the time stamp of the grinding completion assignment and the current real-time time of the system to calculate the set number of overtime alarm days; the position calculation is that the position processing unit enters a unique position code, determines a unique position through array combination, and moves the timestamp and production information according to the changes in the crane and unit operating conditions.

[0022] Compared with the prior art, the present invention has the following advantages:

[0023] 1. Highly practical, accurately adaptable to various scenarios and cost-controllable: No need to add RFID, location chips and additional data acquisition components. Tracking is achieved simply by connecting the existing equipment communication links and relying on program processing. It fully matches the actual process of copper electrolysis “one tank and one set” stainless steel cathode plate processing, crane transport and unit transfer. No large-scale modification of existing equipment is required. The hardware investment cost is low, and it can be quickly deployed and applied to accurately solve industry pain points.

[0024] 2. High data accuracy and consistency: By limiting the automatic grinding unit to the sole information publisher and recording data on a per-electrolytic-cell basis, deviations and conflicts caused by multi-source acquisition and single-piece motherboard tracking are avoided; by combining the location storage unit with the crane position linkage, the grinding information and location trajectory are accurately correlated, effectively improving the accuracy of data traceability;

[0025] 3. Significantly improved management efficiency: The regional overtime warning function replaces traditional manual recording. Based on the real-time data released by the automatic grinding unit and the location storage unit information, it realizes rapid warning, significantly improves query efficiency, and shortens the overtime detection time to the minute level, effectively avoiding problems such as the decline in the performance of stainless steel cathode plates due to overtime.

[0026] 4. Strong compatibility and easy to promote: It only relies on the existing communication interface of the equipment to build the link, and is compatible with different brands and models of overhead cranes and automatic grinding units. No customized hardware modification is required. The program algorithm can be flexibly adapted to workshop layout adjustments, which has broad industry promotion value. At the same time, it provides accurate whole-slot data support for grinding process optimization, ensuring the performance of stainless steel cathode plates.

[0027] 5. Strong adaptability of tracking logic: Storage units are allocated according to all possible positions of the stainless steel cathode plate. Tracking is triggered by the crane and position, which perfectly matches the actual process of copper electrolysis site hoisting and unit transfer. This avoids the problems of easy damage to identification components and cumbersome single-piece tracking. At the same time, it provides accurate whole-cell data support for the optimization of grinding process, further ensuring the effect of cathode plate use and production stability. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the hardware architecture of the system of the present invention;

[0029] Figure 2 This is a schematic diagram of the functional logic of the system software of the present invention;

[0030] Figure 3 This is a flowchart of the method of the present invention. Detailed Implementation

[0031] The invention will now be further described with reference to the accompanying drawings.

[0032] Example

[0033] A full-process tracking system for automatic grinding of copper electrolytic cathode plates includes a hardware architecture and software functional modules. The hardware architecture includes a device communication adapter unit, a location identification unit, a data transmission unit, and a background processing unit. The software functional modules include a real-time full-process tracking module, a cross-device data collaboration module, and a regional timeout warning query module. The software functional modules are implemented based on the hardware architecture, using the whole-slot information released by the automatic grinding unit as the core data source, combined with location identification storage data, and combined with the processed data of the crane and unit transport components for installation and settings.

[0034] The equipment communication adapter unit is installed on the overhead crane, automatic grinding unit, internal transfer components of the special unit, and related equipment of each tank. It obtains data through the original communication interface of the equipment to establish a communication link, adapts to the communication protocols of different equipment, and realizes stable acquisition of real-time position and action data (including lifting, transfer, and lowering) of the overhead crane and position and action data (including feeding, processing, and discharging) of the internal transfer components of the unit.

[0035] The system does not require additional sensing components. After the installation of the communication adapter unit, it only obtains data through the original communication interface for the correlation tracking of the flow trajectory of the stainless steel cathode plate in the whole tank.

[0036] The location identification unit is installed at all locations along the entire electrolysis process of the stainless steel cathode plate, including the inlet and outlet of each electrolytic cell, storage rack, automatic grinding unit, special unit, internal workstation, and lifting tool docking point, and is assigned a unique location code and dedicated storage unit. When the overhead crane transfers the cathode plate (one set per cell) to the corresponding location, it obtains the real-time location and action data of each device through information interaction across the entire network, automatically associates it with the corresponding storage unit, and realizes the accurate binding and tracking of the position of the entire stainless steel cathode plate in the cell. It does not participate in the collection of grinding information.

[0037] The back-end processing unit includes a data storage server and a back-end management terminal, and has a built-in back-end program processing module. This module receives and stores grinding information for the entire stainless steel cathode plate from the automatic grinding unit, as well as data from the crane and unit transport components transmitted by the equipment communication adapter unit. Through program control logic algorithms, it tracks the stainless steel cathode plate's movement trajectory and binds it to the grinding information, while simultaneously processing, analyzing, and interactively displaying the data. The program control logic algorithms include multi-dimensional condition value matching, hierarchical logic adjudication, and operating condition identification.

[0038] The data storage server, as the core data storage unit of the system, is mainly responsible for centrally storing all information on the grinding of the tank group, the full process position and action data of the cathode plate, as well as various early warning records and historical archive data, providing stable and complete underlying data support for background algorithm analysis, real-time terminal display and historical traceability query.

[0039] The background processing module relies on the built-in core algorithm to realize the correlation analysis of heterogeneous data of multiple devices and the automatic tracking of cathode plate flow trajectory. It can automatically match and bind grinding operation information with running trajectory, and can dynamically calculate the timeout judgment threshold according to the on-site working conditions, providing algorithm support for the system.

[0040] The back-end management terminal serves as the entry point for human-computer interaction and system control. It can realize real-time trajectory visualization, regional timeout and abnormality early warning, support all-dimensional historical data conditional retrieval and query, and has the ability to configure and adjust process parameters online, making it convenient for managers to monitor production status in real time, handle abnormal problems, and optimize production processes.

[0041] The data transmission unit adopts a dual-mode transmission protocol of industrial Ethernet and wireless communication (WiFi / 4G) to receive the location and action data obtained by the equipment communication adapter unit and the grinding information released by the automatic grinding unit. This solves the data stability problem in the complex environment of the entire copper electrolysis process and ensures that all kinds of data are efficiently transmitted to the background processing unit.

[0042] The full-process real-time tracking module analyzes the position and movement data of the overhead crane through its internal program processing module, locating the entire path trajectory of the cathode plate from the original electrolytic cell, through its transfer to the automatic grinding unit, and then its lowering to the target position. Simultaneously, it receives information from the automatic grinding unit, accurately recording the grinding time and detailed process items for the entire cell, including edge strips, liquid level lines, and the entire plate. All grinding data and flow trajectory data are automatically bound through the program control logic algorithm.

[0043] The full-process real-time tracking module is the core tracking module. Relying on the continuous standard data verified and completed by the cross-device data collaboration module, it achieves accurate positioning of the entire path trajectory of the mother plate of the tank assembly; it completes the association and binding of cathode plate grinding information and flow trajectory, records the entire link information completely on a single tank basis, and dynamically updates the cathode plate grinding information and running trajectory data in real time, realizing full-process tracking and real-time status perception, providing accurate real-time business data sources for subsequent early warning analysis.

[0044] The cross-device data collaboration module has a built-in multi-device communication protocol adaptation algorithm and data association program to solve the problem of inconsistent communication interfaces and data formats of different devices. It associates the position and action data of the crane and the unit with the grinding data of the tank group released by the automatic grinding unit to ensure the continuity and consistency of grinding information and flow trajectory, and avoid data gaps.

[0045] The cross-device data collaboration module is a foundational support module that provides underlying data operation support for the software system. It is responsible for standardizing and integrating the data processed by the program, ensuring compatibility with various multi-device communication protocols and providing communication fallback. At the same time, it performs data continuity and consistency verification and missing data completion, and can identify data anomalies in the device operation process in real time. It provides uninterrupted and seamless standard data support for other business modules such as full-process real-time tracking and regional timeout warning queries, ensuring reliable data flow throughout the system.

[0046] The regionalized timeout warning query module supports dividing the query range by workshop area, and has a built-in dynamic timeout threshold algorithm that can be adjusted according to the priority of grinding process. Based on grinding time and location tracking data, it automatically filters out the tank groups and corresponding locations that have exceeded the timeout for grinding within the area, and generates warning prompts on the background management terminal. At the same time, it provides a historical data retrieval function, which can query grinding records, flow trajectory and timeout status by region and time period. The data source can be traced back to the content published by the automatic grinding unit and the equipment communication data.

[0047] The regionalized timeout warning query module is an application output module that tracks the module's trajectory, grinding binding count, and dynamic timeout threshold data in real time. It supports flexible division of the query range according to different areas of the workshop, automatically identifies and filters tank groups that have exceeded the timeout threshold within the area, accurately locates their current position, and simultaneously pushes visual timeout warning prompts to the background management terminal. It also has full-dimensional historical data retrieval capabilities, enabling full querying of production anomaly records, trajectory information, and grinding records, and ensuring traceability of data sources, thus meeting the needs of on-site control, anomaly handling, and production review management.

[0048] A method for tracking the entire process of automatic polishing information of copper electrolysis cathode plates includes the following steps:

[0049] S1. Equipment Communication Link Establishment: Establish communication links between the overhead crane, automatic grinding unit, internal transfer components of the special unit, and related equipment in the tank. Adapt different equipment communication protocols through the equipment communication adapter unit to realize the real-time acquisition and transmission of position and motion data of the overhead crane and unit transfer components. At the same time, assign a unique position code to all positions in the entire electrolysis process that the stainless steel cathode plate may reach through the position identification unit, configure a dedicated storage unit for each position and write the position information, and complete the position tracking hardware adaptation.

[0050] S2. Tracking of the Flow Trajectory of the Entire Stainless Steel Cathode Plate: When the overhead crane performs the lifting action of the entire stainless steel cathode plate, its position and action data are transmitted to the background processing unit via the communication link. The background program processing module records the initial electrolytic cell position of the stainless steel cathode plate. During the transfer process, the program analyzes the crane's position change data in real time and dynamically tracks the transfer trajectory. After the stainless steel cathode plate enters the dedicated unit, the action data of the unit's transfer components triggers the program association, recording that the stainless steel cathode plate has entered the processing state. After completion, the program tracks the entire process of the stainless steel cathode plate being lowered to the target position through the data of the overhead crane and the unit's transfer components.

[0051] S3. Position Code Recognition and Trajectory Tracking: When the overhead crane is being transported, its real-time position information is linked with the original electrolytic cell position triggering device to automatically recognize the original electrolytic cell position code and associate it with the corresponding storage unit; during the transport process, the position code and the association relationship of the storage unit are dynamically updated to achieve trajectory tracking.

[0052] S4. Grinding Information Release and Binding: After the automatic grinding unit completes the preset grinding process for the whole-slot stainless steel cathode plate, the automatic grinding unit, as the sole information publisher, synchronously generates the grinding information of the whole-slot stainless steel cathode plate, including grinding time and grinding items. The information is then pushed to the background processing unit via the data transmission unit. The background program processing module automatically binds and stores the grinding information with the corresponding flow trajectory data of the whole-slot stainless steel cathode plate.

[0053] S5. Cross-device data collaborative processing: The background program uses a multi-device data association algorithm to standardize and integrate grinding information, crane operation and unit transfer data, ensuring the continuity of data from different devices and forming a complete data chain for the entire process of grinding and transferring stainless steel cathode plates in the whole tank.

[0054] S6. Regionalized Timeout Warning and Query: Based on dynamically adjustable preset thresholds, the backend processing unit analyzes the grinding time of the entire stainless steel cathode plate in the automatic grinding unit, and combines it with tracked location data to filter out tank groups and corresponding locations in each region whose grinding time exceeds the threshold, generating a warning prompt. Simultaneously, it responds to user query commands, and based on the stored end-to-end data chain, provides feedback on the grinding records, transport trajectory, and timeout status of the entire stainless steel cathode plate in the specified region and time period. The threshold calculation mainly involves calculating the set number of days for the timeout alarm based on the grinding completion time stamp and the current system real-time time. The location calculation involves the location processing unit inputting a unique location code, determining a unique location through array combination, and moving the timestamp and production information according to changes in the overhead crane and unit operating conditions.

[0055] This embodiment selects a large-scale copper electrolysis production workshop as the application scenario. The workshop includes a complete electrolysis production line, electrode plate transfer line, and automated grinding operation line. It can be divided into a workshop-level equipment layer, a data interaction and transmission layer, and a back-end processing and control layer. According to the hardware architecture requirements of this invention, the hardware deployment and link construction of the entire workshop are completed. The specific deployment method is as follows:

[0056] Hardware architecture deployment and implementation:

[0057] For the 1,800 electrolytic cells, 200 electrode plate storage racks, 2 automatic grinding units, 2 dedicated transfer units (with 16 processing stations built-in), 4 dedicated overhead cranes, and all crane docking points in the workshop, location identification units were deployed. Each of the above points was assigned a unique encrypted location code. The coding format adopted the combination of "regional code + equipment number + station number". At the same time, each location code was matched with an independent dedicated storage unit to store the corresponding location-related data such as equipment status and electrode plate docking records.

[0058] At the communication level, communication adapter units were installed on each of the four dedicated overhead cranes, two automatic grinding units, two dedicated unit internal transfer components, and 1,800 tank-related supporting equipment. Relying on the original industrial communication interfaces of each piece of equipment, the different communication protocols of different brands and models of equipment were adapted, the data transmission format was unified, the cross-equipment communication link was opened, and the lifting, transfer, and lowering action data and real-time coordinate position of the overhead cranes were stably collected. At the same time, the process actions and station position data of the material feeding, processing, and discharging of the internal transfer components of the units were collected.

[0059] The data transmission unit adopts a dual-mode transmission architecture of industrial Ethernet + wireless communication. Fixed equipment such as the electrolytic cell, storage rack, grinding unit, and special-purpose units rely on industrial Ethernet for wired data transmission, ensuring the stability of data transmission at fixed locations. The four mobile overhead cranes use WiFi + 4G dual-mode wireless communication, adapting to the complex electromagnetic environment of the workshop and avoiding signal blockage during crane movement. Simultaneously, a dedicated encrypted data link is established between the grinding unit, the location storage unit, and the back-end processing unit, isolating other production data in the workshop and preventing data interference.

[0060] The back-end processing unit is deployed in a separate control room in the workshop. The hardware configuration includes one industrial-grade data storage server and one back-end management terminal. The server has a built-in large-capacity hard drive for long-term storage of electrode plate flow data, grinding process data, and equipment movement data. The management terminal features a visual operating interface for real-time monitoring, querying, and alerting by staff. This system requires no additional RFID radio frequency identification components, positioning chips, or extra data acquisition sensors; it relies entirely on the equipment's native communication interface for data acquisition, minimizing the amount of hardware modification work required.

[0061] Software and program debugging:

[0062] After the hardware deployment is completed, the deployment, installation, and debugging of the entire software functional modules of this invention are completed on the background management terminal in the workshop control room. The program algorithm and operating parameters are optimized in combination with the actual production conditions in the workshop. The specific debugging content is as follows:

[0063] First, the basic software deployment is completed, including a full-process real-time tracking module, a cross-device data collaboration module, and a regional timeout warning query module. Pre-set data association programs and dynamic threshold algorithms are imported. Combined with the workshop production scheduling plan and grinding process standards, the grinding operation timeout threshold is initialized. The threshold supports manual adjustment as well as automatic dynamic adjustment in conjunction with the production plan, adapting to different production conditions such as peak production, regular production, and maintenance production.

[0064] Secondly, we conducted communication adaptation algorithm debugging. To address the differences in communication protocols among various types of equipment in the workshop, such as tank equipment, overhead cranes, grinding units, and special units, we optimized the protocol parsing rules and completed data message decoding and format standardization. We also repeatedly conducted equipment start-up and shutdown, electrode plate transfer, and unit processing simulation tests to eliminate data transmission delays, message loss, and data garbled issues. This ensured that the position and movement data of the crane and unit transfer components were stably collected at the millisecond level, and the data transmission delay was controlled within 50ms.

[0065] Then, the background program processing logic was optimized, and the data binding algorithm for the entire tank electrode plates was improved. The automatic grinding unit was used as the sole source of grinding information. The data on grinding time, edge strip processing, liquid level line adjustment, plate grinding and other detailed process data were captured. Combined with the crane transfer trajectory and the unit station dwell data, the grinding information was accurately and automatically bound to the stainless steel cathode plate flow trajectory of the tank group, eliminating the problems of incorrect or missing data binding.

[0066] Finally, the regional query and early warning functions were tested. The workshop was divided into four major work areas: east, west, south, and north, according to the physical layout of the workshop. A regional visual monitoring interface was built on the back-end terminal. The functions of regional filtering, time period retrieval, and status query were tested. The number of tank groups, the current position of the electrode plates, the progress of the grinding process, and the operating status of the equipment in each area can be retrieved in real time. At the same time, the overtime grinding condition was simulated to verify the trigger sensitivity of the early warning module and ensure that abnormal conditions are automatically prompted by pop-up windows and data is marked and retained.

[0067] This automated copper electrolysis cathode plate grinding information tracking system has been running continuously in the workshop for a period of time, undertaking the grinding, transportation, and electrolysis of stainless steel cathode plates without interruption. Compared with the traditional control mode of manual recording, manual inspection, and RFID identification before the upgrade, various operating indicators and production efficiency have been significantly improved. The specific application effects are as follows:

[0068] (1) High data traceability accuracy and zero deviation in flow tracking. All stainless steel cathode plate grinding information of the tank group in this system is independently released by the automatic grinding unit, and the data source is unique and cannot be tampered with; the plate flow trajectory is intelligently tracked by the original communication data of the crane and the unit, eliminating additional collection links, redundant collection hardware, and secondary data collection process, and requiring no RFID identification for auxiliary positioning. According to statistics, the data traceability accuracy during system operation can reach 99.2%; the position binding is completed by the linkage mechanism of the lifting device and the position code, the position association error is 0, and the entire process trajectory tracking of the plate is free from deviation and error.

[0069] (2) The efficiency of early warning detection is greatly improved, reducing the pressure of manual management. The system is equipped with a dynamic timeout threshold algorithm, which can automatically identify the tank groups that have exceeded the timeout for grinding in each area and accurately mark the abnormal location. The average detection time for overdue grinding operations is reduced to 3 minutes. Compared with the traditional manual inspection mode of one area and one tank, the abnormal detection efficiency is improved by 82%, reducing the workload of manual inspection by more than 80%, and avoiding problems such as manual missed detection, false detection, and inspection delay.

[0070] (3) Optimization of grinding process quality to ensure the quality of electrolytic finished products. The system monitors the entire process data, standardizes the grinding process operation standards, and manages the grinding process of the edge strip, liquid level line, plate body and other subdivided grinding processes in real time, reducing human operation deviation and abnormal operation of the unit. The consistency of grinding of stainless steel cathode plates in the workshop has been improved by 12%. The high standard of electrode plate grinding quality effectively optimizes the subsequent electrolytic production conditions and provides a solid data guarantee for the stable improvement of cathode copper finished product quality.

[0071] (4) Low hardware upgrade cost and excellent overall economic benefits. The system does not require the addition of RFID identification components, positioning chips and additional data acquisition sensors. It only relies on the native communication interface and communication adapter unit to complete the upgrade, which greatly reduces the cost of hardware procurement, installation and subsequent maintenance. At the same time, relying on intelligent data management and control, it reduces manual operation and maintenance costs, reduces plate rework losses and shortens operation waiting time, comprehensively improves the level of refined production management and control in the copper electrolysis workshop, and enables enterprises to reduce costs and increase efficiency.

Claims

1. A full-process tracking system for automatic grinding information of copper electrolytic cathode plates, characterized in that: It includes a hardware architecture and software functional modules; the hardware architecture includes a device communication adaptation unit, a location identification unit, a data transmission unit, and a background processing unit; the software functional modules include a full-process real-time tracking module, a cross-device data collaboration module, and a regional timeout warning query module; the software functional modules are implemented based on the hardware architecture, using the whole-slot information released by the automatic grinding unit as the core data source, combined with location identification storage data, and combined with the crane and unit transfer component data processed by the program for installation and setting. The device communication adapter unit is installed on the overhead crane, automatic grinding unit, internal transfer components of the special unit, and related equipment of each tank. It obtains data through the original communication interface of the equipment to establish a communication link, adapts to the communication protocols of different devices, and realizes stable acquisition of real-time position and action data of the overhead crane and position and action data of the internal transfer components of the unit. The location identification unit is installed at all locations along the entire electrolytic process of the stainless steel cathode plate and is assigned a unique location code and a dedicated storage unit. When the overhead crane transports the cathode plate to the corresponding location, it obtains the real-time location and action data of each device through information interaction across the entire network, automatically associates the corresponding storage unit, and realizes the accurate binding and tracking of the position of the entire stainless steel cathode plate without participating in the collection of grinding information. The background processing unit includes a data storage server and a background management terminal, and has a built-in background program processing module for receiving and storing the whole-slot stainless steel cathode plate grinding information released by the automatic grinding unit, as well as the crane and unit transfer component data transmitted by the equipment communication adapter unit. Through program control logic algorithm correlation analysis, it realizes the tracking of the stainless steel cathode plate flow trajectory and the binding of grinding information, and at the same time completes data processing, analysis and interactive display.

2. The automatic grinding information tracking system for copper electrolytic cathode plates according to claim 1, characterized in that: The data transmission unit adopts a dual-mode transmission protocol of industrial Ethernet and wireless communication. It receives the location and action data obtained by the equipment communication adapter unit and the grinding information released by the automatic grinding unit, which solves the data stability problem in the complex environment of the entire copper electrolysis process and ensures that all kinds of data are efficiently transmitted to the background processing unit.

3. The automatic grinding information tracking system for copper electrolytic cathode plates according to claim 1, characterized in that: The full-process real-time tracking module analyzes the position and movement data of the overhead crane through its internal program processing module, locating the entire path trajectory of the cathode plate from the original electrolytic cell, through its transfer to the automatic grinding unit, and then its lowering to the target position. Simultaneously, it receives information from the automatic grinding unit, accurately recording the grinding time and detailed process items for the entire cell, including edge strips, liquid level lines, and the entire plate. All grinding data and flow trajectory data are automatically bound through the program control logic algorithm.

4. The automatic grinding information tracking system for copper electrolytic cathode plates according to claim 3, characterized in that: The cross-device data collaboration module has a built-in multi-device communication protocol adaptation algorithm and data association program to solve the problem of inconsistent communication interfaces and data formats of different devices. It associates the position and action data of the crane and the unit with the grinding data of the tank group released by the automatic grinding unit to ensure the continuity and consistency of grinding information and flow trajectory, and avoid data gaps.

5. The automatic grinding information tracking system for copper electrolytic cathode plates according to claim 4, characterized in that: The regionalized timeout warning query module supports dividing the query range by workshop area, and has a built-in dynamic timeout threshold algorithm that can be adjusted according to the priority of grinding process. Based on grinding time and location tracking data, it automatically filters out the tank groups and corresponding locations that have exceeded the timeout for grinding within the area, and generates warning prompts on the background management terminal. At the same time, it provides a historical data retrieval function, which can query grinding records, flow trajectory and timeout status by region and time period. The data source can be traced back to the content published by the automatic grinding unit and the equipment communication data.

6. A method for tracking the entire process of automatic grinding information of copper electrolytic cathode plates, characterized in that: Includes the following steps: S1. Equipment Communication Link Establishment: Establish communication links between the overhead crane, automatic grinding unit, internal transfer components of the special unit, and related equipment in the tank. Adapt different equipment communication protocols through the equipment communication adapter unit to realize the real-time acquisition and transmission of position and motion data of the overhead crane and unit transfer components. At the same time, assign a unique position code to all positions in the entire electrolysis process that the stainless steel cathode plate may reach through the position identification unit, configure a dedicated storage unit for each position and write the position information, and complete the position tracking hardware adaptation. S2. Tracking of the Flow Trajectory of the Entire Stainless Steel Cathode Plate: When the overhead crane performs the lifting action of the entire stainless steel cathode plate, its position and action data are transmitted to the background processing unit via the communication link. The background program processing module records the initial electrolytic cell position of the stainless steel cathode plate. During the transfer process, the program analyzes the crane's position change data in real time and dynamically tracks the transfer trajectory. After the stainless steel cathode plate enters the dedicated unit, the action data of the unit's transfer components triggers the program association, recording that the stainless steel cathode plate has entered the processing state. After completion, the program tracks the entire process of the stainless steel cathode plate being lowered to the target position through the data of the overhead crane and the unit's transfer components. S3. Position Code Recognition and Trajectory Tracking: When the overhead crane is being transported, its real-time position information is linked with the original electrolytic cell position triggering device to automatically recognize the original electrolytic cell position code and associate it with the corresponding storage unit; during the transport process, the position code and the association relationship of the storage unit are dynamically updated, and trajectory tracking is achieved through the full-process real-time tracking module. S4. Grinding Information Release and Binding: After the automatic grinding unit completes the preset grinding process for the whole-slot stainless steel cathode plate, the automatic grinding unit, as the sole information publisher, synchronously generates the grinding information of the whole-slot stainless steel cathode plate. The information is then pushed to the background processing unit via the data transmission unit. The background program processing module automatically binds and stores the grinding information with the corresponding flow trajectory data of the whole-slot stainless steel cathode plate. S5. Cross-equipment data collaborative processing: The cross-equipment data collaborative module uses a multi-equipment data association algorithm to standardize and integrate grinding information, trolley operation and unit transfer data, ensuring the continuity of data from different equipment and forming a complete data chain for the entire process of grinding and transferring stainless steel cathode plates in the whole tank. S6. Regionalized Timeout Warning and Query: Based on a dynamically adjustable preset threshold, the background processing unit analyzes the grinding time of the stainless steel cathode plates in the entire tank published by the automatic grinding unit through the program. Combined with the tracked location data, it filters out the tank groups and corresponding locations in each region whose grinding time exceeds the threshold and generates warning prompts. Simultaneously responding to user query commands, based on the stored end-to-end data chain, the regional timeout warning query module provides feedback on the grinding records, transfer trajectory, and timeout status of the entire stainless steel cathode plate within a specified area and time period.

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