WO2023197890A1 - 一种铝电解质化检验样品自动化制样系统及其制样工艺 - Google Patents

一种铝电解质化检验样品自动化制样系统及其制样工艺 Download PDF

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Publication number
WO2023197890A1
WO2023197890A1 PCT/CN2023/085495 CN2023085495W WO2023197890A1 WO 2023197890 A1 WO2023197890 A1 WO 2023197890A1 CN 2023085495 W CN2023085495 W CN 2023085495W WO 2023197890 A1 WO2023197890 A1 WO 2023197890A1
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WO
WIPO (PCT)
Prior art keywords
sample
grinding
sample preparation
aluminum
aluminum electrolyte
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PCT/CN2023/085495
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English (en)
French (fr)
Inventor
曹斌
李毅飞
王洪
王紫千
Original Assignee
中铝智能科技发展有限公司
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Application filed by 中铝智能科技发展有限公司 filed Critical 中铝智能科技发展有限公司
Publication of WO2023197890A1 publication Critical patent/WO2023197890A1/zh

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Classifications

    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N1/00—Sampling; Preparing specimens for investigation
    • G01N1/28—Preparing specimens for investigation including physical details of (bio-)chemical methods covered elsewhere, e.g. G01N33/50, C12Q
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P90/00—Enabling technologies with a potential contribution to greenhouse gas [GHG] emissions mitigation
    • Y02P90/02—Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Definitions

  • the invention belongs to the technical field of sample preparation and testing in the aluminum industry. Specifically, it relates to an automated sample preparation system for aluminum electrolyte testing samples and its sample preparation process.
  • Aluminum electrolyte testing and sample preparation is an important task for aluminum electrolysis enterprises to increase production, efficiency, and quality.
  • electrolyte sample preparation has been done manually, which has problems of low sample preparation efficiency and high labor intensity.
  • manual sample preparation is currently used and can only be completed every 3 to 4 days.
  • the chemical inspection of an electrolyte sample/tank cannot promptly reflect the physical and chemical changes of materials and components within 72 to 96 hours, causing a serious lag in the control of molecular ratios and quality of electrolytic production, resulting in unstable production and fluctuations in output and quality.
  • the production efficiency is not high; and during the sample preparation process, the working environment is open, dust pollution and worker safety are not guaranteed, and there are potential safety and environmental risks.
  • the purpose of the present invention is to provide an automated sample preparation system for aluminum electrolyte testing samples and its sample preparation process to solve the above technical problems.
  • An automated sample preparation system for aluminum electrolyte testing samples including equipment cabinets, loading/unloading tray components, loading and unloading robots, sorting robots, conveying systems, sample grinding systems, turning and dumping systems, sample pressing systems, cleaning and drying systems Dry system, dust removal system and control management system;
  • the loading/unloading tray assembly is used for loading and unloading raw materials and finished products of aluminum electrolyte inspection samples
  • the loading and unloading robot is used to add the raw materials of the aluminum electrolyte test sample into the sample grinding system, and is used to pick up the finished product when the sample pressing system discharges materials;
  • the sample grinding system includes a sample grinding machine body and a sample grinding assembly, which is used to grind the raw materials of aluminum electrolyte test samples into fine powder.
  • the sample grinding assembly includes a sample grinding cover, a sample grinding block, and a sample grinding tank;
  • the sorting robot is used to pick and place the sample grinding components between the sample grinding machine body, the sample pressing system, the cleaning and drying system and the flipping and dumping system;
  • the flipping and pouring system is used to pour the fine powder prepared in the sample grinding assembly into the sample pressing system;
  • the conveying system includes a lifting cylinder, a position sensor, a cylinder clamping component and a belt conveyor, and is used to realize the assembly and transportation of the sample pressing components;
  • the sample pressing system is used to press fine powder materials into preliminary aluminum electrolyte testing samples
  • the equipment cabinet is used for loading/retrieving tray components, loading and unloading robots, sorting robots, conveying systems, sample grinding systems,
  • the turning and dumping system, sample pressing system, cleaning and drying system, dust removal system and control management system are integrated into the integrated structure of the machine tool, and provide a closed dust removal space for the preparation of aluminum electrolyte testing samples;
  • the cleaning and drying system includes high-speed jet flushing, air curtains and drying devices, which are used to rinse and dry the used grinding jars to avoid contamination of subsequent electrolyte sample preparation when the grinding jars are used again; or use High-pressure airflow purges the used grinding sample jar for cleaning purposes to avoid contamination of subsequent electrolyte sample preparation when the grinding sample jar is used again;
  • the dust removal system is used for negative pressure dust removal in the closed dust removal space in the equipment cabinet;
  • the control management system is used to control the loading and unloading tray components, loading and unloading robots, sorting robots, conveying systems, sample grinding systems, flipping and dumping systems, sample pressing systems, cleaning and drying systems and dust removal systems according to predetermined Start, stop and act according to working conditions.
  • the upper/retrieval tray assembly includes a loading tray and a retrieval tray.
  • the loading tray and the retrieval tray are equipped with position sensors, and the loading tray and the retrieval tray are respectively connected to 50 pieces or more aluminum electrolytes.
  • the raw material quantity of the chemical inspection sample matches the finished product quantity.
  • the sample grinding system is used to process the raw materials of aluminum electrolyte test samples with a particle size of ⁇ 10 mm into fine powder with a particle size of better than 140 mesh.
  • the sample grinding machine body adopts a blade-type grinding mechanism and uses a separate
  • the anti-seismic base is connected to the equipment cabinet, which will not transmit vibration to the equipment cabinet. It is also equipped with an anti-skid flip protective cover that automatically opens; the grinding sample tank is used to hold grinding sample blocks and aluminum electrolyte test samples. Raw materials, the detachable cover of the sample grinding cover is provided on the sample grinding tank.
  • a sample grinding tank station, a sample grinding block station and a sample grinding cover station are respectively provided above the belt conveyor.
  • Each station is equipped with a position sensor, and the cylinder clamping assembly includes each station.
  • the lifting cylinder and clamping cylinder configured on the grinding sample assembly are used for lifting and clamping operations.
  • the control and management system uses a PLC controller as the hardware basis and software programming as a means to perform sequence and logic control on each component module of the automated sample preparation system for aluminum electrolyte testing samples;
  • the control and management system includes a host computer. , lower computer and chemical inspection equipment, with the whole life cycle management function of the sample preparation process; set the processing parameters of the automatic sample preparation system for the aluminum electrolytic inspection sample through the upper computer, and display the aluminum electrolytic inspection sample in real time
  • the testing, alarming and process information of the automated sample preparation system can be interfaced and communicated with third-party software;
  • the lower computer works according to the predetermined process flow and work rhythm, and monitors the automated sample preparation system for aluminum electrolyte inspection samples in real time
  • the operation information and process execution status are sent to the upper computer, and the lower computer can control the automatic emergency shutdown of the automatic sample preparation system for aluminum electrolyte inspection samples, and send fault information to the upper computer for storage and analysis.
  • the upper computer can send and receive remote
  • the high-speed jet flushing device is used for high-speed jet flushing of used grinding components, and the air flow
  • the curtain is used to blow off the large water droplets on the cleaned sample grinding components.
  • the drying device uses high-temperature and high-pressure air to dry the sample grinding components.
  • the production cycle of the cleaning and drying system is ⁇ 90s/piece; so The above-mentioned cleaning system can also use high-pressure airflow to purge the used grinding sample jar to achieve cleaning purposes and avoid contamination of subsequent electrolyte sample preparation when the grinding sample jar is used again.
  • the automatic sample preparation system for aluminum electrolyte testing samples can realize the loading/retrieval of ⁇ 50 aluminum electrolyte samples in a single time, the preparation time of a single aluminum electrolyte sample ⁇ 150s, and the cleaning and drying production cycle of a single sample grinding tank ⁇ 90s.
  • the particle size of the electrolyte discharged after grinding is better than 140 mesh
  • the dustproof level of the equipment cabinet reaches IP3 ⁇ IP5 level
  • the noise is controlled at level III
  • the equipment cabinet is equipped with raw materials and finished products to facilitate aluminum electrolyte testing samples
  • the turning and dumping system includes a turning device, a pushing device, a hopper and a sample pressing ring.
  • the turning device is used to turn the sample grinding tank 180′′ so that the electrolyte ground into fine powder in the sample grinding tank is passed through.
  • the hopper is poured into the sample pressing ring, and the pushing device is used to push the sample pressing ring into the sample pressing system.
  • the sample pressing system includes a sample pressing device, a jacking device, a sample ring placing plate and an inkjet coding device.
  • the jacking device is used to drive the sample ring placing plate to move upward.
  • the pressure begins to increase.
  • the fine powder in the sample pressing ring can be prepared into the preliminary aluminum electrolyte test sample.
  • the jacking device is reset and the pressed sample placement tray is moved down, the initial product is grabbed by the sorting robot and put under the inkjet coding device to write the code, and then picked up by the loading and unloading robot into the picking tray.
  • the invention also provides an automated sample preparation process for aluminum electrolyte testing samples, which includes the following steps:
  • the sorting robot grabs the grinding sample cover and grinding block to the cleaning and drying system for cleaning and drying, and clamps the grinding sample tank to the flipping and dumping system. Pour the fine powder in the sample grinding tank into the sample pressing ring, and flip the pouring system to push the sample pressing ring into the sample pressing system. The sample pressing is completed in the sample pressing system to obtain the first product.
  • the sorting robot will The grinding sample tank after pouring the fine powder is also captured into the cleaning and drying system for cleaning and drying;
  • the first product is grabbed by the sorting robot and put on the inkjet coding device.
  • the inkjet device inkjet-codes the first product according to the coding rules to obtain samples;
  • the loading and unloading robot picks up the sample pieces and puts them into the picking tray to complete the preparation of aluminum electrolyte testing samples.
  • the automated sample preparation process for aluminum electrolyte testing samples can realize the loading/retrieval of ⁇ 50 aluminum electrolyte samples at a time.
  • the sample preparation time of a single piece of aluminum electrolyte is ⁇ 150s
  • the cleaning and drying production cycle of a single piece of grinding sample tank is ⁇ 90s
  • the particle size of the electrolyte after grinding is better than 140 mesh (discharging)
  • the dustproof level of the equipment cabinet reaches IP3 ⁇ IP5 level. Noise is controlled at level III.
  • the present invention also includes other equipment or components that can enable the normal use of the automatic sample preparation system for aluminum electrolyte testing samples. These equipment or components adopt conventional technical means in this field. In addition, the devices and components that are not limited in the present invention adopt conventional technical means in the field.
  • the high-speed jet flushing device includes a high-pressure water pump, a nozzle and a water supply pipeline
  • the air curtain includes a fan and an air distribution duct
  • the drying device includes a compressed air duct.
  • the air pipeline and the electric heater located in the compressed air pipeline includes a turning cylinder and a turning jaw
  • the pushing device includes a pushing cylinder and a pushing plate
  • the sample pressing device includes a pressure plate matching the sample pressing ring
  • the lifting device includes The cylinder and top plate are lifted, and the inkjet printer is used as the inkjet printer.
  • Technicians in the field can select the model and installation method of the corresponding devices and components according to actual usage needs, and clearly understand how to install and control them. This is not the case here. Describe in detail.
  • the beneficial effects of the present invention are that it is used for sample preparation and detection of electrolytes in the electrolytic aluminum industry. After the integration of the total system, except for manual loading and unloading, the rest of the sample preparation and distribution actions are automated, data information management is intelligent, and wireless and The wired communication interface realizes data request and transmission functions between the front-end automatic sampler and the back-end data processing system, realizing one-click operation.
  • the invention is used for sample preparation of electrolytes in the electrolytic aluminum industry.
  • the hardware is highly integrated, easy to operate, has stable performance, high production efficiency, is safe and reliable, has cleaning, drying and environmentally friendly dust removal functions, can realize automatic data reading, recording, storage, sharing, statistics and processing functions, and occupies a small space. It can process samples in a single batch in a closed space, and realize automatic dust collection, cleaning, drying, early warning processing, and human-computer interactive one-key operation during the production process, which is conducive to shortening the sample preparation time of a single piece and can achieve the same goal in a closed space.
  • the number of processed samples in a single batch is ⁇ 50
  • the sample preparation time for a single sample is ⁇ 150 seconds
  • the sample quality is guaranteed to be stable.
  • Figure 1 is an overall structural layout diagram of the present invention in an embodiment.
  • Figure 2 is an external structural diagram of the present invention in an embodiment.
  • Figure 3 is a process flow diagram of the present invention in an embodiment.
  • Figure 4 is a control logic diagram of the present invention in an embodiment.
  • 1-Loading/retrieving tray assembly 2-Loading and unloading robot, 3-Sorting robot, 4-Conveying system, 5-Sample grinding system, 6-Turn over and dump system, 7-Sample pressing system, 8- Control management system, 9-cleaning and drying system, 11-dust removal system, 12-equipment cabinet.
  • the invention provides an automated sample preparation system for aluminum electrolyte testing samples, including an equipment cabinet 12, a loading/retrieval tray assembly 1, a loading and unloading robot 2, a sorting robot 3, and a conveyor system 4 , sample grinding system 5, flipping system 6, sample pressing system 7, control management system 8, cleaning and drying system 9 and dust removal system 11;
  • the loading/retrieval tray assembly 1 is used for loading and unloading raw materials and finished products of aluminum electrolyte testing samples
  • the loading and unloading robot 2 is used to add the raw materials of the aluminum electrolyte test sample to the sample grinding system 5, and is used to pick up the finished product when the sample pressing system 7 is discharging;
  • the sample grinding system 5 includes a sample grinding machine body and a sample grinding assembly, which is used to grind the raw materials of aluminum electrolyte test samples into fine powder.
  • the sample grinding assembly includes a sample grinding cover, a sample grinding block, and a sample grinding tank. ;
  • the sorting robot 3 is used to pick and place the grinding sample components between the sample grinding machine body, the sample pressing system 7, the cleaning and drying system 9 and the flipping and dumping system 6;
  • the flipping and pouring system 6 is used to pour the fine powder prepared in the sample grinding assembly into the sample pressing system 7;
  • the conveying system 4 includes a lifting cylinder, a position sensor, a cylinder clamping component and a belt conveyor, and is used to realize the assembly and transportation of sample grinding components;
  • the sample pressing system 7 is used to press fine powder materials into preliminary aluminum electrolyte test samples
  • the equipment cabinet 12 is used for loading/retrieving tray assembly 1, loading and unloading robot 2, sorting robot 3, conveying system 4, sample grinding system 5, flipping and dumping system 6, sample pressing system 7, control and management System 8, cleaning and drying system 9 and dust removal system 11 are integrated into one, and provide a closed dust removal space for the preparation of aluminum electrolyte test samples;
  • the cleaning and drying system 9 includes high-speed jet flushing, air curtain and drying device, which is used to rinse and dry the used grinding sample jar to avoid contamination of subsequent electrolyte sample preparation when the grinding sample jar is used again;
  • the dust removal system 11 is used for negative pressure dust removal in the closed dust removal space within the equipment cabinet 12;
  • the control and management system 8 is used to control the loading/retrieval tray assembly 1, loading and unloading robot 2, sorting robot 3, conveying system 4, sample grinding system 5, turning and dumping system 6, sample pressing system 7, cleaning and drying.
  • the dry system 9 and the dust removal system 11 start, stop and operate according to predetermined working conditions.
  • the loading/retrieving tray assembly 1 includes a loading tray and a retrieving tray.
  • the loading tray and the retrieving tray are equipped with position sensors, and the loading tray and the retrieving tray are respectively connected with Raw materials for more than 50 aluminum electrolyte testing samples The quantity matches the finished product quantity.
  • the sample grinding system 5 is used to process the raw materials of aluminum electrolyte test samples with a particle size of ⁇ 10 mm into fine powder with a particle size of better than 140 mesh.
  • the sample grinding machine body adopts a blade type
  • the grinding mechanism is connected to the equipment cabinet 12 using a separate anti-seismic base, which will not transmit vibration to the equipment cabinet 12. It is also equipped with an anti-skid flip protective cover that automatically opens; the grinding sample tank is used to hold the grinding sample.
  • the sample block and aluminum electrolyte are the raw materials of the test sample, and the removable cover of the sample grinding cover is provided on the sample grinding tank.
  • a sample grinding tank station, a sample grinding block station and a sample grinding cover station are respectively provided above the belt conveyor.
  • Each station is equipped with a position sensor, and the cylinder clamps
  • the components include lifting cylinders and clamping cylinders configured at each station for lifting and clamping the grinding components.
  • the control and management system 8 includes a host computer, a host computer and chemical inspection equipment (not shown in the figure), and has the full life cycle management function of the sample preparation process.
  • the control management system 8 uses PLC controller as the hardware basis and software programming as the medium to control the working process and logic of the aluminum electrolyte inspection sample automatic sample preparation system, set the system parameters and monitor test, alarm, process and other information, And can communicate with third-party software;
  • the lower computer works according to the predetermined process flow and work rhythm, monitors the operation information and process execution status of the aluminum electrolyte inspection sample automatic sample preparation system in real time and sends them to the upper computer
  • the lower computer can control the automatic emergency shutdown of the automatic sample preparation system for aluminum electrolyte inspection samples, and send fault information to the upper computer for storage and analysis;
  • the upper computer can send and receive production status information data of remote production units to carry out sample preparation plans , sample tracking, sample preparation process monitoring, equipment operating status monitoring, quality records, test data statistics, sample traceability and other management, automatically obtain sample preparation data and analyze quality documents.
  • the high-speed jet washing device includes a high-pressure water pump, a nozzle and a water supply pipeline for high-speed jet washing of used sample grinding components
  • the air curtain includes a fan and an air distribution duct for Blow off the large water droplets on the cleaned sample grinding components.
  • the drying device includes a compressed air pipeline and an electric heater located in the compressed air pipeline, and uses high-temperature and high-pressure air to dry the sample grinding components; The production cycle of the above cleaning and drying system is ⁇ 90s/piece.
  • the automatic sample preparation system for aluminum electrolyte testing samples can realize the loading/retrieval of ⁇ 50 aluminum electrolyte samples in a single time, the preparation time of a single aluminum electrolyte sample ⁇ 150s, and the cleaning and drying of a single sample grinding tank.
  • the dry production cycle is ⁇ 90s, and the electrolyte discharged after grinding is fine powder better than 140 mesh.
  • the dustproof level of the equipment cabinet 12 reaches IP5 level, the noise is controlled at level III, and the equipment cabinet 12 is equipped with a convenient aluminum
  • the flipping and dumping system 6 includes a flipping device, a pushing device, a hopper and a sample pressing ring.
  • the flipping device includes a flipping cylinder, which is used to flip the sample grinding tank 180′′ to make the grinding sample The electrolyte ground into fine powder in the tank is poured into the sample pressing ring through the hopper.
  • the pushing device includes a pushing cylinder for pushing the sample pressing ring to the sample pressing system. In the system.
  • the sample pressing system 7 includes a sample pressing device, a lifting device, a sample pressing ring placement disk and an inkjet coding device.
  • the lifting device includes a lifting cylinder for driving the sample pressing ring placement.
  • the plate moves upward, and the sample pressing device includes a pressure plate.
  • the pressure plate When the fine powder in the sample pressing ring contacts the bottom of the pressure plate of the sample pressing device, the pressure begins to increase. After reaching the set working pressure and maintaining it for a period of time, the pressure can be The fine powder in the sample ring is prepared into the first product of the aluminum electrolyte test sample. After the jacking device is reset and the pressure sample placement plate is moved downward, the sorting robot places the first product under the inkjet device and injects codes to form the finished product.
  • the invention is used for sample preparation and detection of electrolytes in the electrolytic aluminum industry. It has the advantages of safety, high efficiency, low labor cost, improved working environment for workers, intrinsic safety, stable sample preparation quality, high detection efficiency and high degree of automation; it can be realized Highly integrated software and hardware, easy to operate, stable performance, high production efficiency, safe and reliable, with cleaning, drying and environmentally friendly dust removal functions, it can realize automatic data reading, recording, storage, sharing, statistics and processing functions, and it occupies a small space , can achieve a single batch loading/retrieval of processing samples in a closed space of ⁇ 50 pieces, a single sample sample preparation time of ⁇ 150 seconds, and the sample quality is stable.
  • An automated sample preparation system for aluminum electrolyte testing samples in this embodiment is a dust removal system that performs negative pressure dust removal in a closed dust removal space within an equipment cabinet; an independent dust removal box is placed, and can be captured and transported by a logistics robot, and can be separately
  • the screen, grinding tank cover, and powder collection device use negative pressure to remove particles attached to the surface.
  • the dust removal system can be configured with different functions according to the on-site process requirements. If the overall process does not include a cleaning and drying system, the dust removal system can increase the process flow and add grinding tanks and screens at designated placement stations for negative pressure dust removal.
  • An operation interface is provided on the cabinet casing, including a touch LCD screen and an emergency stop button.
  • the touch LCD screen and emergency stop button are respectively connected to the control system for communication.
  • the invention provides an automated sample preparation process for aluminum electrolyte testing samples, which includes the following steps:
  • the sorting robot 3 grabs the grinding sample cover and grinding sample block to the cleaning and drying system 9 for cleaning and drying, and clamps the grinding sample jar to the flipping and dumping system 6.
  • the pouring system 6 pours the fine powder in the sample grinding tank into the sample pressing ring, and flips the pouring system to push the sample pressing ring to the sample pressing system 7.
  • the sample pressing is completed in the sample pressing system 7 to obtain
  • the sorting robot 3 will also grab the grinding sample jar that has poured the fine powder into the cleaning and drying system 9 for cleaning and drying.
  • the first product is grabbed by the sorting robot 3 and onto the inkjet coding device.
  • the inkjet device inkjet-codes the first product according to the coding rules to obtain samples.
  • the loading and unloading robot 2 picks up the sample pieces and puts them into the picking tray to obtain the finished product; thereby completing the preparation of the aluminum electrolyte inspection sample.
  • the automated sample preparation process for aluminum electrolyte testing samples can realize loading/retrieving ⁇ 50 aluminum electrolyte samples in a single time, the sample preparation time of a single aluminum electrolyte is ⁇ 150s, the cleaning and drying production cycle of a single sample grinding tank is ⁇ 90s, and the grinding time is ⁇ 90s.
  • the particle size of the discharged electrolyte is better than 140 mesh, the dustproof level of the equipment cabinet reaches IP3 ⁇ IP5 level, and the noise is controlled at level III.
  • the sorting robot 3 can grab the finished product and send it to the detection analyzer for detection. After the detection is completed, the sorting robot 3 will grab the finished product to the temporary storage table, and the detection analyzer will store, analyze, and display the detected data.
  • the loading tray and unloading tray components can place more than 50 pieces of raw materials and finished products corresponding to aluminum electrolyte inspection samples at a time.
  • the upper computer adopts an industrial all-in-one machine
  • the lower computer adopts a PLC control system.
  • the PLC control system is responsible for controlling the entire process flow. It controls each equipment in the system to complete the corresponding processes through I/O connections, communications, etc., and monitors them in real time. The operation information and process execution status of each equipment are sent to the industrial all-in-one machine. When the equipment in the system fails, it automatically implements an emergency stop and sends the fault information to the industrial all-in-one machine for storage to facilitate later maintenance.
  • the management system performs tasks such as production scheduling/quality and recording/production history, automatic recording/detection data analysis, storage, and uploading in the entire aluminum electrolyte inspection sample automatic sample preparation system. Responsible for entering the identity of the test sample and sending it to the PLC control system; tracking the product process during the production process; when the workpiece measurement is completed and offline, automatically obtain and analyze the quality file, form quality data, and store and record it in the quality database .
  • this embodiment provides an automated sample preparation process for aluminum electrolyte testing samples, including the following steps:
  • the sorting robot grabs the grinding sample cover to the cleaning and drying system for cleaning and drying.
  • the fine powder in the grinding sample tank is poured into the screen through the flipping and dumping system, and the screening is suitable
  • the powder is placed in the sample pressing ring, and the pouring system is turned over to push the sample pressing ring into the sample pressing system.
  • the sample pressing is completed in the sample pressing system to obtain the first product.
  • the sorting robot will pour the finished product.
  • the fine powder screen is also captured into the cleaning and drying system for cleaning and drying.
  • the sorting robot grabs the grinding sample cover into the dust removal system, and pours the fine powder in the grinding sample tank into the screen through the flipping system to screen the powder suitable for making finished products. Then it is placed in the sample pressing ring, and the pouring system is turned over to push the sample pressing ring into the sample pressing system. The sample pressing is completed in the sample pressing system to obtain the first product. At the same time, the sorting robot will pour the fine powder onto the screen. Also grab the dust removal system for dust removal.
  • the first product is grabbed by the sorting robot and put on the inkjet coding device.
  • the inkjet device inkjet-codes the first product according to the coding rules to obtain samples.
  • the loading and unloading robot picks up the sample pieces and puts them into the picking tray to complete the preparation of aluminum electrolyte testing samples.
  • the automated sample preparation process for aluminum electrolyte testing samples can realize loading/retrieving ⁇ 50 aluminum electrolyte samples in a single time, the sample preparation time of a single aluminum electrolyte is ⁇ 150s, the cleaning and drying production cycle of a single sample grinding tank is ⁇ 90s, and the grinding time is ⁇ 90s.
  • the particle size of the discharged electrolyte is better than 140 mesh, the dustproof level of the equipment cabinet reaches IP3 ⁇ IP5 level, and the noise is controlled at level III.
  • the loading and unloading robot picks up the sample pieces and puts them into the picking tray to complete the preparation of aluminum electrolyte testing samples.
  • the automated sample preparation process for aluminum electrolyte testing samples can realize the loading/retrieval of ⁇ 50 aluminum electrolyte samples in a single time, the sample preparation time of a single aluminum electrolyte is ⁇ 150s, and the electrolyte particle size after grinding is ⁇ 140 mesh, and the equipment cabinet machine
  • the dustproof level reaches IP3 ⁇ IP5 level, and the noise is controlled at level III.

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Abstract

一种铝电解质化检验样品自动化制样系统及其制样工艺，包括设备柜机（12）、上/取料盘组件（1）、装卸料机器人（2）、分拣机器人（3）、磨样系统（5）、翻转倒料系统（6）、压样系统（7）、输送系统（4）、控制管理系统（8）、清洗烘干系统（9）和除尘系统（11），除人工上下料外，其余制样分步动作均实现过程自动化，可实现软硬件的高度集成，数据信息管理智能化，操作简单，性能稳定，安全高效，可实现数据自动读取、记录、存储、共享、统计及处理功能，占地空间小，能够在封闭空间内单次批量加工样品，有利于缩短单件样品制样时间，保证样品质量的稳定性。

Description

一种铝电解质化检验样品自动化制样系统及其制样工艺 技术领域
本发明属于铝行业制样检测技术领域，具体地，涉及一种铝电解质化检验样品自动化制样系统及其制样工艺。
背景技术
铝电解质检化验制样是铝电解企业提产、提效、提质的重要工作。长期以来，电解质制样工作由人工完成，存在制样效率低、劳动强度大的问题，以一个40万吨的电解铝厂为例，目前采用人工方式制样，每3～4天只能完成一个电解质样品/槽的化检验，不能及时反映物料、成分等在72～96小时内的物理化学变化，使电解生产的分子比、质量等管控严重滞后，导致生产不稳定，产量与质量波动，生产效率不高；而且在制样过程中，工作环境开放，扬尘污染、工人作业安全均得不到保障，存在安全和环保隐患。
发明内容
本发明的目的是提供一种铝电解质化检验样品自动化制样系统及其制样工艺，以解决上述技术问题。
基于本发明的一个方面，采用了以下技术方案：
一种铝电解质化检验样品自动化制样系统，包括设备柜机、上/取料盘组件、装卸料机器人、分拣机器人、输送系统、磨样系统、翻转倒料系统、压样系统、清洗烘干系统、除尘系统和控制管理系统；
所述上/取料盘组件，用于铝电解质化检验样品的原料和成品的上料与取料；
所述装卸料机器人，用于将铝电解质化检验样品的原料添加到磨样系统中，并用于压样系统出料时成品的拾取；
所述磨样系统，包括磨样机本体和磨样组件，用于将铝电解质化检验样品的原料磨制成细粉料，所述磨样组件包含磨样盖、磨样块和磨样罐；
所述分拣机器人，用于将磨样组件在磨样机本体、压样系统、清洗烘干系统和翻转倒料系统之间进行取放；
所述翻转倒料系统，用于将磨样组件中制备好的细粉料倒入压样系统中；
所述输送系统，包括顶升气缸、位置传感器、气缸夹持组件和皮带输送机，用来实现压样组件的组合和运输；
所述压样系统，用于将细粉料压制成铝电解质化检验样品的初品；
所述设备柜机，用于将上/取料盘组件、装卸料机器人、分拣机器人、输送系统、磨样系统、 翻转倒料系统、压样系统、清洗烘干系统、除尘系统和控制管理系统集成为机床一体式结构，并为铝电解质化检验样品的制备提供密闭除尘空间；
所述清洗烘干系统，包括高速射流冲洗、风幕和烘干装置，用于冲洗、烘干使用过的磨样罐，避免再次使用磨样罐时，对后续电解质制样造成污染；或者采用高压气流吹扫使用过的磨样罐，以达到清洁目的，避免再次使用磨样罐时，对后续电解质制样造成污染；
所述除尘系统，用于对设备柜机内的密闭除尘空间进行负压除尘；
所述控制管理系统，用于控制上/取料盘组件、装卸料机器人、分拣机器人、输送系统、磨样系统、翻转倒料系统、压样系统、清洗烘干系统和除尘系统按预定的工作条件进行启停和动作。
优选的，上/取料盘组件包括上料盘和取料盘，所述上料盘和取料盘上均装有位置传感器，且上料盘和取料盘分别与50件及以上铝电解质化检验样品的原料量和成品量相匹配。
优选的，所述磨样系统用于将颗粒度≤10mm的铝电解质化检验样品的原料，加工成颗粒度优于140目的细粉料，所述磨样机本体采用刀片式研磨机构，且采用单独的抗震底座连接在设备柜体内，不会把振动传递到设备柜体上，同时配置有自动开启的防滑翻转防护罩；所述磨样罐用于盛放磨样块和铝电解质化检验样品的原料，所述磨样盖可拆卸盖设在磨样罐上。
优选的，所述皮带输送机的上方分别设置有磨样罐工位、磨样块工位及磨样盖工位，各个工位均配置有位置传感器，所述气缸夹持组件包括各工位上配置的对磨样组件进行升降和夹持操作的升降气缸与夹持气缸。
优选的，所述控制管理系统以PLC控制器为硬件基础，以软件编程为手段，对铝电解质化检验样品自动化制样系统各个组成模块间进行顺序与逻辑控制；所述控制管理系统包括上位机、下位机和化检验设备，具有制样过程全生命周期管理功能；通过所述上位机设定所述铝电解质化检验样品自动化制样系统的加工参数，并实时展示所述铝电解质化检验样品自动化制样系统的测试、报警和工艺信息，并可与第三方软件进行接口通讯；所述下位机按照预定的工艺流程和工作节拍进行工作，实时监控所述铝电解质化检验样品自动化制样系统的运行信息、工序执行情况并发送到上位机，且下位机可控制所述铝电解质化检验样品自动化制样系统自动紧急停机，并将故障信息发送到上位机保存和分析，上位机可以收发远程生产单元的生产状态信息数据，进行制样计划、样品跟踪、制样过程监控、设备运行状态监视、质量记录、检测数据统计和样品溯源管理，自动获取制样数据和分析质量文件。
优选的，所述高速射流冲洗装置用于将使用过的磨样组件进行高速射流冲洗，所述风 幕用于将清洗过的磨样组件上的大颗粒水珠吹掉，所述烘干装置采用高温高压空气对磨样组件进行烘干，所述清洗烘干系统生产节拍≤90s/件；所述清洗系统也可以采用采用高压气流吹扫使用过的磨样罐，以达到清洁目的，避免再次使用磨样罐时，对后续电解质制样造成污染。
优选的，所述铝电解质化检验样品自动化制样系统实现单次铝电解质样品上/取料≥50件，单件铝电解质制样时间≤150s，单件磨样罐清洗烘干生产节拍≤90s，磨后出料电解质颗粒度优于140目，所述设备柜机的防尘等级达到IP3～IP5级，噪音控制在Ⅲ等级，且设备柜机上设有方便铝电解质化检验样品的原料和成品的上料与取料的防护罩门，且所述除尘系统中配置有负压式除尘器。
优选的，所述翻转倒料系统包括翻转装置、推送装置、料斗和压样环，所述翻转装置用于将磨样罐进行180″翻转，使磨样罐中磨成细粉料的电解质经料斗倒入压样环中，所述推送装置用于将压样环推送到压样系统中。
优选的，所述压样系统包括压样装置、顶升装置、压样环放置盘和喷码装置，所述顶升装置用于驱动压样环放置盘向上移动，当压样环中的细粉料接触到压样装置底部时，压力开始增加，达到设定工作压力并保持一段设定工作时间后，即可将压样环中的细粉料制备成铝电解质化检验样品的初品，在顶升装置复位带动压样放置盘下移后，初品经分拣机器人抓取至喷码装置下喷写编码，再经装卸料机器人拾取至取料盘中。
基于本发明的另一个方面，本发明还提供了一种铝电解质化检验样品自动化制样工艺，包括以下步骤：
(1)通过人工使上料盘和取料盘就位，关闭防护罩门；
(2)将磨样罐经输送系统传送至上料位，通过装卸料机器人把上料盘的料杯里的铝电解质化检验样品的原料倒入磨样罐中，且在磨样罐中放入磨样块后盖上磨样盖，分拣机器人把磨样罐抓取到磨样机本体上，按照控制管理系统的指令进行磨样；
(3)磨样完成后，分拣机器人把磨样盖和磨样块抓取到清洗烘干系统进行清洗和烘干，并将磨样罐夹持至翻转倒料系统，通过翻转倒料系统将磨样罐中的细粉料倒入压样环中，且翻转倒料系统将压样环推送到压样系统中，在压样系统内完成压样，得到初品，同时分拣机器人将倒完细粉料的磨样罐也抓取到清洗烘干系统进行清洗和烘干；
(4)初品经分拣机器人抓取到喷码装置上，喷码装置按照编码规则对初品进行喷码得到样片；
(5)装卸料机器人拾取样片至取料盘中，从而完成铝电解质化检验样品的制样。
所述铝电解质化检验样品自动化制样工艺能实现单次铝电解质样品上/取料≥50件， 单件铝电解质制样时间≤150s，单件磨样罐清洗烘干生产节拍≤90s，磨后电解质颗粒度优于140目(出料)，设备柜机的防尘等级达到IP3～IP5级，噪音控制在Ⅲ等级。
本发明还包括能够使该一种铝电解质化检验样品自动化制样系统正常使用的其它设备或组件，这些设备或组件均采用本领域的常规技术手段。另外，本发明中未加限定的装置和组件均采用本领域中的常规技术手段，如高速射流冲洗装置包括高压水泵、喷头和供水管路，风幕包括风机和布风管，烘干装置包括压缩空气管道和设于压缩空气管道内的电加热器，翻转装置包括翻转气缸和翻转夹爪、推送装置包括推送气缸和推板，压样装置包括与压样环相匹配的压板，顶升装置包括顶升气缸和顶板，喷码装置采用喷码机，本领域的技术人员可根据实际的使用需求来选择相应装置和组件的型号、安装方式，明确的了解其具体如何安装与控制，在此不再详细描述。
本发明的有益效果是，用于电解铝行业电解质的制样及检测，总系统集成后，除人工上下料外，其余制样分布动作均实现过程自动化，数据信息管理实现智能化，配置无线与有线通讯接口，实现与前端自动取样机，后端数据处理系统间的数据请求、传输功能，实现一键式操作。本发明用于电解铝行业电解质的样品制样，具有安全、高效、人工成本低，改善劳动者工作环境、体现本质安全、制样质量稳定、检测效率高、自动化程度高的优点；可实现软硬件的高度集成，操作简单，性能稳定，生产效率高，安全可靠，具有清洗烘干和环保除尘功能，可实现数据自动读取、记录、存储、共享、统计及处理功能，占地空间小，能够在封闭空间内单次批量加工样品，在生产过程实现自动集尘、清洗、烘干、预警处理、人机交互式一键操作，有利于缩短单件样品制样时间，能实现封闭空间内单次批量上/取加工样品数量≥50件，单件样品制样时间≤150秒钟，且保证样品质量稳定。
附图说明
下面结合附图和实施例对本发明进一步说明。
图1是实施例中本发明的整体结构布局图。
图2是实施例中本发明的外形结构图。
图3是实施例中本发明的工艺流程图。
图4是实施例中本发明的控制逻辑图。
图中：1-上/取料盘组件、2-装卸料机器人、3-分拣机器人、4-输送系统，5-磨样系统、6-翻转倒料系统、7-压样系统、8-控制管理系统、9-清洗烘干系统，11-除尘系统，12-设备柜机。
具体实施方式
下面结合本发明实施例中的附图以及具体实施例对本发明进行清楚地描述，在此处的描述仅仅用来解释本发明，但并不作为对本发明的限定。基于本发明中的实施例，本领域技术人员在没有做出创造性劳动前提下所获得的所有其他实施例，所做的任何修改、等同替换、改进等，均应包含在本发明的保护范围之内。
实施例1
请参照图1～4，本发明提供的一种铝电解质化检验样品自动化制样系统，包括设备柜机12、上/取料盘组件1、装卸料机器人2、分拣机器人3、输送系统4、磨样系统5、翻转倒料系统6、压样系统7、控制管理系统8、清洗烘干系统9和除尘系统11；
所述上/取料盘组件1，用于铝电解质化检验样品的原料和成品的上料与取料；
所述装卸料机器人2，用于将铝电解质化检验样品的原料添加到磨样系统5中，并用于压样系统7出料时成品的拾取；
所述磨样系统5，包括磨样机本体和磨样组件，用于将铝电解质化检验样品的原料磨制成细粉料，所述磨样组件包含磨样盖、磨样块和磨样罐；
所述分拣机器人3，用于将磨样组件在磨样机本体、压样系统7、清洗烘干系统9和翻转倒料系统6之间进行取放；
所述翻转倒料系统6，用于将磨样组件中制备好的细粉料倒入压样系统7中；
所述输送系统4，包括顶升气缸、位置传感器、气缸夹持组件和皮带输送机，用来实现磨样组件的组合和运输；
所述压样系统7，用于将细粉料压制成铝电解质化检验样品的初品；
所述设备柜机12，用于将上/取料盘组件1、装卸料机器人2、分拣机器人3、输送系统4、磨样系统5、翻转倒料系统6、压样系统7、控制管理系统8、清洗烘干系统9和除尘系统11集成为一体，并为铝电解质化检验样品的制备提供密闭除尘空间；
所述清洗烘干系统9，包括高速射流冲洗、风幕和烘干装置，用于冲洗、烘干使用过的磨样罐，避免再次使用磨样罐时，对后续电解质制样造成污染；
所述除尘系统11，用于对设备柜机12内的密闭除尘空间进行负压除尘；
所述控制管理系统8，用于控制上/取料盘组件1、装卸料机器人2、分拣机器人3、输送系统4、磨样系统5、翻转倒料系统6、压样系统7、清洗烘干系统9和除尘系统11按预定的工作条件进行启停和动作。
作为上述实施例的进一步改进，上/取料盘组件1包括上料盘和取料盘，所述上料盘和取料盘上均装有位置传感器，且上料盘和取料盘分别与50件以上铝电解质化检验样品的原料 量和成品量相匹配。
作为上述实施例的进一步改进，所述磨样系统5用于将颗粒度≤10mm的铝电解质化检验样品的原料，加工成颗粒度优于140目的细粉料，所述磨样机本体采用刀片式研磨机构，且采用单独的抗震底座连接在设备柜体12内，不会把振动传递到设备柜体12上，同时配置有自动开启的防滑翻转防护罩；所述磨样罐用于盛放磨样块和铝电解质化检验样品的原料，所述磨样盖可拆卸盖设在磨样罐上。
作为上述实施例的进一步改进，所述皮带输送机的上方分别设置有磨样罐工位、磨样块工位及磨样盖工位，各个工位均配置有位置传感器，所述气缸夹持组件包括各工位上配置的对磨样组件进行升降和夹持操作的升降气缸与夹持气缸。作为上述实施例的进一步改进，所述控制管理系统8包括上位机、下位机和化检验设备(图中未示出)，具有制样过程全生命周期管理功能。该控制管理系统8以PLC控制器为硬件基础，以软件编程为媒介，对铝电解质化检验样品自动化制样系统工作工艺及逻辑进行控制，设置系统的参数和监视测试、报警、工艺等信息，并可与第三方软件进行接口通讯；所述下位机按照预定的工艺流程和工作节拍进行工作，实时监控所述铝电解质化检验样品自动化制样系统的运行信息、工序执行情况并发送到上位机，且下位机可控制所述铝电解质化检验样品自动化制样系统自动紧急停机，并将故障信息发送到上位机保存和分析；上位机可以收发远程生产单元的生产状态信息数据，进行制样计划、样品跟踪、制样过程监控、设备运行状态监视、质量记录、检测数据统计、样品溯源等管理，自动获取制样数据和分析质量文件。
作为上述实施例的进一步改进，所述高速射流冲洗装置包括高压水泵、喷头和供水管路，用于将使用过的磨样组件进行高速射流冲洗，所述风幕包括风机和布风管，用于将清洗过的磨样组件上的大颗粒水珠吹掉，所述烘干装置包括压缩空气管道和设于压缩空气管道内的电加热器，采用高温高压空气对磨样组件进行烘干；所述清洗烘干系统生产节拍≤90s/件。
作为上述实施例的进一步改进，所述铝电解质化检验样品自动化制样系统实现单次铝电解质样品上/取料≥50件，单件铝电解质制样时间≤150s，单件磨样罐清洗烘干生产节拍≤90s，磨后出料电解质是优于140目的细粉料，所述设备柜机12的防尘等级达到IP5级，噪音控制在Ⅲ等级，且设备柜机12上设有方便铝电解质化检验样品的原料和成品的上料与取料的防护罩门，且所述除尘系统11中配置有负压式除尘器。
作为上述实施例的进一步改进，所述翻转倒料系统6包括翻转装置、推送装置、料斗和压样环，所述翻转装置包括翻转气缸，用于将磨样罐进行180″翻转，使磨样罐中磨成细粉料的电解质经料斗倒入压样环中，所述推送装置包括推送气缸，用于将压样环推送到压样系 统中。
作为上述实施例的进一步改进，所述压样系统7包括压样装置、顶升装置、压样环放置盘和喷码装置，所述顶升装置包括顶升气缸，用于驱动压样环放置盘向上移动，所述压样装置包括压板，当压样环中的细粉料接触到压样装置的压板底部时，压力开始增加，达到设定工作压力并保持一段时间后，即可将压样环中的细粉料制备成铝电解质化检验样品的初品，在顶升装置复位带动压样放置盘下移后，分拣机器人将初品放到喷码装置下喷写编码形成成品。
本发明用于电解铝行业电解质的制样及检测，具有安全、高效、人工成本低，改善劳动者工作环境、体现本质安全、制样质量稳定、检测效率高、自动化程度高的优点；可实现软硬件的高度集成，操作简单，性能稳定，生产效率高，安全可靠，具有清洗烘干和环保除尘功能，可实现数据自动读取、记录、存储、共享、统计及处理功能，占地空间小，能实现封闭空间内单次批量上/取加工样品数量≥50件，单件样品制样时间≤150秒钟，且样品质量稳定。
实施例2
本实施例的一种铝电解质化检验样品自动化制样系统，在设备柜机内的密闭除尘空间进行负压除尘的除尘系统；并且放置独立除尘箱，通过物流机器人抓取、运输，可分别对筛网、磨样罐盖、粉末收集装置进行负压除去表面附着颗粒物。
除尘系统可根据现场工艺要求进行不同功能配置，若整体工艺不包含清洗烘干系统，除尘系统可增加工艺流程，增加磨样罐、筛网在制定放置工位进行负压除尘功效。
在柜机外壳上设置有操作界面，包括触摸式液晶屏和急停按钮，所述触摸式液晶屏和急停按钮分别与控制系统通讯连接。
实施例3
请参照图1～4，本发明提供的一种铝电解质化检验样品自动化制样工艺，包括以下步骤：
(1)通过人工使上料盘和取料盘就位，关闭防护罩门。
(2)将磨样罐经输送系统4传送至上料位，通过装卸料机器人2把上料盘的料杯里的铝电解质化检验样品的原料倒入磨样罐中，且在磨样罐中放入磨样块后盖上磨样盖，分拣机器人3把磨样罐抓取到磨样机本体上，按照控制管理系统8的指令进行磨样。
(3)磨样完成后，分拣机器人3把磨样盖和磨样块抓取到清洗烘干系统9进行清洗和烘干，并将磨样罐夹持至翻转倒料系统6，通过翻转倒料系统6将磨样罐中的细粉料倒入压样环中，且翻转倒料系统将压样环推送到压样系统7中，在压样系统7内完成压样，得到 初品，同时分拣机器人3将倒完细粉料的磨样罐也抓取到清洗烘干系统9进行清洗和烘干。
(4)初品经分拣机器人3抓取到喷码装置上，喷码装置按照编码规则对初品进行喷码得到样片。
(5)装卸料机器人2拾取样片至取料盘中，得到成品；从而完成铝电解质化检验样品的制样。
所述铝电解质化检验样品自动化制样工艺能实现单次铝电解质样品上/取料≥50件，单件铝电解质制样时间≤150s，单件磨样罐清洗烘干生产节拍≤90s，磨后出料电解质颗粒度优于140目，设备柜机的防尘等级达到IP3～IP5级，噪音控制在Ⅲ等级。
制样完成后，分拣机器人3可抓取成品至检测分析仪进行检测，检测完成后分拣机器人3将成品抓取至暂存台，检测分析仪对所检测的数据存储、分析、显示，上料盘和取料盘组件一次分别可以放置50件以上铝电解质化检验样品所对应的原料量和成品量。
该实施例中，上位机采用工业一体机，下位机采用PLC控制系统，PLC控制系统负责整个工艺流程的控制，通过I/O连接、通信等方式控制系统中各设备完成相应的工序，实时监控各设备运行信息、工序执行情况，并发送到工业一体机。当系统中设备发送故障时，自动实现紧急停止，并将故障信息发送到工业一体机保存，便于后期维护。管理系统在整个铝电解质化检验样品自动化制样系统中执行生产调度/质量和记录/生产履历、自动记录/检测数据分析、存储、上传等任务。负责录入检测试样身份，并下发给PLC控制系统；在生产过程中跟踪产品的流程；在工件测量结束并下线时，自动获取和分析质量文件，形成质量数据，存储记录到质量数据库中。
实施例4
进一步的，本实施例提供的一种铝电解质化检验样品自动化制样工艺，包括以下步骤：
包括以下步骤：
(1)通过人工使上料盘和取料盘就位，关闭防护罩门。
(2)将磨样罐经输送系统传送至上料位，通过装卸料机器人把上料盘的料杯里的铝电解质化检验样品的原料倒入磨样罐中，且在磨样盖将磨样罐盖上后，按照控制管理系统的指令进行磨样。
(3)磨样完成后，分拣机器人把磨样盖抓取到清洗烘干系统进行清洗和烘干，通过翻转倒料系统将磨样罐中的细粉料倒入筛网中，筛选适用于制作成品的粉料后放置于压样环中，且翻转倒料系统将压样环推送到压样系统中，在压样系统内完成压样，得到初品，同时分拣机器人将倒完细粉料的筛网也抓取到清洗烘干系统进行清洗和烘干。
(4)磨样完成后，分拣机器人把磨样盖抓取到除尘系统中，通过翻转倒料系统将磨样罐中的细粉料倒入筛网中，筛选适用于制作成品的粉料后放置于压样环中，且翻转倒料系统将压样环推送到压样系统中，在压样系统内完成压样，得到初品，同时分拣机器人将倒完细粉料的筛网也抓取到除尘系统进行除尘。
(5)初品经分拣机器人抓取到喷码装置上，喷码装置按照编码规则对初品进行喷码得到样片。
(6)装卸料机器人拾取样片至取料盘中，从而完成铝电解质化检验样品的制样。
所述铝电解质化检验样品自动化制样工艺能实现单次铝电解质样品上/取料≥50件，单件铝电解质制样时间≤150s，单件磨样罐清洗烘干生产节拍≤90s，磨后出料电解质颗粒度优于140目，设备柜机的防尘等级达到IP3～IP5级，噪音控制在Ⅲ等级。
(7)装卸料机器人拾取样片至取料盘中，从而完成铝电解质化检验样品的制样。
所述铝电解质化检验样品自动化制样工艺能实现单次铝电解质样品上/取料≥50件，单件铝电解质制样时间≤150s，磨后出料电解质粒径≥140目，设备柜机的防尘等级达到IP3～IP5级，噪音控制在Ⅲ等级。
以上已经描述了本发明的实施例，上述说明是示例性的，并非穷尽性的，并且也不限于所披露的实施例。在不偏离所说明实施例的范围和精神的情况下，对于本技术领域的普通技术人员来说许多修改和变更都是显而易见的。

Claims (12)

  1. 一种铝电解质化检验样品自动化制样系统，其特征在于：包括为铝电解质化检验样品的制备提供密闭除尘空间的设备机柜；设备机柜中集成有：
    上/取料盘组件，用于铝电解质化检验样品的原料和成品的上料与取料；
    物流机器人，用于设备内部物流转运及铝电解质化检验样品的原料添加或用于压样系统出料时成品的拾取；
    磨样系统，包括磨样机本体和磨样组件，磨样组件将铝电解质化检验样品的原料磨制成细粉料；
    翻转倒料系统，用于将磨样组件中制备好的细粉料倒入压样系统中；
    压样系统，用于将细粉料压制成铝电解质化检验样品的初品；
    喷码系统，用于成品出料后，对成品表面喷印管理信息码。
  2. 根据权利要求1所述的铝电解质化检验样品自动化制样系统，其特征在于：上/取料盘组件包括上料盘和取料盘，所述上料盘和取料盘上均装有位置传感器，且上料盘和取料盘分别与50件及以上铝电解质化检验样品的原料量和成品量相匹配。
  3. 根据权利要求1所述的铝电解质化检验样品自动化制样系统，其特征在于：所述磨样系统用于将铝电解质化检验样品的原料整体放置于磨样罐中，利用电机带动刀片高速旋转一次将样品原料加工成颗粒度优于140目的细粉料，所述磨样机本体采用刀片式研磨机构，采用单独的抗震底座连接在设备柜体内，同时配置有自动开启的防滑翻转防护装置；所述磨样组件包含磨样盖、刀片和磨样罐；所述磨样罐用于盛放磨样块和铝电解质化检验样品的原料，所述磨样盖可拆卸盖设在磨样罐上。
  4. 根据权利要求1或2或3所述的铝电解质化检验样品自动化制样系统，其特征在于：还包括输送系统，包括顶升气缸、位置传感器和皮带输送机，用来实现磨样组件的组合和运输；所述磨样系统设置有磨样罐工位、磨样盖工位，各个工位均配置有位置传感器，所述气缸夹持组件包括各工位上配置的对磨样组件进行升降和夹持操作的升降气缸与夹持气缸。
  5. 根据权利要求1所述的铝电解质化检验样品自动化制样系统，其特征在于：还集成有控制管理系统，用于控制上/取料盘组件、物流机器人、分拣机器人、输送系统、磨样系统、翻转倒料系统、压样系统、清洗烘干系统和除尘系统按预定的工作条件进行启停和动作；所述控制管理系统以PLC控制器为硬件基础，以软件编程为手段，对铝电解质化检验样品自动化制样系统各个组成模块间进行顺序与逻辑控制；所述控制管理系统包括上位机、下位机和化检验设备，具有制样过程全生命周期管理功能；
    通过所述上位机设定所述铝电解质化检验样品自动化制样系统的加工参数，实时展示所述铝 电解质化检验样品自动化制样系统的测试、报警和工艺信息，能够与第三方软件进行接口通讯；
    所述下位机按照预定的工艺流程和工作节拍进行工作，实时监控所述铝电解质化检验样品自动化制样系统的运行信息、工序执行情况并发送到上位机；下位机能够控制所述铝电解质化检验样品自动化制样系统自动紧急停机，并将故障信息发送到上位机保存和分析；上位机收发远程生产单元的生产状态信息数据，根据工艺顺序系统发出对应控制指令进行制样计划、样品跟踪、制样过程监控、设备运行状态监视、质量记录、检测数据统计和样品溯源管理收集数据，从而自动获取制样数据和分析质量文件，以全过程保证产品质量及系统安全，实现制样过程全生命周期管理功能。
  6. 根据权利要求1所述的铝电解质化检验样品自动化制样系统，其特征在于：还集成有清洗烘干系统，用于将磨样罐清洗干净与烘干；包括高速射流冲洗、风幕和烘干装置，用于冲洗、烘干使用过的磨样罐；所述高速射流冲洗装置用于将使用过的磨样组件进行高速射流冲洗，所述风幕用于将清洗过的磨样组件上的水珠吹掉，所述烘干装置采用高温高压空气对磨样组件进行烘干；所述清洗烘干系统生产节拍≤90s/件。
  7. 根据权利要求1所述的铝电解质化检验样品自动化制样系统，其特征在于：还集成除尘系统，在设备柜机内的密闭除尘空间进行负压除尘的除尘系统；并且放置独立除尘箱，通过物流机器人抓取、运输，可分别对筛网、磨样罐盖、粉末收集装置进行负压除去表面附着颗粒物。
  8. 根据权利要求1所述的铝电解质化检验样品自动化制样系统，其特征在于：所述铝电解质化检验样品自动化制样系统上/取料盘组件能够一次性放置≥50件的样品，实现单次铝电解质样品上/取料≥50件；根据优化集中的工艺顺序，在短时间内实现电解质样品的取料、磨样至完成压样，实现单件铝电解质制样时间≤150s；单件磨样罐清洗烘干生产节拍≤90s，磨后出料电解质颗粒度优于140目，设备柜机的防尘等级达到IP3～IP5级，噪音控制在Ⅲ等级，且设备柜机上设有方便铝电解质化检验样品的原料和成品的上料与取料的防护罩门，且内部还集成有用于对设备柜机内的密闭除尘空间进行负压除尘的除尘系统。
  9. 根据权利要求3所述的铝电解质化检验样品自动化制样系统，其特征在于：所述翻转倒料系统包括翻转装置、推送装置、料斗和压样环，所述翻转装置用于将磨样罐进行翻转，使磨样罐中磨成细粉料的电解质经料斗倒入压样环中，所述推送装置用于将压样环推送到压样系统中。
  10. 根据权利要求8所述的铝电解质化检验样品自动化制样系统，其特征在于：所述压样系 统包括压样装置、顶升装置、压样环放置盘和喷码装置，所述顶升装置用于驱动压样环放置盘向上移动，当压样环中的细粉料接触到压样装置盘底部时，压力开始增加，达到设定工作压力并保持一段设定工作时间后，将压样环中的细粉料制备成铝电解质化检验样品的初品，在顶升装置复位带动压样放置盘下移后，初品经分拣机器人抓取至喷码装置下喷写编码，再经装卸料机器人拾取至取料盘中。
  11. 根据权利要求1～10中任一项所述的铝电解质化检验样品自动化制样系统，其特征在于：在柜机外壳上设置有操作界面，包括触摸式液晶屏和急停按钮，所述触摸式液晶屏和急停按钮分别与控制系统通讯连接。
  12. 一种铝电解质化检验样品自动化制样工艺，采用如权利要求1-11中任意一项所述的铝电解质化检验样品自动化制样系统，其特征在于：包括以下步骤：
    (1)通过人工使上料盘和取料盘就位，关闭防护罩门；
    (2)将磨样罐经输送系统传送至上料位，通过装卸料机器人把上料盘的料杯里的铝电解质化检验样品的原料倒入磨样罐中，且在磨样盖将磨样罐盖上后，按照控制管理系统的指令进行磨样；
    (3)磨样完成后，分拣机器人把磨样盖抓取到清洗烘干系统进行清洗和烘干，通过翻转倒料系统将磨样罐中的细粉料倒入筛网中，筛选适用于制作成品的粉料后放置于压样环中，且翻转倒料系统将压样环推送到压样系统中，在压样系统内完成压样，得到初品，同时分拣机器人将倒完细粉料的筛网也抓取到清洗烘干系统进行清洗和烘干；
    (4)磨样完成后，分拣机器人把磨样盖抓取到除尘系统中，通过翻转倒料系统将磨样罐中的细粉料倒入筛网中，筛选适用于制作成品的粉料后放置于压样环中，且翻转倒料系统将压样环推送到压样系统中，在压样系统内完成压样，得到初品，同时分拣机器人将倒完细粉料的筛网也抓取到除尘系统进行除尘；
    (5)初品经分拣机器人抓取到喷码装置上，喷码装置按照编码规则对初品进行喷码得到样片；
    (6)装卸料机器人拾取样片至取料盘中，从而完成铝电解质化检验样品的制样；
    所述铝电解质化检验样品自动化制样工艺能实现单次铝电解质样品上/取料≥50件，单件铝电解质制样时间≤150s，单件磨样罐清洗烘干生产节拍≤90s，磨后出料电解质颗粒度优于140目，设备柜机的防尘等级达到IP3～IP5级，噪音控制在Ⅲ等级；
    (7)装卸料机器人拾取样片至取料盘中，从而完成铝电解质化检验样品的制样；
    所述铝电解质化检验样品自动化制样工艺能实现单次铝电解质样品上/取料≥50件，单件铝电解质制样时间≤150s，磨后出料电解质颗粒度优于40目，设备柜机的防尘等级达到IP3～IP5 级，噪音控制在Ⅲ等级。
PCT/CN2023/085495 2022-04-15 2023-03-31 一种铝电解质化检验样品自动化制样系统及其制样工艺 WO2023197890A1 (zh)

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