NOUFERROUS METALLURGICAL EQUIPMENT

To address the challenges of low efficiency and inconsistent quality in traditional furnace-lining processes for aluminum electrolysis cells, this study proposes an automated robot system based on integrally formed cathodes. Analysis of the furnace-lining process in 200kA aluminum electrolysis cells identified manual construction as the primary cause of defects such as lining cracks and delamination, attributed to insufficient compaction pressure (＜0.8MPa) and uneven temperature distribution. Key performance metrics-including bulk density, resistivity, and compressive strength-were found to fall below industry standards. To address these constraints, a robotic furnace-lining system was developed, integrating shaftless spiral material distribution, vibration compaction, a four-axis gantry mechanism, and 3D laser monitoring. The system achieves autonomous navigation, automated material placement, self-regulated compaction, real-time process monitoring, and electromagnetic compatibility (EMC). Implementation reduced the furnace-lining cycle per cell from 6-7 days (manual operation) to 3 days, providing an innovative solution for high-efficiency, high-precision furnace construction. This advancement supports cost reduction, operational optimization, and intelligent transformation in industrial practice.