Automatic Cathode Lifting Frame
High-Speed, Precision Handling for Large-Scale Electrowinning
The Automatic Cathode Lifting Frame is engineered for high-volume electrowinning plants, automating cathode lifting, transfer, and stacking to maximize throughput. Equipped with motorized actuators, sensors, and programmable logic controllers (PLC), it reduces manual labor by 90% while minimizing cathode damage. Designed to integrate with plant SCADA systems, it ensures consistent, safe handling even in 24/7 operation.
Technical Specifications
|
Parameter |
Specification |
Why It Matters |
|
Material |
316 stainless steel frame + titanium hooks |
Resists aggressive acid environments (e.g., 10% sulfuric acid); 15+ year lifespan. |
|
Load Capacity |
Customized according to customer requirements |
Handles large batches to match high-production lines. |
|
Lift Speed |
0.5m/s (adjustable via PLC) |
Reduces cycle time to <60 seconds per batch. |
|
Control System |
PLC with touchscreen HMI; compatible with SCADA |
Allows remote monitoring/operation; stores 50+ custom lifting programs. |
|
Safety Features |
Laser sensors + emergency stops buttons |
Stops operation if obstacles (e.g., workers) are detected; prevents overloading. |
|
Power Supply |
380V AC (50/60Hz); optional battery backup |
Works with standard industrial power; backup avoids downtime during outages. |
Product Advantages
- Automated cycle: From lifting cathodes out of cells to stacking them in storage, the entire process runs without manual intervention - ideal for 10,000+ TPA plants.
- PLC programming: Stores custom settings for different cathode sizes (e.g., 1.2m vs. 1.5m length), ensuring precision even with mixed batches.
- Laser alignment: Ensures hooks engage cathode bars with <2mm tolerance, eliminating misalignment (a common cause of cathode bending).
- Redundant systems: Dual motors and sensors prevent single-point failures; emergency stop buttons at 3 locations for worker safety.
- SCADA connectivity: Sends real-time data (e.g., cycles completed, load weight) to plant management systems for production tracking.
- Compatibility: Works with robotic transfer systems, conveyor belts, and automatic stripping machines for end-to-end automation.
Application Scenarios
- Large-scale copper electrowinning plants
- High-capacity copper electrorefineries
- Automated tankhouse with automatic stripping machines
- Greenfield tankhouse construction projects
- Existing plant automation and efficiency upgrades
- Operations targeting reduced manual labor
Procurement & Application
|
Pain Point |
Our Solution |
|
High labor costs for manual handling |
Reduces 2–3 workers per shift; ROI achieved in <18 months for large plants. |
|
Inconsistent handling leading to defects |
Sensor-guided hooks reduce cathode bending/damage by 95% vs. manual lifting. |
|
Need for 24/7 operation |
Durable design with self-diagnostic features; requires <1 hour/week maintenance. |
Case Highlight: Mega Copper Plant
Challenge
A 50,000 TPA copper plant struggled with labor shortages and inconsistent cathode handling (10% of cathodes bent during lifting).
Solution
Installed 4 Automatic Cathode Lifting Frames integrated with their SCADA system.
Result
Throughput increased by 30% (from 800 to 1,040 cathodes/day); bending defects dropped to <0.5%; annual labor savings of $450,000.
Packaging & Transportation
Modular Shipping
Delivered in 3–4 modules (frame, control cabinet, hooks) for easy on-site assembly.
Climate-Controlled Packaging
Electronics sealed in moisture-proof enclosures; frame wrapped in anti-corrosion film.
Commissioning Support
Included on-site technician for PLC programming, SCADA integration, and operator training.
FAQ
Q1: Does it work with all types of permanent cathodes?
A: The lifting frame is designed to match your specific cathode plate dimensions and bar configuration. We customize the engagement mechanism to fit your cathode type - whether stainless steel, titanium or other permanent cathode materials.
Q2: Can it integrate with our existing stripping machine?
A: In most cases, yes. We design the lifting frame to interface with your stripping machine specifications. We would need details about your current stripping equipment to confirm compatibility and design the appropriate interface.
Q3: How much does automation improve throughput?
A: Automatic lifting frames typically achieve significantly faster cycle times than manual methods, often increasing handling throughput by 50–100% or more depending on the specific operation.
Q4: What if a cathode is misaligned or damaged?
A: The system can include detection features to identify misaligned or damaged cathodes, and can either handle them automatically or alert the operator for manual intervention, depending on the configuration.
Q5: What maintenance is required?
A: Regular maintenance includes lubrication, inspection of hooks and engagement mechanisms, calibration checks and periodic replacement of wear parts. We provide detailed maintenance guidelines and spare parts support.
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