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炭碗自动填充装置：破解铝工业生产痛点，引领铝用炭素智能转型新路径

2025-10-15 16:50:20 来源：北方有色网责任编辑：王欣悦

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炭碗自动填充装置在技术突破层面实现了从“人工依赖”到“智能自主”的范式革新，该装置集成“激光三维检测+六轴机械臂定位+PLC协同控制”系统，通过12个高清传感器实时采集炭碗尺寸参数，定位精度达±0.1mm，能实现填料量与压实度的闭环控制;对比行业同类设备如綦江企业碳块填碗机70秒/个的效率，其120块/小时(即30秒/块)的作业效率提升40%以上，良品率较人工操作也提高13个百分点。同时，该装置的创新成果获得权威背书，所获“有色金属工业科学技术二等奖”属省部级认可，该奖项作为国家科技奖的重要遴选基础，2024年仅有433个项目通过受理，凸显技术的行业引领性，且此前获郑州市“五小”创新成果二等奖的原型设备，已完成从实验室到工业化的迭代升级。

在行业价值上，该装置有效破解了炭素生产的“卡脖子”痛点。从生产端来看，它彻底解决了传统工艺的三大难题，即人工填料粉尘浓度超20mg/m³的职业健康风险、单块炭碗180秒的低效作业，以及合格率仅86%的质量波动;按单条生产线年处理10万块炭块计算，可减少人工成本300万元/年，废品损失降低80%。在产业升级支撑方面，其与中铝郑州研究院另一项“提高阳极抗氧化性技术”形成协同，前者解决生产过程智能化，后者提升产品性能(空气反应残余率≥85%)，共同推动铝用炭素行业从“经验控制”向“数字标准”转型，为国家电投等企业的智能工厂建设提供核心装备支撑。

从政策衔接角度，该装置的入选契合河南装备攻坚战略布局。此次入选是河南省2023-2025年重大技术装备攻坚方案的关键成果体现，该方案明确2025年目标培育600项省级首台(套)装备，装置凭借“全流程无人化”的原创性突破，有望纳入示范应用基地建设清单。同时，根据河南省政策，入选装备可获得三方面支持，包括试验验证平台优先接入、知识产权快速维权通道，以及参与行业标准制定;结合其已获的省级优秀专利一等奖，未来有望主导制定《铝用炭素智能填充装备技术规范》，进一步巩固技术领先地位。

在发展展望上，该装置将实现从“单点突破”到“生态构建”的跨越。技术迭代方向上，下一步将融合中铝集团“3+4+4+4”体系中的“新型功能材料”方向，开发陶瓷基复合材料填料喷头，解决高温磨损问题，目标将设备寿命从当前1.5年延长至3年。产业辐射效应方面，参照中商碳素研究院节能焙烧技术的推广路径，该装置已与3家电解铝企业达成试用协议，预计2026年市场渗透率可达20%，带动河南高端装备产业新增产值超5亿元，为区域产业高质量发展注入新动能。

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