Apparatus for shaping anodes

An apparatus for shaping anodes for electrolytic refining in the form of flat plates having support ears extending outwardly of a top edge and opposite side edges thereof, the apparatus including a receptacle for holding the plates parallel, vertical and spaced apart, vertically movable beams engaging the ears for supporting the plates, shaping devices movable toward and away from opposing sides of the receptacle for shaping the under-surfaces of the support ears, and a device movable vertically and horizontally for transferring the plates into the receptacle for being shaped and for transferring the shaped plates from the receptacle, whereby the support ears may be shaped concurrently for improving the contact of the anodes with bus bars.

BACKGROUND OF THE INVENTION 
1. Field of the Invention 
The present invention relates to an apparatus for shaping anodes to be 
employed in the electrolytic refining of metals. 
2. Description of the Prior Art 
For carrying out an electrolysis operation in the electrolytic refining of 
metals, the electrolytic plant should have a large capacity and at the 
same time the clearance between an anode and a cathode in the cells should 
be minimized. 
Crude copper, crude nickel, crude lead and the like are cast to form 
rectangular plates having support members or ears protruding outwardly 
from opposing side edges at an upper edge thereof, the support ears being 
suspended on longitudinal flange portions at the upper portion of the cell 
and the cast plates being electrolyzed as the anodes. Such anode plates 
are prepared by casting a molten material onto recessed molds having a 
shape as shown in FIG. 1, and placed horizontally to enable the casting in 
the simplest manner, cooling the surface of the cast material by spraying 
water thereon and stripping the solidified cast material from the molds. 
In order to facilitate the removal of the cast plates from the molds, the 
side walls of the recess in the molds are inclined outwardly so that the 
sides of the cast anode are sloped. 
Refined thin metal sheets are suspended vertically in the cells as the 
cathodes. When each anode cast, as stated above, is suspended between the 
two cathodes by being supported on the longitudingal flanges of the cell 
by its support ears, the undersurfaces of the ears are not perpendicular 
to the surface walls of anodes but are inclined with respect thereto. 
Accordingly, when the anodes are supported on the longitudinal flanges of 
the cell, the bottom surfaces are out of full contact therewith since only 
edges having acute angles on bottom surfaces contact the flanges. 
Therefore, the anodes cannot be placed vertically in position but must be 
inclined to the vertical. Hence, the clearance between the anode and the 
cathode at the lower portion differs from that at the upper portion. 
During the electrolysis operation, such an inclination causes a difference 
in the dissolving rate at the upper and lower portions. Hence the cast 
anodes cannot be fully exhausted and the remaining portion must be cast 
again for the re-use; thus, the utility efficiency of the anodes is 
markedly reduced. In addition, in order to avoid a direct contact of the 
anode with the cathode because of the inclined anodes, the clearance 
between an anode and a cathode should be maintained larger for the purpose 
of safety than would be maintained if the anode were suspended vertically 
in position. This, however, results in a reduced utility of the 
electrolytic cell. 
In order to eliminate such problems, the positioning of the support ears or 
members has been positively adjusted by inserting copper liners or the 
like below the undersurfaces thereof so that the anode is suspended 
vertically in position. However, such an adjustment requires much time and 
labor. 
In order to reduce such labor, the shape of the molds has been improved so 
that the undersurfaces are perpendicular to the parallel side surfaces to 
be electrolyzed, or so that the inclination of the undersurfaces of one 
support member is reversed relative to that of another support member. 
However, as the casting accuracy of the anode plates cannot be controlled 
precisely because of the simple casting procedure involved, it has been 
difficult to overcome such problems by such a control in the shape of the 
cast anodes. In addition, the surface of the cast anodes is so rough that 
the electric resistance between an anode and a bus bar becomes so high as 
to significantly reduce the electrolysis efficiency. 
SUMMARY OF THE INVENTION 
For overcoming such problems, the undersurfaces of the support ears or 
members of the anodes are worked, in accordance with the invention, by 
shaping them to provide an arcuate surface having a radius R of which the 
center lies substantially on the centerline of the thickness of the anodes 
so that the anodes hang vertically in position when their support ears or 
members are suspended on the flanges of the cell. 
A primary object of the present invention is to provide an apparatus for 
efficiently shaping anode plates in that the undersurfaces of support ears 
of a plurality of anode plates are concurrently shaped to increase the 
number of the plates to be worked per unit time, and to reduce the 
installation space as well as the investment and running costs as an 
accessory for a large scale electrolytic plant. 
According to the present invention, the apparatus for shaping anode plates 
includes a receptacle having a plurality of vertical walls with a height 
and a width slightly greater than that of the anodes so as to define 
channels in equally spaced relation for the reception of the plates having 
their support ears extending outwardly of opposing side edges of the 
walls, the plates being clamped against adjacent wall surfaces. Shaping 
devices are disposed at the lateral sides of the receptacle, such devices 
having cutters movable toward and away from the receptacle to concurrently 
shape the undersurfaces of the support ears or members of a plurality of 
anodes. And, a vertically and horizontally movable transfer device effects 
the transfer of a plurality of anodes to and from the channel of the 
receptacle.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
As shown in FIGS. 3, 4 and 5, a plurality of vertical walls 3a having a 
width slightly greater than that of anodes 1 are arranged parallel to one 
another and are spaced apart a distance somewhat greater than the 
thickness of anodes 1. This distance is determined by the ease in 
transferring the anodes in and out of receptacle 3 and the thickness of 
walls 3a determined by the retracted position of cylinders 3c housed 
therein and by the length of piston rods 3d. The walls are interconnected 
at the bottom thereof so as to form a plurality of channels 3b opening 
upwardly and extending laterally between walls 3a. In each wall 3a except 
the wall 3a', three oil pressure cylinders 3c are provided in spaced-apart 
relation and lie perpendicular to the wall surfaces so as to be positioned 
at apices of a triangle (FIGS. 5B and 6). Clamping device or receptacle 3 
includes piston rods 3d of oil pressure cylinders 3c protruding through 
the wall surface of adjacent walls 3a. Hence anodes 1 can be pinched or 
clamped in place within channels 3b by inserting anodes 1 vertically into 
channels 3b parallel to each other and pressing each anode against the 
surface of an adjacent wall 3a by means of piston rods 3d. 
A support device 4 is provided at opposite sides of receptacle 3, as shown 
in FIGS. 3, 4 and 6. Support device 4 includes support beams 4a arranged 
horizontally adjacent walls 3a and parallel to the side edges thereof. 
Vertical piston rods 4c of oil pressure cylinders 4b are connected to 
opposite ends of the beams. Guide bars 4d are secured at one end thereof 
to the undersurfaces of support beams 4a and extend downwardly from 
support beams 4a into guide channels 4e disposed centrally of beams 4a. 
Support device 4 thus supports support ears 2 at the lateral sides of 
anodes 1 which have been transferred by the transfer device and inserted 
into channels 3b on the top surface of support beams 4a. Support beams 4a 
are raised together to a predetermined position by piston rods 4c of oil 
pressure cylinders 4b. Anodes 1, supported by support beams 4a, are then 
clamped in place by pressing them against walls 3a by protruding piston 
rods 3d. Piston rods 4c are then retracted into oil pressure cylinders 4b, 
and support beams 4a are allowed to lower so as to disengage from support 
ears 2 (see FIG. 5B). 
As shown in FIGS. 5B and 6, anodes 1 clamped in place by device 3 are held 
in a condition such that support ears 2 protrude laterally outwardly from 
walls 3a between channels 3b. Shaping devices 5 are disposed at opposite 
sides of anodes 1 which are held in place by device 3. Cutter holders 5b 
are movable toward and away from receptacle 3 by means of oil pressure 
cylinders 5c fixedly mounted on beds 5a. A tongue and groove arrangement 
is provided at the mating surfaces of beds 5a and holders 5b in the 
advancing direction of holders 5b for guiding the holders along such 
direction. Motors 5e are fixedly mounted on holders 5b for driving shafts 
5f disposed parallel to support beams 4a. Milling cutters 5g, having 
concave blade tips 5h as shown in FIG. 9, are attached to each shaft 5f at 
positions corresponding to the support ears of anodes 1 so as to shape 
undersurfaces 2a of ears 2 to suitable lengths. Hence, the apparatus is 
designed to support a number of anodes 1 by means of support beams 4a, 
then clamp the anodes by means of clamping device 3, allow support beams 
4a to lower, allow milling cutters 5g to shape undersurfaces 2a of support 
ears 2 and then retract milling cutters 5g so as to disengage from the 
anodes. 
As shown in FIGS. 4 and 6, a transfer device 6 is supported on legs 6a 
above clamping device 3 for inserting anodes 1 into channels 3b of 
clamping device 3 and for withdrawing anodes 1 from channels 3b. Beams 6b 
interconnect the top ends of legs 6a so as to form square frames 
surrounding clamping device 3, and rails 6c are provided thereon parallel 
to support beams 4a. A carrier 6d is mounted on rails 6c for movement from 
a position outwardly of one end of clamping device 3 to a position 
outwardly of the opposite end of clamping device 3 in a direction parallel 
to walls 3a. Two hanging frames 6e are disposed between beams 6b (FIG. 6) 
and are suspended by piston rods 6g of oil pressure cylinders 6f fixedly 
mounted on carrier 6d for movement vertically up and down along guide 
pipes 6m. Carrier 6d is movable by oil pressure cylinders 6h secured to 
opposite ends of beams 6 b. If carrier 6d is moved to the right or to the 
left in FIG. 4, one of hanging frames 6e will be positioned immediately 
above clamping device 3 (FIG. 4A) and the other hanging frame will be 
positioned to the front or to the rear of clamping device 3. 
As shown in detail in FIGS. 7 and 8, links 6i are arranged inwardly of 
frame beams 6n of each hanging frame 6e. Pins 6j are fixedly secured to 
hooks 6l located outwardly of beams 6n, the pins being rotatably mounted 
on beams 6n and being fixedly secured to short links connected to links 
6i. Thus hooks 6l may be swung back and forth about the pin axes upon 
actuation of oil pressure 6k mounted on hanging frame 6e. Opposing pairs 
of hooks 61 engage support ears 2 for supporting a plurality of anodes 1 
which rest on a so-called "constantly pitching" conveyor 7 provided at the 
front of clamping device 3. The anodes are spaced apart distances equal to 
the spacing of channels 3b of clamping device 3 so that, when lifted by 
hooks 6l of hanging frames 6e, they may be inserted into channels 3b. 
Opposing pairs of hooks 6l also lift the anodes from channels 3b of 
clamping device 3 for discharging them onto an endless discharge conveyor 
8 provided at the rear of clamping device 3. Conveyor 7 and discharge 
conveyor 8 move and stop simultaneously and their rates of movement are 
equal. 
A plurality of anodes 1 transferred by means of a forklift are mounted on a 
base 9b positioned at a predetermined elevation by means of a cylinder 9a. 
When the forklift is retracted, the anodes are carried by conveyor 9. 
Then, by simultaneously projecting a pair of lateral positioner devices 9c 
secured to the head portions of the piston rods 9o of cylinders 9n so as 
to orient the center of feed conveyor 9 and the center in the width 
direction of the anodes, base 9b is lowered and lateral positioner devices 
9c are retracted by cylinders 9n, whereby the anodes are hung by their 
ears on feed conveyor 9 in parallel abutting relationship as seen in FIG. 
10. 
Referring to FIGS. 3, 4A, 10 and 11, feed conveyor 9 effects the transfer 
of anodes 1 by driving a motor 9d for rotating oppositely disposed 
sprockets 9m through sprockets 9e, 9g, 9i, 9k, chains 9f, 9j and shafts 
9h, 9l. A pair of discs 10 having a larger diameter than that of sprockets 
9m are disposed inwardly of and coaxially with sprockets 9m in opposite 
relation to each other through sprockets 10c so as to be simultaneously 
rotated Discs 10 are rotated by a driving motor 10a through sprockets 10b, 
10c, shafts 10d, 10f and a chain 10e. Reference numeral 7b is an idle 
pulley, the outer periphery of which being engaged with the conveyor 7 
driven by the motor. 
Each of the discs 10 is provided on its periphery with projecting 
triangular pawls 10g (FIG. 10) which are radially spaced equal distances 
apart, for example, 60.degree.. The pawls are in registry between the 
discs. And, discs 10 are synchronized with conveyor 7 in such a manner as 
to transfer the anodes in succession onto conveyor 7, as shown in FIG. 11. 
Anodes 1, which hang by their support ears along conveyor 9, are advanced 
toward discs 10 by motor 9d. When the first of such anodes approaches the 
discs before contacting discs 10, it impinges on a limit switch 10h which 
stops the movement of conveyor 9 and simultaneously actuates motor 10a 
which thereby effects rotation of the discs. Thereafter, when such anode 
makes contact with discs 10, the relative disposition of conveyor 9 and 
the discs is such that support ears 2 are lifted upwardly by pawls 10g to 
an uppermost position as shown in FIG. 11. However, before reaching such 
uppermost position, the anode impinges on a limit switch 10i which acts to 
stop rotation of the discs, stop movement of conveyor 7 and to again 
actuate feeding conveyor 9. 
Thus, anodes 1 which hang by their ears on conveyor 9 are lifted upwardly 
one-by-one by pawls 10g depending on the alternating movement of conveyor 
9 and discs 10, and are transferred onto the constantly pitching conveyor 
7 by pawls 10g in such a manner that the anodes are aligned on conveyor 7 
at an equal spacing. Such as equal spacing, as shown to the right in FIGS. 
10 and 11, is maintained by teeth 7a provided on conveyor 7 in spaced 
relationship equal to the spacing of channels 3b. In other words, teeth 
7a are equally spaced apart distances equal to the equal spacing between 
channels 3b. Thus conveyor 7 is termed "constantly pitching." When the 
foremost anode on conveyor 7 reaches the forward end thereof and impinges 
on a limit switch (not shown) provided near wuch forward end, conveyors 9 
and 7 and discs 10 are stopped. 
Anodes 1 are conveyed under such condition by means of feed conveyor 9 to 
constantly pitching conveyor 7 and, when anodes 1 are transferred from 
feed conveyor 9 to constantly pitching conveyor 7, anodes 1 maintain the 
same spaced relation to that of channels 3b. 
When the same number of anodes 1 as that of channels 3b arrives immediately 
below transfer device 6 by means of constantly pitching conveyor 7, the 
movements of feed conveyor 9 and constantly pitching conveyor 7 are 
stopped. These conveyors are shown in more detail in Japanese Utility 
Model lay open Print No. 45378/1973, published June 13, 1973 and commonly 
owned herewith. Then, hanging frame 6e at the left side in FIG. 4 above 
conveyor 7 is lowered and hooks 6l are operated to engage ears 2 of anodes 
1 so as to lift them, insert them into clamping device 3 and place them on 
support beams 4a of support device 4 (see FIG. 5B). After the completion 
of these operations, the operations of feed conveyor 9 and constantly 
pitching conveyor 7 are restarted for repeating the preceding cycle. 
Carrier 6d is returned to the original position and hanging frame 6e at 
the left side is returned above constantly pitching conveyor 7. The anodes 
which have been passed shift from support device 4 to device 3, are then 
shaped as described above by means of shaping device 5, and are then 
supported again by support device 4 simultaneously with release of 
clamping device 3. Then hanging frame 6e above constantly pitching 
conveyor 7, and hanging frame 6e immediately above clamping device 3, are 
lowered together for lifting the anodes as hooks 6l engage ears 2 thereof. 
It can therefore be seen that the leftward hanging frame transfers the 
unworked anodes supported on constantly pitching conveyor 7 to clamping 
device 3, and the rightward hanging frame transfers the worked anodes from 
clamping device 3 to discharge conveyor 8. 
By precisely supporting the anodes in a predetermined position within 
channels 3b by means of hooks 6l, it is possible to support anodes 1 by 
means of the transfer device instead of the support device until anodes 1 
are clamped by the clamping device, thereby avoiding the need for a 
support device. 
In the embodiment described above, support beam 4a may be arranged for 
longitudinal movement and the anodes may be so conveyed that they are laid 
down horizontally to constantly pitching conveyor 7 and may be vertically 
separated on conveyor 7. In addition, transfer device 6 may comprise a 
hanging frame hung from a crane. Still further, the present apparatus may 
be employed in combination with a constantly pitching conveyor 
corresponding to the anode pitch in an electrolyzing cell. 
To briefly summarize the operation of the apparatus according to the 
present invention, a plurality of the anodes, equal to the number of 
channels 3b of receptacle 3, are conveyed first along conveyor 9 and then 
along conveyor 7, conveyor 7 is then stopped so that the plurality of 
anodes, which are supported vertically at a predetermined spacing with 
their portions at the upper ends of the plates, are made to lie directly 
beneath the left hanging frame 6e positioned as in FIG. 4 to the leftmost 
end of transfer device 6. The right hanging frame 6e is, in such position, 
directly above receptacle 3 as shown. Cylinders 6b are then actuated to 
extend their piston rods 6g thereby simultaneously lowering both hanging 
frames sufficiently so that hooks 6l will engage the undersurfaces of ears 
2 so the hooks are swung beneath the ears upon actuation of link mechanism 
6i by cylinders 6k. Both hanging frames are then moved forward only to the 
right, when viewing FIG. 4A, until the left hanging frame lies directly 
above receptacle 3. Such horizontal movement is carried out by cylinders 
6h. Both hanging frames are then again lowered upon actuation of their 
cylinders 6f for insertion of the anodes into channels 3b. Just prior to 
such insertion, support beams 4a are raised, by the actuation of their 
cylinders 4b, to a position shown in phantom outline in FIG. 5B. The 
anodes may then be lowered into receptacle 3 until their support ears 2 
rest on the top surfaces of support beams 4a. The lower level of hanging 
frame 6e and hooks 6l thereof are shown in phantom outline in FIG. 5B. 
Cylinders 3c are then actuated to extend their piston rods 3d so as to 
pinch or clamp the anodes in place against the surfaces of walls 3a. Hooks 
6l are then swung out of engagement with ears 2 upon actuation of link 
mechanism 6i, the left hanging frame is then raised, support beams 4a are 
lowered, and undersurfaces 2a of support ears 2 are shaped or milled by 
cutters 5a as cutter holders 5b are moved toward receptacle 3 upon 
actuation of a piston rod 5d of cylinders 5c. Upon completion of the 
shaping or milling operation, the cutter holders 5b are shifted away from 
receptacle 3 to their position shown in phantom outline in FIG. 5B, beams 
4a are elevated to their phantom outline position shown in this figure, 
both hanging frames are moved horizontally back to their position shown in 
FIG. 4, both hanging frames are lowered, and hooks 6l on the right hanging 
frame are swung to engage ears 2 of the now-shaped anodes in receptacle 3, 
and hooks 6l of the left hanging frame are swung to engage the support 
ears of a plurality of anodes yet to be worked on and which now lie 
directly therebeneath on conveyor 7 as described earlier. Both hanging 
frames are then raised for simultaneously moving the unworked and the 
worked sets of anodes upwardly. Horizontal shifting of the hanging frames 
then transfers the finished anodes to overlie conveyor 8 and the 
unfinished anodes to overlie receptacle 3. Upon the lowering of the 
hanging frame, and a swinging of their hooks to disengage them from the 
support ears of the anodes, the finished sets of anodes are deposited onto 
conveyor 8, and the unfinished set of anodes are lowered into channels 3b 
of receptacle 3 in the same manner as described hereabove. The operation 
cycle is then repeated as detailed above. And, it should be pointed out 
that the hydraulic cylinders provided for lateral positioner device 9 c, 
base 9b, transfer device 6, clamping device 3 and shaping device 5 are 
controlled by a hydraulic sequence control system in any normal manner. 
From the foregoing, it can be seen that the apparatus according to the 
present invention is capable of economically and efficiently shaping the 
support ears of a plurality of anodes to be supplied to an electrolyzing 
cell on a large scale. In addition, contacting the anodes with bus bars is 
improved significantly to reduce cell voltage. 
Obviously, many modifications and variations of the present invention are 
made possible in the light of the above teachings. It is therefore to be 
understood that within the scope of the appended claims, the invention may 
be practiced otherwise than as specifically described.