Continuous vacuum suction casting system and method for rare earth metal electrolytic furnace

Abstract

The present application provides a continuous vacuum suction casting system and method for a rare earth metal electrolytic furnace, and relates to the field of metal casting technology. The continuous vacuum suction casting system includes a vacuum system, a furnace-out moving vehicle and an AGV moving vehicle; the furnace-out moving vehicle can move between multiple rare earth electrolytic furnaces to extract rare earth metal liquid and perform vacuum suction casting operations, and the furnace-out moving vehicle includes a movable furnace-out vehicle body, a vacuum ingot casting mechanism and a driving mechanism. The vacuum ingot casting mechanism is equipped with two ingot mold stations, which can alternately form a vacuum suction casting working chamber, and provide a vacuum environment through a vacuum system. The siphon is connected to the rare earth electrolytic furnace for conveying the rare earth metal liquid to the ingot mold. The driving mechanism can change the position of the vacuum suction casting working chamber on the two ingot mold stations between different ingot mold stations by cooperating with the lifting device. The AGV moving vehicle is responsible for conveying the cast ingot mold and the empty ingot mold. The system can improve the efficiency of rare earth metal ingot casting and achieve continuous and stable production.

Description

Technical Field

[0001] The present application relates to the technical field of metal casting, and in particular to a continuous vacuum suction casting system and method for a rare earth metal electrolytic furnace. Background Art

[0002] Due to their unique optical, electrical, and magnetic properties, rare earth metals are widely used in high-tech fields such as electronics, new energy, and aerospace. Rare earth metals are typically produced using molten salt electrolysis, which generates molten rare earth metal liquid. This electrolysis process requires a specific ingot casting process to convert the molten metal into ingots for subsequent processing and application. The ingot casting process in rare earth metal smelting is a crucial step influencing product quality and production efficiency. Precisely casting the high-temperature molten rare earth metal liquid into a mold and achieving continuous and efficient production during the smelting process is a major technical challenge in this field.

[0003] Current methods for casting rare earth metal ingots primarily include manual scooping, the crucible method, and vacuum casting. Manual scooping is complex, inefficient, labor-intensive, and difficult to control ingot quality, leading to its gradual elimination. While the crucible method reduces manual intervention, it is complex and requires bulky equipment, making it unsuitable for large-scale production. While vacuum casting, which uses a vacuum to draw molten metal into a mold, achieves a degree of automation, existing equipment typically utilizes a single mold and a single furnace discharge system, leading to production interruptions and low efficiency.

[0004] The biggest drawback of current vacuum casting processes is their inability to achieve continuous and efficient ingot casting. Existing systems typically only process a single mold, requiring production to be interrupted to replace the mold after casting, resulting in low production efficiency. Therefore, a system that can improve production efficiency and achieve continuous ingot casting is urgently needed to meet the needs of modern rare earth metal smelting. Summary of the Invention

[0005] The present application provides a continuous vacuum suction casting system and method for a rare earth metal electrolytic furnace, which are used to solve the problems of low production efficiency and inability to continuously cast ingots in the existing rare earth metal ingot casting method.

[0006] In order to solve the above technical problems, this application adopts the following technical solutions:

[0007] In one aspect, the present application provides a continuous vacuum suction casting system for a rare earth metal electrolytic furnace. The system comprises a vacuum system, a furnace discharge mobile vehicle, and an AGV (Automated Guided Vehicle).

[0008] The vacuum system is used to provide a vacuum suction casting environment;

[0009] The furnace-discharging moving vehicle is used to move between multiple rare earth electrolytic furnaces to extract rare earth metal liquid from the rare earth electrolytic furnaces for vacuum suction casting. The furnace-discharging moving vehicle includes a movable furnace-discharging vehicle body, a vacuum ingot casting mechanism equipped with two ingot mold stations, and a driving mechanism capable of lifting and moving operations; the vacuum ingot casting mechanism is arranged above the furnace-discharging vehicle body and is connected to the vacuum system. The vacuum ingot casting mechanism can alternately form a vacuum suction casting working chamber on the two ingot mold stations. The vacuum suction casting working chamber is provided with a vacuum environment by the vacuum system, and the vacuum suction casting working chamber is connected to the vacuum system. A siphon tube is provided extending outside the vacuum ingot casting mechanism, and an ingot mold is placed on each of the two ingot mold stations. One end of the siphon tube is used to transport the rare earth metal liquid required for ingot casting to the ingot mold in the vacuum suction casting operation chamber, and the other end of the siphon tube is connected to the rare earth electrolytic furnace to extract the rare earth metal liquid. The driving mechanism is provided on one side of the furnace discharge vehicle body, and the driving mechanism is connected to a lifting device located above the vacuum ingot casting mechanism. The lifting device can alternately change the position of the vacuum suction casting operation chamber on the two ingot mold stations under the control of the driving mechanism.

[0010] The AGV mobile car is used to transport the ingot mold after the ingot casting is completed from the furnace-discharging mobile car and can transport the empty ingot mold back to the furnace-discharging mobile car;

[0011] The vacuum ingot casting mechanism comprises an ingot casting box bottom, a vacuum box cover and an electric heating plate;

[0012] The bottom of the ingot box is provided with two ingot mold stations on its upper surface for carrying the ingot mold, so as to support the vacuum suction casting operation during the ingot casting process;

[0013] The vacuum box cover is arranged on the bottom of the ingot box, an exhaust hole is arranged on the top of the vacuum box cover and is connected to the vacuum system through the exhaust hole, the side of the vacuum box cover is connected to the siphon tube, the vacuum box cover can be sealed and buckled on any of the ingot mold stations on the bottom of the ingot box, and the vacuum box cover can form a sealed vacuum suction casting working chamber with the ingot box bottom during the ingot casting process;

[0014] The electric heating plates are used to preheat the ingot mold. There are two groups of electric heating plates. Both groups of electric heating plates are arranged in the bottom of the ingot box and correspond to the two ingot mold stations respectively.

[0015] In an optional embodiment, the vacuum box cover and the ingot box bottom are sealed by a convex-groove matching structure, and the ingot box bottom is provided with a circle of grooves on the two ingot mold stations for sealing and fastening the vacuum box cover, and the grooves are provided with sealing rings.

[0016] In an optional embodiment, the ingot mold is a multi-cavity structure, which is provided as at least two mutually isolated casting cavities, and the ingot mold is provided with an overflow trough above the connection between adjacent casting cavities.

[0017] In an optional embodiment, the ingot mold is composed of 15 independent casting cavities, and the 15 casting cavities are distributed in a 3×5 matrix. Each casting cavity has a stepped structure that is narrow at the bottom and wide at the top. The inclination angle of the cavity side wall of the casting cavity is not less than 19°, and the boundary of the casting cavity is provided with a circular chamfer, and the chamfer radius is not less than 20 mm.

[0018] In an optional embodiment, the driving mechanism includes a hydraulic lifting cylinder and a single-arm crane;

[0019] The hydraulic lifting cylinder is vertically fixedly installed on one side of the exterior of the furnace unloading vehicle body, and the output end of the hydraulic lifting cylinder is vertically upward;

[0020] The single-arm crane is arranged above the hydraulic lifting cylinder and is connected to the output end of the hydraulic lifting cylinder. The lifting device is connected to the single-arm crane, which can enable the lifting device to switch positions between the two ingot mold stations and perform lifting and positioning operations. The lifting device is a hook.

[0021] In an optional embodiment, the vacuum system includes a vacuum pump, a vacuum tank, a vacuum pipe and a time relay;

[0022] The vacuum pump is used to extract air to form a negative pressure environment during the vacuum suction casting operation, and the vacuum pump is connected to the vacuum casting mechanism through the vacuum pipe;

[0023] The vacuum tank is connected to the vacuum pump and is used to store gas during the vacuum extraction process;

[0024] The vacuum pipe connects the vacuum pump and the vacuum ingot casting mechanism and is used to quickly extract vacuum during the ingot casting operation;

[0025] The time relay is electrically connected to the vacuum pump and is used to control the pumping time of the vacuum pump to ensure that the extraction amount of the rare earth metal liquid is within a predetermined range.

[0026] In an optional embodiment, the rare earth electrolytic furnace has an upper anode and cathode structure, and a receiver for connecting to the siphon is provided below the rare earth electrolytic furnace. The receiver can be used to receive rare earth metal liquid and provide a metal liquid flow interface for the siphon.

[0027] In an optional embodiment, the furnace-discharging car body is an electrically driven car body.

[0028] On the other hand, the present application also provides a method for continuous vacuum casting in a rare earth metal electrolytic furnace, which uses the continuous vacuum casting system provided by the present application, including the following steps:

[0029] Step 1: Start the vacuum casting operation through the vacuum system to form a negative pressure environment and form a vacuum casting operation cavity on one of the ingot mold stations;

[0030] Step 2: The furnace unloading mobile vehicle moves to the bottom of the rare earth electrolytic furnace and connects the siphon tube to the rare earth electrolytic furnace;

[0031] Step 3: extracting the molten rare earth metal liquid from the rare earth electrolysis furnace through a siphon and transporting it to the ingot mold at the ingot mold station where the vacuum suction casting operation cavity is formed;

[0032] Step 4: After the rare earth metal liquid is injected into the ingot mold, the vacuum system is controlled to maintain a vacuum environment, so that the rare earth metal liquid cools and solidifies in the ingot mold until the ingot is cast;

[0033] Step 5: After the ingot casting operation is completed in the vacuum casting working chamber, the driving mechanism is controlled to transfer the vacuum casting working chamber to another ingot mold station through the lifting device to continue the ingot casting operation;

[0034] Step 6: The AGV mobile vehicle transports the completed ingot mold to the demoulding area, and transports the empty ingot mold back to the furnace mobile vehicle to prepare for the next round of ingot casting operations;

[0035] Step 7: Repeat steps 3 to 6 to perform continuous rare earth metal ingot casting.

[0036] Compared with the prior art, this application has the following beneficial effects:

[0037] 1. The present application is for a continuous vacuum suction casting system for a rare earth metal electrolytic furnace. The vacuum ingot casting mechanism used is designed to have two ingot mold stations, and a vacuum suction casting working chamber can be alternately formed at these two ingot mold stations. Through this double-station design, after the furnace moving vehicle completes the ingot casting operation in one ingot mold, it can immediately control the lifting device through the drive mechanism to transfer the vacuum suction casting working chamber to another ingot mold station, thereby continuing the ingot casting operation. This alternating working mode greatly shortens the downtime of the equipment. Unlike the single mold operation in the prior art, it can achieve more continuous and efficient ingot casting operations, solving the problem in the prior art that the ingot casting process requires frequent mold replacement, resulting in low production efficiency. In addition, the double-station layout allows production to be replaced without affecting the mold, which helps to improve the continuity and operating efficiency of the overall production line.

[0038] 2. The vacuum system of the present application is connected to the vacuum ingot casting mechanism to provide a stable vacuum environment for the vacuum suction casting working chamber. At the same time, one end of the siphon tube is connected to the rare earth electrolytic furnace, and the other end extends into the vacuum suction casting working chamber, which is used to accurately transport the molten rare earth metal liquid to the ingot mold in the vacuum suction casting working chamber. The present application combines the vacuum system and the siphon tube with the vacuum ingot casting mechanism and applies them in the continuous vacuum suction casting system of the present application. It can better ensure that the metal liquid is sucked into the ingot mold in the vacuum suction casting working chamber under the control of the vacuum system, avoiding the problem of unstable metal liquid amount control in traditional technology and preventing the quality difference of the ingot caused by excessive or insufficient metal liquid. Through such a structural method, the present application realizes the precise transportation and vacuum suction casting of rare earth metal liquid, which can better ensure the stability of the metal liquid amount in the ingot mold, thereby improving the dimensional accuracy and consistency of the ingot.

[0039] 3. The furnace-discharging mobile car used in this application sets the vacuum ingot casting mechanism equipped with two ingot mold stations on the movable furnace-discharging mobile car body, and cooperates with the setting of the AGV mobile car and the driving mechanism, so that the furnace-discharging mobile car carrying the vacuum ingot casting mechanism can not only move between multiple rare earth electrolytic furnaces to perform ingot casting operations, making it a movable operating system, but also can replace the mold at the two ingot mold stations without affecting continuous production. The position of the vacuum suction casting working cavity can be flexibly adjusted through the lifting device on the driving mechanism, and the AGV mobile car is responsible for transporting the completed ingot mold from the furnace-discharging mobile car and returning the empty ingot mold; adopting this method greatly reduces manual intervention and improves the safety and efficiency of the production process. In particular, through the controllable transportation of the AGV mobile car, the various steps of the ingot casting process can be well connected, avoiding the delays and safety hazards of manual operation in traditional processes, making the entire production process more automated, and significantly improving the reliability and safety of production, meeting the needs of modern efficient large-scale production. BRIEF DESCRIPTION OF THE DRAWINGS

[0040] In order to more clearly illustrate the embodiments of the present application or the technical solutions in the prior art, a brief introduction will be given below to the drawings required for use in the embodiments or the description of the prior art. Obviously, the drawings described below are some embodiments of the present application. For ordinary technicians in this field, other drawings can be obtained based on these drawings without any creative work.

[0041] Figure 1 A schematic diagram of a continuous vacuum suction casting system for a rare earth metal electrolysis furnace provided in one embodiment of the present application;

[0042] Figure 2 A schematic diagram of the structure of a furnace-unloading mobile vehicle provided in one embodiment of the present application;

[0043] Figure 3 A schematic diagram of the structure of the vacuum box without the cover provided in one embodiment of the present application;

[0044] Figure 4 A schematic structural diagram of the unloading mobile vehicle provided in one embodiment of the present application from another angle;

[0045] Figure 5 A schematic structural diagram of an ingot mold provided in one embodiment of the present application;

[0046] Figure 6 A schematic flow chart of a method for continuous vacuum suction casting in a rare earth metal electrolytic furnace provided in one embodiment of the present application.

[0047] Description of reference numerals:

[0048] 100. Vacuum system; 110. Vacuum pump; 120. Vacuum tank; 130. Vacuum pipe; 140. Time relay; 200. Unloading vehicle; 210. Unloading vehicle body; 220. Vacuum ingot casting mechanism; 2201. Ingot mold station; 2202. Vacuum suction casting working chamber; 2203. Siphon; 2204. Ingot mold; 22041. Casting cavity; 22042. Overflow trough; 221. Ingot box bottom; 2211. Groove; 222. Vacuum box cover; 223. Electric heating plate; 230. Driving mechanism; 2301. Lifting device; 231. Hydraulic lifting cylinder; 232. Single-arm crane; 300. AGV mobile vehicle; 400. Rare earth electrolytic furnace; 410. Receiver. DETAILED DESCRIPTION

[0049] To make the purpose, technical solutions, and advantages of the embodiments of this application more clear, the technical solutions in the embodiments of this application are clearly and completely described below. Obviously, the described embodiments are part of the embodiments of this application, not all of them. Based on the embodiments in this application, all other embodiments obtained by ordinary technicians in this field without making creative efforts also fall within the scope of protection of this application.

[0050] In the description of this application, it should be understood that the terms "center", "up", "down", "front", "back", "left", "right", "vertical", "horizontal", "top", "bottom", "inside", "outside", etc., indicating the orientation or position relationship, are based on the orientation or position relationship shown in the accompanying drawings, and are only for the convenience of describing this application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation on this application.

[0051] The terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance or implicitly specifying the number of the technical features being referred to. Thus, a feature specified as "first" or "second" may explicitly or implicitly include one or more of such features. Throughout this application, unless otherwise specified, "plurality" means two or more.

[0052] In the description of this application, it should be noted that, unless otherwise specified or limited, the terms "installed," "connected," and "connected" should be understood in a broad sense. For example, they can refer to fixed connections, detachable connections, or integral connections. Those skilled in the art will understand the specific meanings of these terms in this application based on the specific circumstances.

[0053] refer to Figures 1 to 6 , Figure 1 A schematic diagram of a continuous vacuum suction casting system for a rare earth metal electrolysis furnace provided in one embodiment of the present application; Figure 2 A schematic diagram of the structure of a furnace-unloading mobile vehicle provided in one embodiment of the present application; Figure 3 A schematic diagram of the structure of the vacuum box without the cover provided in one embodiment of the present application; Figure 4 A schematic structural diagram of the unloading mobile vehicle provided in one embodiment of the present application from another angle; Figure 5 A schematic structural diagram of an ingot mold provided in one embodiment of the present application; Figure 6 This is a flow chart of a method for continuous vacuum casting of rare earth metal electrolytic furnaces provided in one embodiment of the present application. Figure 1-Figure 5 As shown, the continuous vacuum suction casting system for a rare earth metal electrolytic furnace provided in the embodiment of the present application includes a vacuum system 100, a furnace-discharging mobile vehicle 200, and an AGV mobile vehicle 300. The detailed description is as follows:

[0054] The vacuum system 100 is used to provide a vacuum suction casting environment.

[0055] The furnace-discharging moving vehicle 200 is used to move between multiple rare earth electrolytic furnaces 400 to extract rare earth metal liquid from the rare earth electrolytic furnaces 400 for vacuum suction casting. The furnace-discharging moving vehicle 200 includes a movable furnace-discharging vehicle body 210, a vacuum ingot casting mechanism 220 equipped with two ingot mold stations 2201, and a driving mechanism 230 capable of lifting and moving operations; Figure 1 As shown, the vacuum casting mechanism 220 is arranged above the furnace car body 210 and is connected to the vacuum system 100. The vacuum casting mechanism 220 can alternately form a vacuum suction casting working chamber 2202 on the two ingot mold stations 2201. The vacuum suction casting working chamber 2202 is provided with a vacuum environment by the vacuum system 100. Figure 2As shown, a siphon 2203 extending to the outside of the vacuum casting mechanism 220 is connected to the vacuum casting chamber 2202, and an ingot mold 2204 is placed on each of the two ingot mold stations 2201. One end of the siphon 2203 is used to transport the rare earth metal liquid required for ingot casting to the ingot mold 2204 in the vacuum casting chamber 2202. Figure 2 As shown, the other end of the siphon tube 2203 is connected to the rare earth electrolytic furnace 400 to extract the rare earth metal liquid; the driving mechanism 230 is arranged on one side of the furnace car body 210, and the driving mechanism 230 is connected to a lifting device 2301 located above the vacuum ingot casting mechanism 220. The lifting device 2301 can alternately change the position of the vacuum suction casting working chamber 2202 on the two ingot mold stations 2201 under the control of the driving mechanism 230.

[0056] The AGV mobile vehicle 300 is used to transport the completed ingot mold 2204 from the furnace-outgoing mobile vehicle 200 and can transport the empty ingot mold 2204 back to the furnace-outgoing mobile vehicle 200.

[0057] The embodiment of the present application is a continuous vacuum suction casting system for a rare earth metal electrolytic furnace. The vacuum ingot casting mechanism 220 used is designed to have two ingot mold stations 2201, and a vacuum suction casting working chamber 2202 can be alternately formed on these two ingot mold stations 2201. Through this double-station design, after the furnace moving vehicle completes the ingot casting operation on one ingot mold 2204, it can immediately control the lifting device through the drive mechanism to transfer the vacuum suction casting working chamber 2202 to another ingot mold station 2201, thereby continuing the ingot casting operation. This alternating working mode greatly shortens the downtime of the equipment. Unlike the single mold operation in the prior art, it can achieve more continuous and efficient ingot casting operations, solving the problem in the prior art that the ingot casting process requires frequent mold replacement, resulting in low production efficiency. In addition, the double-station layout does not affect production while changing the mold, which helps to improve the continuity and operating efficiency of the overall production line.

[0058] In the embodiment of the present application, the vacuum system 100 is connected to the vacuum casting mechanism 220 to provide a stable vacuum environment for the vacuum suction casting operation chamber 2202. At the same time, one end of the siphon tube 2203 is connected to the rare earth electrolytic furnace, and the other end extends into the vacuum suction casting operation chamber 2202, for accurately conveying the molten rare earth metal liquid to the ingot mold 2204 in the vacuum suction casting operation chamber 2202. The embodiment of the present application combines the vacuum system 100 and the siphon tube 2203 with the vacuum casting mechanism 220 in the continuous vacuum suction casting system of the present application, which can better ensure that the molten metal is sucked into the ingot mold 2204 in the vacuum suction casting operation chamber 2202 under the control of the vacuum system 100, avoiding the problem of unstable metal liquid amount control in traditional technology and preventing the quality difference of the ingot caused by excessive or insufficient metal liquid. Through such a structural method, the present application realizes the precise conveying and vacuum suction casting of rare earth metal liquid, which can better ensure the stability of the metal liquid amount in the ingot mold 2204, thereby improving the dimensional accuracy and consistency of the ingot.

[0059] The continuous vacuum suction casting system for a rare earth metal electrolytic furnace of the embodiment of the present application adopts a furnace-discharging moving vehicle 200, and sets a vacuum ingot casting mechanism 220 equipped with two ingot mold stations 2201 on a movable furnace-discharging vehicle body 210, and cooperates with the setting of the AGV moving vehicle 300 and the driving mechanism 230, so that the furnace-discharging moving vehicle 200 carrying the vacuum ingot casting mechanism 220 can not only move between multiple rare earth electrolytic furnaces 400 to perform ingot casting operations, making it a movable operating system, but also can replace the mold at the two ingot mold stations 2201 without affecting the continuous generation, through the starting and stopping of the driving mechanism 230. The lifting device 2301 can flexibly adjust the position of the vacuum casting working chamber 2202, and the AGV mobile vehicle 300 is responsible for transporting the completed ingot mold 2204 from the furnace-discharging mobile vehicle 200 and returning the empty ingot mold 2204; this method greatly reduces manual intervention and improves the safety and efficiency of the production process. In particular, through the controllable transportation of the AGV mobile vehicle 300, the various steps of the ingot casting process can be well connected, avoiding delays and safety hazards caused by manual operations in traditional processes, making the entire production process more automated, significantly improving production reliability and safety, and meeting the needs of modern efficient large-scale production.

[0060] In some embodiments, as Figure 4 As shown, the vacuum ingot casting mechanism 220 includes an ingot box bottom 221, a vacuum box cover 222 and an electric heating plate 223; specifically:

[0061] The ingot box bottom 221 has two ingot mold stations 2201 on its upper surface for carrying ingot molds 2204, which are used to support vacuum suction casting during the ingot casting process.

[0062] The vacuum box cover 222 is arranged on the ingot box bottom 221. An exhaust hole is provided above the vacuum box cover 222 and is connected to the vacuum system 100 through the exhaust hole. The side of the vacuum box cover 222 is connected to a siphon tube 2203. The vacuum box cover 222 can be sealed and buckled on any ingot mold station 2201 on the ingot box bottom 221, and the vacuum box cover 222 can form a sealed vacuum suction casting working chamber 2202 with the ingot box bottom 221 during the ingot casting process.

[0063] The electric heating plate 223 is used to preheat the ingot mold 2204. Figure 4 As shown, there are two groups of electric heating plates 223 , both of which are arranged in the ingot box bottom 221 and correspond one to one with the two ingot mold stations 2201 .

[0064] In this embodiment, two ingot mold stations 2201 are provided on the upper surface of the ingot casting box bottom 221 for carrying the ingot mold 2204 and supporting the vacuum suction casting operation. During use, the setting of the two ingot mold stations 2201 allows one ingot mold 2204 to perform ingot casting while the other ingot mold station 2201 can be preheated or perform other preparatory work. Such a double-station design can reduce the downtime of the operation and improve the overall operating efficiency of the production line. Moreover, through the alternating operation of the double stations, the ingot casting box bottom 221 can carry more ingot casting tasks, and there is no need to frequently change the mold during operation, which reduces the production interruption caused by changing the mold in the traditional single-station system.

[0065] Furthermore, in this embodiment, a vacuum chamber cover 222 is positioned on the ingot casting chamber bottom 221 and is connected to the vacuum system 100 via an exhaust port, forming a vacuum casting chamber 2202. A siphon tube 2203 is also connected to the side of the vacuum chamber cover 222 for transferring molten metal. This structural design allows the vacuum chamber cover 222 to seal against the ingot mold station 2201, located on the ingot casting chamber bottom 221, during use, ensuring a stable vacuum environment within the vacuum casting chamber 2202. This sealing structure not only prevents gas leakage but also maintains uniform pressure, ensuring smooth ingot casting. Furthermore, an exhaust port is provided above the vacuum chamber cover 222, connecting it to the vacuum system 100 via the exhaust port. During use, when the vacuum system 100 is turned on, the vacuum chamber cover 222 maintains the vacuum level within the vacuum casting chamber 2202, and in conjunction with the siphon tube 2203, ensures stable extraction and transfer of the rare earth metal liquid. This structure avoids the problem of ingot quality degradation caused by gas intrusion. At the same time, the vacuum box cover 222 can be flexibly moved between the two ingot mold stations 2201. This flexible sealing design greatly improves the continuity of the ingot casting operation and the flexibility of operation, and adapts to the needs of double-station continuous production.

[0066] Furthermore, in this embodiment, an electric heating plate 223 is provided in the bottom of the ingot box 221. The electric heating plate 223 can be used to preheat the ingot mold 2204. The number of electric heating plates 223 is two groups, and they correspond one to one with the two ingot mold stations 2201. During use, the electric heating plate 223 can preheat the ingot mold 2204 before ingot casting, and can maintain the fluidity of the rare earth metal liquid when entering the ingot mold 2204, preventing the rare earth metal liquid from prematurely condensing or slag inclusion in the mold, thereby ensuring the quality of the ingot. Moreover, the preheating function of the electric heating plate 223 ensures that the temperature of the rare earth metal liquid remains consistent during each ingot casting process, so that the quality of each batch of castings is uniform and stable, reducing product defects or quality inconsistencies caused by mold temperature differences. Since the two sets of electric heating plates 223 correspond one-to-one with the two ingot mold stations 2201, the two ingot molds 2204 can be preheated at the same time, so that when one ingot mold station 2201 is performing ingot casting, the other ingot mold station 2201 can simultaneously complete preheating preparations, shortening the production cycle and improving energy efficiency. Compared with the existing technology that relies on ambient temperature or overall heating, this embodiment uses a preheating design of two sets of electric heating plates 223, which is highly targeted. By using the electric heating plates 223 corresponding to the two ingot mold stations 2201, a precise preheating function can be achieved, ensuring that the rare earth metal liquid maintains optimal fluidity when entering the ingot mold, significantly improving the uniformity and quality of the ingots.

[0067] It should also be noted that the continuous vacuum suction casting system for a rare earth metal electrolytic furnace provided in the embodiments of the present application can also achieve uniform and stable cooling of rare earth metal liquid during the rare earth metal production process. Detailed description is as follows:

[0068] The vacuum system 100 of the embodiment of the present application provides a low-pressure environment. Within the vacuum casting chamber 2202, air is extracted by the vacuum system 100 to create a negative pressure environment, significantly reducing the amount of air and gas within the vacuum casting chamber 2202. Because heat conduction and convection are weakened in a low-pressure environment, the rare earth metal liquid dissipates heat primarily through radiation, minimizing environmental impact while avoiding contamination and oxidation. This approach prevents the formation of bubbles or oxides during the cooling of the molten metal, resulting in more uniform solidification.

[0069] In addition, the dual-station design allows each ingot mold station 2201 to independently complete the ingot casting operation and cooling process without affecting the work of the other station. In this way, cooling can be carried out quickly without waiting for the entire system to complete a cycle, avoiding the stagnation time in the traditional single-station system. In this embodiment, by switching the vacuum suction casting working chamber 2202 between different ingot mold stations 2201, the vacuum suction casting working chamber 2202 can promptly carry out the next round of casting operation, while the ingot mold station 2201 that has completed the ingot casting can be cooled independently. This continuous operation mode not only improves the cooling efficiency, but also greatly reduces the cooling waiting time between each round of ingot casting.

[0070] Furthermore, the embodiment of the present application extracts rare earth metal liquid from the rare earth electrolysis furnace 400 via siphon 2203, enabling the rare earth metal liquid to be transferred to the ingot mold 2204 at a stable and appropriate temperature. During the transfer process, the closed nature of the transfer reduces heat exchange with the external environment, preventing the rare earth metal liquid from cooling too rapidly during transfer, thereby ensuring stable cooling of the rare earth metal liquid after entering the ingot mold. The present application utilizes this closed transfer design for the rare earth metal liquid, preventing the influence of environmental factors (such as air or impurities) on the temperature of the rare earth metal liquid, ensuring that the rare earth metal liquid begins to cool and solidify rapidly only after entering the ingot mold 2204, thereby improving product quality.

[0071] In some embodiments, the vacuum box cover 222 and the ingot box bottom 221 are sealed by a convex-concave matching structure, such as Figure 2 and Figure 3 As shown, the ingot box bottom 221 is provided with a circle of grooves 2211 on the two ingot mold stations 2201 for sealing and fastening the vacuum box cover 222, and the grooves 2211 are provided with sealing rings.

[0072] In this embodiment, the vacuum box cover 222 and the ingot box bottom 221 are sealed with a convex-groove structure, and a sealing ring is provided in the groove 2211. This sealing design makes full use of the combination of mechanical locking and elastic sealing materials, thereby ensuring the airtightness of the vacuum suction casting working chamber 2202 formed.

[0073] Specifically, the mechanical fit of the convex-concave structure between the vacuum box cover 222 and the ingot box bottom 221 enables the vacuum box cover 222 to be tightly fastened on the ingot box bottom 221, ensuring that there is no obvious gap. The addition of the sealing ring provides an additional elastic sealing layer, further improving the sealing performance and preventing gas leakage, thereby ensuring the stability of the negative pressure environment in the vacuum suction casting operation chamber 2202. This double-layer sealing design exhibits excellent airtightness and stability under vacuum conditions. Moreover, the application of the sealing ring can resist the thermal expansion and contraction effects of the material caused by temperature changes during operation, ensuring that the vacuum degree will not fluctuate or decrease due to such effects, and can meet the requirements of continuous production operations for a stable vacuum environment. Traditional mechanical sealing structures are prone to leakage due to external shocks, vibrations or pressure changes, while the embodiments of the present application can resist these external interferences through the double sealing of the convex-concave fitting and the sealing ring, ensuring the stability of the vacuum environment and greatly improving the reliability of the system.

[0074] In this embodiment, grooves 2211 are provided on both ingot mold stations 2201 on the ingot casting box bottom 221. These grooves 2211 engage with the vacuum box cover 222 via convex and concave portions. During each operation, the vacuum box cover 222 is simply snapped into place with the corresponding ingot mold station 2201 to achieve a quick seal, eliminating the need for complex steps. This simplifies the process and improves efficiency.

[0075] It can be seen that the vacuum box cover 222 and the ingot box bottom 221 are sealed by a convex-concave structure, which enables the vacuum box cover 222 to be quickly buckled onto the ingot box bottom 221 and sealed. During use, only a simple mechanical locking action is required, which greatly shortens the operation preparation time and improves the overall production efficiency. Moreover, due to the simplification of the sealing design, when the ingot mold 2204 needs to be replaced, the vacuum box cover 222 can be removed by simply pulling and unlocking the vacuum box cover 222, and then moved to another ingot mold station 2201. Compared with traditional bolt fixing or snap fixing methods, this design can ensure quick replacement without reducing the sealing effect. In addition, the sealing ring in the groove 2211 has a long service life and low replacement cost. Even after multiple operations, it can maintain a good sealing effect. Therefore, this matching structure is not only easy to operate, but also has low maintenance costs, which improves the economy and sustainability of the production system.

[0076] In addition, the vacuum box cover 222 is connected to the ingot box bottom 221 through the groove 2211 and the sealing ring, which enables the vacuum box cover 222 to be flexibly moved and operated between the two ingot mold stations 2201. The convex-groove matching structure can adapt to the use requirements of the ingot mold station 2201, and the vacuum box cover 222 can be flexibly switched between the two ingot mold stations 2201, providing a highly flexible production layout that is suitable for a multi-task parallel production environment. Moreover, this sealing structure allows the system to be expanded or adjusted in the future. For example, when production demand increases, ingot mold stations can be added without making large-scale changes to the existing vacuum system. This design can be flexibly expanded as production needs change. In addition, the convex-groove matching structure and the sealing ring design allow any worn or damaged parts to be easily replaced without the need for large-scale disassembly of the entire system, thereby reducing downtime and improving the maintenance efficiency of the system.

[0077] like Figure 5 As shown, in some embodiments, the ingot mold 2204 is a multi-cavity structure, which is provided with at least two mutually isolated casting cavities 22041 , and the ingot mold 2204 is provided with an overflow trough 22042 above the connection between adjacent casting cavities 22041 .

[0078] In this embodiment, the multi-cavity structure design of the ingot mold 2204 can ensure that the rare earth metal liquid is distributed more evenly to each independent casting cavity 22041 during the ingot casting process, avoiding the uneven distribution of rare earth metal liquid due to the excessive volume of a single cavity. Through this independent cavity design, the consistency of the ingot can be improved and the quality of each casting can be ensured to be stable. Moreover, the multiple isolated casting cavities 22041 can effectively control the flow of rare earth metal liquid and reduce the phenomenon of impurities such as bubbles and slag inclusions being deposited in a single large cavity, thereby reducing the incidence of ingot casting defects. This design is easier to control quality problems during the ingot casting process than the existing single-cavity structure. Since the ingot mold 2204 uses multiple casting cavities 22041, multiple casting cavities 22041 can perform ingot casting operations at the same time. Compared with a single cavity, more castings can be produced in the same time, thereby improving overall production efficiency.

[0079] In addition, the ingot mold 2204 is provided with an overflow groove 22042 above the connection between adjacent casting cavities 22041. This design can effectively control the flow of rare earth metal liquid, so that the rare earth metal liquid can be better filled in each casting cavity 22041, and can prevent the rare earth metal liquid from excessively overflowing outside the ingot mold 2204 when entering a certain casting cavity 22041, thereby helping to ensure that the metal liquid in each casting cavity 22041 remains uniform and appropriate, and prevent overflow from affecting the quality of the casting.

[0080] The presence of overflow trough 22042 effectively controls the flow path of the rare earth metal liquid, ensuring a consistent amount of rare earth metal liquid entering each mold cavity 22041. This avoids problems such as uneven casting and casting defects caused by excessive rare earth metal liquid entering a particular mold cavity 22041. Furthermore, the presence of overflow trough 22042 not only ensures uniform distribution of the rare earth metal liquid, but also reduces operational difficulties and control issues caused by excessive accumulation of rare earth metal liquid, making the casting process more stable and controllable, and effectively improving the reliability of the ingot casting process.

[0081] In some embodiments, as Figure 5 As shown, the ingot mold 2204 is composed of 15 independent casting cavities 22041, and the 15 casting cavities 22041 are distributed in a 3×5 matrix. Each casting cavity 22041 is a stepped structure that is narrow at the bottom and wide at the top. The inclination angle of the cavity side wall of the casting cavity 22041 is not less than 19°, and the boundary of the casting cavity 22041 is provided with a circular chamfer, and the chamfer radius is not less than 20 mm.

[0082] In this embodiment, the ingot mold 2204 is composed of 15 independent casting cavities 22041, which are arranged in a 3×5 matrix structure. Each casting cavity 22041 is an independent casting unit. This 3×5 matrix design can simultaneously cast 15 independent castings in the same operation cycle. Compared with the single-cavity mold structure, this multi-cavity design significantly increases the number of ingots per unit time, thereby improving the production efficiency of the production line. Moreover, the multi-cavity structure ensures that the rare earth metal liquid can be evenly distributed in each cavity. Such uniform distribution reduces the uneven flow or poor solidification that may occur during the casting process, which is conducive to ensuring the quality consistency of each casting.

[0083] In addition, this embodiment further optimizes the ingot mold 220415 from the perspective of the ingot demolding process. In this embodiment, each casting cavity 22041 has a stepped structure that is narrow at the bottom and wide at the top. The sidewalls of the casting cavity 22041 have an inclination angle of no less than 19°, which not only ensures fluidity during the casting process but also ensures smooth demolding. Specifically, the stepped structure, narrow at the bottom and wide at the top, allows the rare earth metal liquid to flow naturally downward within the casting cavity 22041. At the same time, the sidewall inclination angle of more than 19° helps the liquid evenly fill the entire cavity, avoiding accumulation of molten metal in corners. This optimized design significantly improves fluidity during the casting process.

[0084] The narrow-at-the-bottom, wide-at-the-top stepped structure of the mold cavity 22041, along with the angled design of the cavity sidewalls, ensures smooth demolding of the casting after cooling and solidification. This reduces friction between the casting and the mold, lowering the risk of damage during demolding. This structure significantly improves the efficiency of demolding ingots, especially in large-scale production. Furthermore, the stepped structure and angled design help reduce defects such as slag inclusions and condensation during the casting process, improving the uniformity and smoothness of the casting surface quality and avoiding surface irregularities and holes common in existing technologies.

[0085] The boundary of the mold cavity 22041 is provided with a circular chamfer with a chamfer radius of not less than 20mm. This design can effectively prevent defects caused by stress concentration during the casting process. The circular chamfer design can effectively reduce stress concentration during the cooling process of the ingot, especially in the corners of the mold. The chamfer can alleviate the local stress caused by thermal expansion and contraction, reducing the risk of cracks or breakage in the corners of the casting. The chamfer design not only optimizes the quality of the casting during the ingot casting process, but also reduces the difficulty of mold cleaning and maintenance. The chamfered area is not prone to the accumulation of metal residues or impurities, which extends the service life of the mold and facilitates the cleaning and maintenance of the mold.

[0086] In some embodiments, the driving mechanism 230 includes a hydraulic lifting cylinder 231 and a single-arm crane 232 .

[0087] The hydraulic lifting cylinder 231 is vertically fixedly installed on one side of the exterior of the furnace-unloading vehicle body 210 , and the output end of the hydraulic lifting cylinder 231 is vertically upward.

[0088] The single-arm crane 232 is arranged above the hydraulic lifting cylinder 231 and is connected to the output end of the hydraulic lifting cylinder 231. The single-arm crane 232 is connected to a lifting device 2301, which can enable the lifting device 2301 to switch positions between the two ingot mold stations 2201 and perform lifting and positioning operations. The lifting device 2301 is a hook.

[0089] In this embodiment, the drive mechanism 230 adopts a combined design of a hydraulic lifting cylinder 231 and a single-arm crane 232. The hydraulic lifting cylinder 231 is vertically fixedly mounted on the outer side of the furnace car body 210, with its output end facing vertically upward. During use, the hydraulic lifting cylinder 231 can achieve stable and precise vertical lifting movement, ensuring the up and down movement accuracy of each component during the ingot casting process. This precision is crucial for accurate lifting and placement operations and can avoid the error accumulation problem in traditional mechanical lifting. Moreover, the hydraulic lifting cylinder 231 has a large load-bearing capacity and can provide stable lifting power. Especially when frequent up and down movement is required, it ensures that there will be no shaking or instability during the lifting and placement process, ensuring the safety of the entire production process. In addition, the hydraulic system of the hydraulic lifting cylinder 231 can achieve smooth starting and stopping, providing a soft start-stop effect, which can reduce the damage to other components of the system caused by impact force, thereby extending the service life of the equipment.

[0090] The single-arm crane 232 ensures flexible switching and efficient operation between the two ingot mold stations 2201. In this embodiment, the single-arm crane 232 is arranged above the hydraulic lifting cylinder 231 and connected to the output end of the hydraulic lifting cylinder 231, taking on the task of horizontal movement between the two ingot mold stations 2201.

[0091] During use, the single-arm crane 232 cooperates with the hydraulic lifting cylinder 231 to enable the lifting device 2301 to switch horizontally between the two ingot mold stations 2201. This structural design greatly improves operational flexibility between stations and reduces switching time between stations, thereby improving production line efficiency. Through the horizontal movement of the single-arm crane, the lifting device can easily switch between different ingot mold stations, especially when frequent station changes are required, which can significantly improve production continuity and ease of operation.

[0092] Compared to traditional multi-arm manipulators, the single-arm crane 232 is more compact and occupies less space. It can achieve a larger horizontal range within the limited space of the vehicle, providing greater space advantages for the integration and optimization of the entire system. The lifting device 2301, connected to the single-arm crane 232, can switch between the two ingot mold stations 2201 and perform precise lifting and positioning operations. The lifting device 2301 uses a hook structure, which can stably lift the ingot molds.

[0093] During use, the lifting device 2301, guided by the single-arm crane 232, can achieve precise horizontal and vertical movement between the ingot mold stations 2201. This precise positioning capability is particularly important for ingot casting operations, as it ensures the precise positioning of the ingot mold within the ingot casting chamber, avoiding ingot quality issues caused by inaccurate positioning. Furthermore, the lifting device 2301 utilizes a hook structure, offering a simple design and ease of operation. It also possesses strong durability and is easy to maintain and service. This simple and effective lifting device not only reduces equipment maintenance costs but also extends its service life.

[0094] In an embodiment of the present application, the lifting device 2301 is mainly responsible for lifting the vacuum box cover 222 and lifting the ingot mold 2204. The lifting device 2301 lifts the vacuum box cover 222 during use so as to seal or open the ingot mold 2204 during the ingot casting operation. When the vacuum box cover 222 needs to be lifted, the lifting device 2301 is connected to the ear or hook reserved on the vacuum box cover through a hook. This connection method can be a snap-on or magnetic adsorption type, or a special mechanical clamp can be used to ensure a firm connection. After the connection is completed, the drive mechanism 230 controls the hydraulic lifting cylinder 231 to raise the output end of the hydraulic lifting cylinder 231, thereby lifting the lifting device 2301, and then driving the vacuum box cover 222 away from the ingot box bottom 221. When the vacuum chamber cover 222 needs to be transferred to another ingot mold station 2201, the lifting device 2301 is repositioned above the casting chamber bottom 221 by horizontally moving the single-arm crane 232. The lifting device 2301 is then raised and lowered by the hydraulic lift cylinder 231 to ensure accurate lifting and placement of the vacuum chamber cover 222, avoiding damage or interference to surrounding equipment and the casting station. After casting is complete, the lifting device 2301 lowers the vacuum chamber cover 222 again, resealing it with the casting chamber bottom 221 to form a vacuum casting chamber 2202, ensuring smooth and continuous casting operations. During operation, the lifting and lowering of the vacuum chamber cover 222 must be smooth and precise to avoid misalignment or damage to the vacuum chamber cover 222 and the casting chamber bottom 221 due to improper operation. During sealing, the vacuum chamber cover 222 maintains the integrity of the vacuum environment through a convex-concave groove structure and a sealing ring (such as an O-ring). The lifting device 2301 is used to lift and lower the ingot mold 2204. Since the ingot mold 2204 is usually heavy, a plurality of lifting lugs can be provided around the upper portion of the ingot mold 2204 during design to facilitate lifting the ingot mold 2204. In actual use, the lifting device 2301 and the ingot mold 2204 can be connected by a rope to smoothly lift the ingot mold 2204. During use, the lifting device 2301 can transfer the lifted ingot mold 2204 to the AGV mobile vehicle 300, which is responsible for transporting the ingot mold 2204 to the demoulding area, achieving smooth cooperation with the AGV mobile vehicle 300.

[0095] In some embodiments, as Figure 1 As shown, the vacuum system 100 includes a vacuum pump 110, a vacuum tank 120, a vacuum pipe 130, and a time relay 140. The vacuum pump 110 is used to extract air to create a negative pressure environment during vacuum suction casting. The vacuum pump 110 is connected to the vacuum casting mechanism 220 via the vacuum pipe 130. The vacuum tank 120 is connected to the vacuum pump 110 to store gas during the vacuum extraction process. The vacuum pipe 130 connects the vacuum pump 110 and the vacuum casting mechanism 220 to quickly extract vacuum during the casting operation. The time relay 140 is electrically connected to the vacuum pump 110 to control the extraction time of the vacuum pump 110 to ensure that the extraction amount of rare earth metal liquid is within a predetermined range.

[0096] In this embodiment, the vacuum system 100 includes a vacuum pump 110, a vacuum tank 120, a vacuum line 130, and a time relay 140. The combination of the vacuum pump 110 and the vacuum tank 120 ensures that the vacuum system 100 can provide an efficient and stable vacuum environment. During use, the vacuum pump 110 is responsible for extracting air during the vacuum casting process, creating a negative pressure environment, while the vacuum tank 120 is used to store the extracted air. By efficiently extracting air, the vacuum pump 110 can quickly establish a negative pressure environment, ensuring stable fluidity of the rare earth metal liquid during the ingot casting process, preventing oxidation and bubbles caused by air intrusion, and thus ensuring the quality of the ingot. The vacuum tank 120 acts as a buffer during the air extraction process by the vacuum pump 110, storing the extracted gas and maintaining vacuum pressure stability, preventing air pressure fluctuations from affecting the flow of the liquid metal during the casting process. Compared to solutions that directly use a vacuum pump for continuous extraction, this design significantly improves the system's pressure stability. Optionally, in this embodiment, the vacuum pump 110 is mounted on the vacuum tank 120.

[0097] Moreover, this embodiment stores part of the extracted air through the vacuum tank 120, reducing the need for the vacuum pump 110 to work continuously, avoiding damage to the equipment caused by excessive vacuuming, and extending the service life of the vacuum pump 110. This not only reduces energy consumption, but also improves the stability and reliability of the entire system.

[0098] In this embodiment, the vacuum pipe 130 connects the vacuum pump 110 and the vacuum casting mechanism 220. The provision of the vacuum pipe 130 enables rapid vacuum extraction during the casting operation and rapid removal of the vacuum when necessary, greatly shortening the preparation time for the casting operation and improving production efficiency. When the vacuum environment needs to be removed, the vacuum pipe 130 can also quickly release the gas, allowing the casting operation to quickly transition to subsequent steps such as demolding, avoiding production line delays caused by slow vacuum removal. This flexibility ensures efficient and smooth operation.

[0099] Furthermore, in this embodiment, the time relay 140 of the vacuum system 100 is electrically connected to the vacuum pump 110 and is responsible for controlling the vacuum pump 110's pumping time to ensure that the amount of rare earth metal liquid extracted is within a predetermined range. The provision of the time relay 140 enables precise control of the vacuum pump 110's pumping time, ensuring that the rare earth metal liquid is accurately extracted during the ingot casting operation and preventing excessive or insufficient metal liquid from entering the ingot casting mold. This control method effectively improves the quality of the ingot casting and ensures the stability of the rare earth metal liquid under vacuum conditions. Optionally, the time relay 140 can be mounted on a control panel adjacent to the vacuum pump 110 or integrated into the furnace carriage 210 of the furnace carriage 200. This not only shortens the connection distance between the time relay 140 and the vacuum pump 110 and reduces wiring complexity, but also reduces the impact of vibration and temperature, and also facilitates operator control at any time.

[0100] The introduction of the time relay 140 in the vacuum system 100 prevents waste of molten metal caused by excessive vacuuming, while also avoiding incomplete or defective ingots due to insufficient vacuuming. Compared to manual control or simple timing systems, this precise time control reduces operational errors and improves production reliability. Furthermore, the time relay 140 enables automated control of the vacuum pump 110, reducing operator intervention and increasing the degree of automation throughout the ingot casting process. This not only reduces the possibility of human error but also improves production line efficiency, particularly by enabling the stable output of high-quality castings during continuous production.

[0101] In some embodiments, the rare earth electrolysis furnace 400 has an upper anode and cathode structure, and a receiver 410 for connecting to the siphon 2203 is provided below the rare earth electrolysis furnace 400. The receiver 410 can be used to receive rare earth metal liquid and provide a metal liquid flow interface for the siphon 2203.

[0102] In this embodiment, the rare earth electrolysis furnace 400 adopts an upper anode and cathode structure design, which can optimize the electrolysis process. The upper anode and cathode structure can ensure that the electric field is evenly distributed in the electrolytic cell, thereby making the electrolysis process of the rare earth metal liquid more uniform and improving the purity and quality of the rare earth metal liquid. This electric field uniformity can reduce impurity residues during the electrolysis process and ensure high-quality output of the ingot. Moreover, the reasonable layout of the anode and cathode shortens the path of current transmission, reduces the loss of electrical energy, and improves the electrolysis efficiency. In addition, the rare earth electrolysis furnace 400 adopts an upper anode and cathode structure, which can effectively reduce the occurrence of anode effect during the electrolysis process and make the electrolysis process more stable.

[0103] Furthermore, in this embodiment of the present application, a receiver 410 is disposed below the rare earth electrolysis furnace 400 for connection to the siphon tube 2203. Receiver 410 provides a molten metal flow interface for the siphon tube 2203. In this embodiment, the provision of receiver 410 enables the rare earth metal liquid in the rare earth electrolysis furnace 400 to be stably and accurately transferred via the siphon tube 2203 to the ingot mold 2204 within the vacuum casting chamber 2202. The sealed connection between receiver 410 and siphon tube 2203 prevents waste of the rare earth metal liquid due to leakage or uneven flow during transfer, ensuring a stable flow of the liquid metal. Furthermore, receiver 410 provides a closed transmission channel for the rare earth metal liquid, effectively preventing contamination from the external environment during transfer. This closed structure significantly improves the quality of the final product, particularly during the high-temperature casting of rare earth metal ingots. The receiver 410 in the embodiment of the present application is a component of the rare earth electrolytic furnace 400, primarily used to connect to the siphon 2203 to receive and transport the molten rare earth metal liquid. In existing rare earth metal smelting equipment, receivers are typically made of high-temperature and corrosion-resistant materials, such as aluminum oxide, silicon carbide, or high-temperature alloys. These materials can withstand molten metal temperatures of up to 1000°C or even higher, and exhibit excellent flow control and high-temperature stability. In the embodiment of the present application, the primary function of the receiver 410 is to ensure that the rare earth metal liquid can be stably and continuously transported to the ingot mold 2204 via the siphon 2203 during the ingot casting process, thereby preventing leakage or uneven flow during the rare earth metal liquid transfer process. This type of receiver is widely used in the rare earth smelting field and is a mature technology. Therefore, no special modifications are required to adapt it to the continuous vacuum casting system of the present application.

[0104] In some embodiments, the unloading carriage 210 utilizes an electric drive system. In specific applications, the unloading carriage 210 utilizes an electric drive system instead of a traditional mechanical or hydraulic drive. The electric motor provides power to drive the carriage. Furthermore, the electric drive system enables precise speed control and position adjustment, ensuring that the unloading carriage can be precisely docked at the designated location. Furthermore, the electric drive system is compact and space-saving. In practical applications, the electric motor and its control system can be conveniently integrated within the unloading carriage 210, enabling efficient energy management through an intelligent control system.

[0105] The present application also provides a method for continuous vacuum casting of a rare earth metal electrolytic furnace. The continuous vacuum casting system for a rare earth metal electrolytic furnace provided in the present application is used. Figure 6 , specifically including the following steps:

[0106] Step 1: Start the vacuum casting operation through the vacuum system 100 to form a negative pressure environment and form a vacuum casting operation cavity 2202 on one of the ingot mold stations 2201;

[0107] Step 2: The furnace moving vehicle 200 moves to the bottom of the rare earth electrolytic furnace 400 and connects the siphon tube 2203 to the rare earth electrolytic furnace 400;

[0108] Step 3: extracting the molten rare earth metal liquid from the rare earth electrolysis furnace 400 through the siphon 2203 and transporting it to the ingot mold 2204 on the ingot mold station 2201 where the vacuum suction casting operation cavity 2202 is formed;

[0109] Step 4: After the rare earth metal liquid is injected into the ingot mold, the vacuum system 100 is controlled to maintain a vacuum environment, so that the rare earth metal liquid is cooled and solidified in the ingot mold until the ingot is cast;

[0110] Step 5: After the vacuum casting operation chamber 2202 completes the ingot casting operation, the driving mechanism 230 is controlled to transfer the vacuum casting operation chamber 2202 to another ingot mold station 2201 via the lifting device 2301 to continue the ingot casting operation;

[0111] Step 6: The AGV mobile vehicle 300 transports the completed ingot mold 2204 to the demoulding area, and transports the empty ingot mold 2204 back to the furnace moving vehicle 200 to prepare for the next round of ingot casting operation;

[0112] Step 7: Repeat steps 3 to 6 to perform continuous rare earth metal ingot casting.

[0113] The method for continuous vacuum casting of a rare earth metal electrolytic furnace provided in this embodiment is as follows: in step one, the vacuum casting operation is started by the vacuum system 100 to form a negative pressure environment, and a vacuum casting operation chamber 2202 is formed on the ingot mold station 2201. During the operation, the vacuum system 100 can extract air to form a negative pressure environment during the ingot casting process, effectively preventing impurities or gas inclusions in the air from entering the rare earth metal liquid, thereby avoiding defects such as pores and inclusions in the casting, and significantly improving the overall quality of the ingot. Moreover, under the negative pressure environment, the fluidity of the rare earth metal liquid is improved, and it can be more evenly filled into the ingot mold 2204, ensuring that the ingot has a good forming effect, thereby improving the consistency and surface quality of the casting.

[0114] In step 2, the collaboration between the furnace transport vehicle 200 and the siphon tube 2203 efficiently extracts the rare earth metal liquid from the rare earth electrolytic furnace 400 and rapidly transfers it to the vacuum casting chamber 2202. This process reduces manual intervention, improves the efficiency of rare earth metal liquid transfer, and avoids the time delays and errors associated with manual operation. Furthermore, the provision of the siphon tube 2203 ensures accurate transfer of the rare earth metal liquid, reduces waste and spillage during transfer, and prevents solidification caused by a drop in liquid temperature.

[0115] In this embodiment, through the cooperation of the driving mechanism 230, the lifting device 2301 and the AGV mobile vehicle 300, the system can realize the rapid switching, movement and demolding operations of the ingot mold 2204. In this embodiment, by controlling the driving mechanism 230, the vacuum suction casting working chamber 2202 can be flexibly switched between different ingot mold stations 2201. This switching method not only improves the operating efficiency, but also realizes continuous production, and significantly improves the continuity of the ingot casting process. The AGV mobile vehicle 300 is responsible for transporting the ingot mold 2204 with completed ingot casting to the demolding area, and transporting the empty ingot mold 2204 back to the furnace mobile vehicle 200 to prepare for the next round of ingot casting operations. This method reduces the labor intensity of manual handling, shortens the ingot casting production cycle, and ensures the efficiency and smoothness of the ingot casting process.

[0116] This embodiment uses this continuous production method to ensure the quality consistency of each round of ingot casting, especially in the batch production process, avoiding errors caused by human intervention, thereby improving the consistency and pass rate of finished castings.

[0117] It should also be noted that the method for continuous vacuum casting in a rare earth metal electrolytic furnace described in the above embodiment is merely one method for rare earth metal casting production using the continuous vacuum casting system for a rare earth metal electrolytic furnace provided in the embodiments of this application. In practical applications, the continuous vacuum casting system for a rare earth metal electrolytic furnace provided in the embodiments of this application can be flexibly adjusted to achieve rare earth metal casting production. For example, after the rare earth metal liquid is injected into the ingot mold 2204, the ingot mold 2204 can be immediately transferred to a conventional cooling environment for natural cooling to ensure that the casting gradually solidifies at a controlled temperature. This cooling process is coordinated by the drive mechanism 230 and the lifting device 2301. Specifically, after the rare earth metal liquid is injected, the negative pressure in the vacuum casting chamber 2202 is released, releasing the ingot mold 2204 from the vacuum environment. Subsequently, the drive mechanism 230 controls the lifting device 2301 to lift the vacuum chamber cover 222 and move it to another ingot mold station 2201 to begin a new round of vacuum casting of the rare earth metal liquid.

[0118] This flexible switching method not only ensures that the rare earth metal liquid injected into the ingot mold can cool and solidify under normal cooling conditions, but also maintains production continuity. This operation method is particularly suitable for production needs with lower cooling rate requirements or when the ingot can be cooled over a longer period of time. By flexibly controlling the switching timing of each station, the quality of the ingot can be guaranteed while adjusting the cooling method according to different process requirements, thereby improving the adaptability of the entire production line and the stability of product quality.

[0119] In summary, it can be seen that the continuous vacuum suction casting system for rare earth metal electrolytic furnaces provided in this application is first of all more complex and innovative in terms of system structure design. By adopting the coordinated cooperation of the vacuum system 100, the furnace moving vehicle 200 and the AGV moving vehicle 300, the continuous vacuum suction casting system of this application can move between multiple rare earth electrolytic furnaces 400 to perform continuous casting operations of rare earth metal liquid. Compared with the existing technology, this application breaks through the limitations of single-station casting, realizes continuous and large-scale casting production, and effectively solves the problems of low production efficiency and long downtime in the existing technology. This design greatly improves production efficiency, significantly optimizes the overall ingot casting process, and ensures the reliability and stability of the system during long-term operation.

[0120] Secondly, the present application has significant differences in the design of key components, especially the vacuum casting mechanism 220 of the present application, which can achieve rapid transmission and recycling of ingot molds 2204 by flexibly switching the vacuum suction casting working chamber 2202 on the two ingot mold stations 2201, in conjunction with the AGV mobile vehicle 300, thereby forming an efficient continuous production process. In contrast, the devices of the prior art still remain in the single-station operation mode and cannot achieve continuous switching and rapid operation of the system. The continuous vacuum suction casting system of the present application greatly reduces the downtime of the system through the dual-station design, ensures the continuity and flexibility of the production process, and significantly improves the efficiency of rare earth metal casting.

[0121] In addition, the present application also makes important improvements in cooling and metal liquid transmission control. Although the prior art has already involved some basic cooling and liquid level control, the present application further optimizes the vacuum system 100 and the transmission method of rare earth metal liquid.

[0122] This application uses an electric heating plate 223 to preheat the ingot mold 2204, control the negative pressure environment in the vacuum casting chamber 2202, and coordinate the transmission of the rare earth metal liquid. This ensures the stability and efficiency of the ingot casting process, effectively avoiding ingot quality issues caused by temperature fluctuations or oxidation. This design ensures uniform transmission and cooling of the rare earth metal liquid, greatly improving the continuity and consistency of the production line.

[0123] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present application, rather than to limit them. Although the present application has been described in detail with reference to the above embodiments, those skilled in the art should understand that they can still modify the technical solutions described in the above embodiments, or make equivalent replacements for some or all of the technical features therein. However, these modifications or replacements do not deviate the essence of the corresponding technical solutions from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A continuous vacuum suction casting system for a rare earth metal electrolytic furnace, characterized in that: It includes a vacuum system (100), a furnace unloading mobile vehicle (200) and an AGV mobile vehicle (300); The vacuum system (100) is used to provide a vacuumized suction casting environment; The furnace-discharging moving vehicle (200) is used to move between a plurality of rare earth electrolytic furnaces (400) to extract rare earth metal liquid from the rare earth electrolytic furnaces (400) for vacuum suction casting. The furnace-discharging moving vehicle (200) comprises a movable furnace-discharging vehicle body (210), a vacuum ingot casting mechanism (220) equipped with two ingot mold stations (2201), and a driving mechanism (230) capable of lifting and moving operations. The vacuum ingot casting mechanism (220) is arranged above the furnace-discharging vehicle body (210) and is connected to the vacuum system (100). The vacuum ingot casting mechanism (220) can alternately form a vacuum suction casting operation chamber (2202) on the two ingot mold stations (2201). The vacuum environment of the vacuum suction casting operation chamber (2202) is provided by the vacuum system (100). The vacuum suction casting operation chamber (2202) is connected to a vacuum chamber extending to the vacuum system (100). A siphon (2203) outside the vacuum ingot casting mechanism (220), an ingot mold (2204) is placed on each of the two ingot mold stations (2201), one end of the siphon (2203) is used to transport rare earth metal liquid required for ingot casting to the ingot mold (2204) in the vacuum suction casting operation chamber (2202), and the other end of the siphon (2203) is connected to a rare earth electrolytic furnace (400) to extract rare earth metal liquid; the driving mechanism (230) is arranged on one side of the furnace discharge vehicle body (210), the driving mechanism (230) is connected to a lifting device (2301) located above the vacuum ingot casting mechanism (220), and the lifting device (2301) can alternately change the position of the vacuum suction casting operation chamber (2202) on the two ingot mold stations (2201) under the control of the driving mechanism (230); The AGV mobile vehicle (300) is used to transport the ingot mold (2204) after the ingot casting is completed from the furnace-outgoing mobile vehicle (200) and can transport the empty ingot mold (2204) back to the furnace-outgoing mobile vehicle (200); The vacuum ingot casting mechanism (220) comprises an ingot casting box bottom (221), a vacuum box cover (222) and an electric heating plate (223); The ingot casting box bottom (221) has two ingot mold workstations (2201) on its upper surface for carrying the ingot mold (2204), so as to support the vacuum suction casting operation during the ingot casting process; The vacuum box cover (222) is arranged on the bottom (221) of the ingot box, an air extraction hole is arranged on the top of the vacuum box cover (222) and is connected to the vacuum system (100) through the air extraction hole, the side of the vacuum box cover (222) is connected to the siphon (2203), the vacuum box cover (222) can be sealed and buckled on any of the ingot mold stations (2201) on the bottom (221) of the ingot box, and the vacuum box cover (222) can form a sealed vacuum suction casting working chamber (2202) with the ingot box bottom (221) during the ingot casting process; The electric heating plates (223) are used to preheat the ingot mold (2204). The number of the electric heating plates (223) is two groups. The two groups of electric heating plates (223) are both arranged in the bottom (221) of the ingot box and correspond one-to-one to the two ingot mold stations (2201) respectively.

2. The continuous vacuum suction casting system for a rare earth metal electrolytic furnace according to claim 1, characterized in that: The vacuum box cover (222) and the ingot box bottom (221) are sealedly connected via a convex-concave groove matching structure; the ingot box bottom (221) is provided with a circle of grooves (2211) on the two ingot mold stations (2201) for sealingly buckling the vacuum box cover (222); and the grooves (2211) are provided with sealing rings.

3. The continuous vacuum suction casting system for a rare earth metal electrolytic furnace according to claim 1 or 2, characterized in that: The ingot mold (2204) is a multi-cavity structure, and is provided with at least two mutually isolated casting cavities (22041). The ingot mold (2204) is provided with overflow grooves (22042) above the connection between adjacent casting cavities (22041).

4. The continuous vacuum suction casting system for a rare earth metal electrolytic furnace according to claim 3, characterized in that: The ingot mold (2204) is composed of 15 independent casting cavities (22041), and the 15 casting cavities (22041) are distributed in a 3×5 matrix, and each casting cavity (22041) is a stepped structure that is narrow at the bottom and wide at the top. The inclination angle of the cavity side wall of the casting cavity (22041) is not less than 19°, and the boundary of the casting cavity (22041) is provided with an arc chamfer, and the chamfer radius is not less than 20 mm.

5. The continuous vacuum suction casting system for a rare earth metal electrolytic furnace according to claim 2, characterized in that: The driving mechanism (230) comprises a hydraulic lifting cylinder (231) and a single-arm crane (232); The hydraulic lifting cylinder (231) is vertically fixedly installed on one side of the exterior of the furnace-exiting vehicle body (210), and the output end of the hydraulic lifting cylinder (231) is vertically upward; The single-arm crane (232) is arranged above the hydraulic lifting cylinder (231) and is connected to the output end of the hydraulic lifting cylinder (231). The lifting device (2301) is connected to the single-arm crane (232), and the lifting device (2301) can be switched between the two ingot mold workstations (2201) and perform lifting and positioning operations. The lifting device (2301) is a hook.

6. The continuous vacuum suction casting system for a rare earth metal electrolytic furnace according to claim 1 or 2, characterized in that: The vacuum system (100) comprises a vacuum pump (110), a vacuum tank (120), a vacuum pipeline (130) and a time relay (140); The vacuum pump (110) is used to extract air to form a negative pressure environment during the vacuum suction casting operation, and the vacuum pump (110) is connected to the vacuum ingot casting mechanism (220) via the vacuum pipeline (130); The vacuum tank (120) is connected to the vacuum pump (110) and is used to store gas during the vacuum extraction process; The vacuum pipeline (130) is connected to the vacuum pump (110) and the vacuum ingot casting mechanism (220) and is used to quickly extract vacuum during the ingot casting operation; The time relay (140) is electrically connected to the vacuum pump (110) and is used to control the vacuum pump (110) pumping time to ensure that the amount of rare earth metal liquid extracted is within a predetermined range.

7. The continuous vacuum suction casting system for a rare earth metal electrolytic furnace according to claim 1, characterized in that: The rare earth electrolysis furnace (400) is a structure with an anode and a cathode inserted upward, and a receiver (410) for connecting to the siphon (2203) is arranged below the rare earth electrolysis furnace (400). The receiver (410) can be used to receive rare earth metal liquid and provide a metal liquid flow interface for the siphon (2203).

8. The continuous vacuum suction casting system for a rare earth metal electrolytic furnace according to claim 1, characterized in that: The furnace-exiting vehicle body (210) is an electrically driven vehicle body.

9. A method for continuous vacuum suction casting in a rare earth metal electrolytic furnace, characterized in that: The continuous vacuum suction casting system according to any one of claims 1 to 8 comprises the following steps: Step 1: starting a vacuum suction casting operation through a vacuum system (100) to form a negative pressure environment, and forming a vacuum suction casting operation chamber (2202) on one of the ingot mold stations (2201); Step 2: The furnace unloading mobile vehicle (200) moves to the bottom of the rare earth electrolytic furnace (400), and connects the siphon tube (2203) to the rare earth electrolytic furnace (400); Step 3: extracting molten rare earth metal liquid from the rare earth electrolytic furnace (400) through a siphon (2203), and transporting the molten rare earth metal liquid to an ingot mold (2204) on an ingot mold station (2201) where a vacuum suction casting operation cavity (2202) is formed; Step 4: After the rare earth metal liquid is injected into the ingot mold, the vacuum system (100) is controlled to maintain a vacuum environment, so that the rare earth metal liquid is cooled and solidified in the ingot mold until the ingot casting is completed; Step 5: After the ingot casting operation is completed in the vacuum suction casting working chamber (2202), the driving mechanism (230) is controlled to transfer the vacuum suction casting working chamber (2202) to another ingot mold station (2201) through the lifting device (2301) to continue the ingot casting operation; Step 6: The ingot mold (2204) of the completed ingot is transported to the demoulding area by the AGV mobile vehicle (300), and the empty ingot mold (2204) is transported back to the furnace-out mobile vehicle (200) to prepare for the next round of ingot casting operation; Step 7: Repeat steps 3 to 6 to perform continuous rare earth metal ingot casting operations.

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