Large brick machine

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Operation Of The Forming Machine Of Cement-free Sintering Brick Machine And Maintenance Method Of 2-hole Hollow Brick Mold

 

The cement free brick making machine, also known as an unburned brick machine, is a new type of ecological brick product that does not require sintering when producing colored bricks, grass bricks, square bricks, permeable bricks, curbstones, and other products but is formed by strong vibration pressing and naturally maintained. The daily operation of the molding machine requires some technical knowledge to ensure the quality of the products produced. The mold is an essential tool for product production. During the entire production process of the cement brick machine, the daily maintenance and adjustment of the 2-hole hollow brick mold is very important.

 

Operation Instructions of the forming machine of cement-free burning brick-making machine

 

During the shutdown process, it is necessary to clean up everything on the brick machine, take appropriate rain and moisture-proof measures, and store the brick machine in a dry and ventilated environment.

All reducers should be covered with standard tarpaulins after each work to prevent rain or other liquids from entering the reducer and causing various faults.

 

If the mold of the unfired brick machine is not in use, it also needs to be disassembled, properly stored in an environment that meets the requirements, and sprayed with anti-rust paint and other products.

 

 

Host Machine Power	44.4KW
Host Machine Weight	12tons
Dimension	5030×2620×3750mm
Pallet Size	1380×780×(25-45)mm
Moulding Cycle	15-20 sec/time
Excitation Force	108KN
Production Capacity	39.60million pcs/year (240×115×53mm)
Operation Standard	JC/T2094-2021

 

 

After each inspection, maintenance, and servicing, a written record should be made. When feeding, avoid all kinds of debris and hard objects, especially various metals, steel, and other items, which can easily damage the brick-making machine.

 

For the installation and operation environment of such equipment, its voltage and current must be consistent with the equipment, otherwise, some devices need to be properly adjusted.

 

 

1. The upper mold is raised to the upper limit, the lower mold is lowered to the lower limit, the material car is withdrawn to the rear limit, and the feed plate is sent to the front limit to ensure that the lower mold is in place.

2. After each shift, the parts in contact with ash and slag should be cleaned in time to ensure that the cement does not agglomerate. There should be no dust and slag on the rotating, walking parts and bearings.

3. During the operation of the equipment, check at any time that there are no large stones in the hopper to prevent damage to the stirring teeth. When large pieces of hard material fall into the mold, it will also cause damage to the mold.

 

 

Main causes of mold cracking:

 

(1) The lower mold pressure is too low: The lower mold pressure of the equipment should be checked regularly during the operation of the equipment. Inspection method: When the equipment is operating normally, the mold vibration amplitude should be controlled between 2 and 4 mm. If the mold amplitude is greater than 4 mm, the mold pressure is lower than the normal value, and the mold pressure should be adjusted at this time. The specific operation method is to adjust the lower mold pressure regulating valve to gradually increase the lower mold pressure until the mold amplitude is controlled within 4 mm.

(2) The pressure on the left and right sides of the lower mold is inconsistent, and the lifting is not stable: Before each shift of production, the equipment should be tested for empty operation, and the upper and lower molds should be lifted and lowered several times. Pay attention to whether the upper and lower molds are lifted and lowered smoothly. Normal production can only be carried out after the inspection is correct. If the left and right lifting is found to be unstable, the equipment should be adjusted immediately.

 

 

The vibrator operation test should be carried out before each shift of production. The detection method is to place the pallet on the vibration table, place the lower mold on the pallet normally, raise the upper mold to the upper limit, start the vibrator, and observe whether the pallet moves left and right. If the movement is too large, the equipment should be adjusted immediately.

 

There is dust falling from the bottom of the core, so that the bottom of the core is subjected to force on the support plate during production, and the mold frame is suspended so that the core and the hanging beam are subjected to excessive force, causing the hanging beam to drop the core. Because the material laying time is too long during the production of free bricks, generally about 10 seconds, due to the long time during the material laying process, there is no pressure control on the lower mold, and the lower mold oil cylinder is easy to release pressure under the action of high-frequency vibration, resulting in a decrease in the pressure of the lower mold and an increase in the amplitude of the mold. At this time, you should pay attention to observing at any time. Once the amplitude of the lower mold is found to increase, the lower mold drop rod should be pressed down immediately to ensure the stability of the lower mold pressure.

 

 

 

The value of mechanical equipment comes from the products produced and their quality and function. Only with a long service life can the foundation of its use value be laid. As a green and intelligent machine, brick machine equipment cannot avoid damage caused by operating errors, friction, improper maintenance, and overload operation.

 

In the operation and use of brick machine equipment, problems such as human error, improper maintenance, and overload operation can be comprehensively improved through professional training, and detailed operating procedures can also be formulated for strict control. Friction can only be reduced through reasonable and effective lubrication, but it always exists and is inevitable. If users want to use unburned brick machines to obtain greater benefits, they must do the following.

 

1. Purchase high-quality free brick machine equipment;

2. Develop a detailed and strict management system;

3. Conduct detailed on-the-job training regularly;

4. Clarify the maintenance rules for each component of the equipment;

5. Use the equipment reasonably for production;

6. Regular maintenance

 

 

Frequently Asked Questions

 

1. What is a large brick machine?

The large brick machine is a large model among the brick machines. Its main features are a large number of formed blocks, high output, and large appearance size. This type of equipment usually has significant characteristics such as large investment, high output, huge profit returns, large floor area, large number of employees, and a high degree of automation.

 

2. What is the main function of a large brick machine?

High output: Compared with small brick machines, large brick machines have more formed blocks and higher output. This is due to its large production scale and advanced automated production line, which can complete the production of a large number of bricks in a short time.
Continuous operation: Large brick machines usually can operate continuously, without frequent shutdowns for stacking, which greatly improves production efficiency.
A variety of products: By changing the mold, large brick machines can produce a variety of types of bricks, such as standard bricks, hollow bricks, blind hole bricks, square bricks, grass bricks, pavement bricks, etc., to meet the needs of different projects.
Large and consistent appearance size: The bricks produced by large brick machines have large appearance sizes, and due to the use of advanced production processes and equipment, they can ensure that the bricks produced are of consistent size, which improves the overall quality of the product.

 

3. What common faults may a large brick machine encounter during use?

Hydraulic pump failure: The hydraulic pump is the core component of the hydraulic system and is responsible for providing power. Common faults include pump body wear, leakage caused by aging of seals, blockage caused by oil contamination, etc. These problems may cause the hydraulic system to be under pressure or unable to work properly.
Hydraulic cylinder failure: The hydraulic cylinder is an actuator responsible for converting hydraulic energy into mechanical energy. Common faults include cylinder body wear, piston rod bending, seal damage, etc., which cause the hydraulic cylinder to fail to work properly or leak.
Hydraulic valve failure: The hydraulic valve is used to control the flow, pressure, and direction of the hydraulic system. Common faults include valve core stuck, valve body wear, poor sealing, etc., which cause the hydraulic valve to be unable to accurately control the operation of the hydraulic system.
Motor failure: The motor is a key component that drives the hydraulic pump and other electrical components. Common faults include motor overheating, motor burnout, unstable motor speed, etc., which may be caused by power supply problems, motor failure, or excessive load.
Control circuit failure: The control circuit is responsible for controlling the coordinated work of various parts of the large brick machine. Common faults include poor line contact, relay damage, PLC failure, etc., which cause the equipment to fail to run according to the preset program.

 

4. How to maintain the large brick machine to ensure its normal operation?

Check each component regularly: Check key components such as motors, reducers, bearings, chains, etc. regularly to ensure that they are in good working condition. Wear or failure of these components will directly affect the operating efficiency and stability of the brick machine. Check whether fasteners such as bolts and nuts are loose. If they are loose, they should be tightened in time to prevent vibration or damage caused by looseness.
Cleaning work: Keep the brick machine equipment clean, especially the parts that are prone to dust accumulation such as conveyor belts and molds. Remove residues and dust regularly to avoid blockage and wear. Clean up debris and waste around the machine to ensure a clean and safe production environment.
Lubrication: Lubrication can reduce friction and wear and extend the service life of the equipment. Pay special attention to the refueling amount and refueling cycle of each lubrication point to avoid excessive or insufficient lubrication.
Check the hydraulic system: For brick machines equipped with hydraulic systems, check the oil level and quality of the hydraulic oil regularly. Too low oil levels or poor oil quality will affect the normal operation of the hydraulic system. Regularly replace hydraulic oil and filter elements to ensure the cleanliness and efficiency of the hydraulic system.

 

5. What factors affect the durability of large brick machines?

Material selection: The quality of the materials selected for the main components of the large brick machine, such as the frame, mold, transmission system, etc., directly affects its durability. The use of high-strength, wear-resistant, and corrosion-resistant materials can significantly increase the service life of the equipment.
Manufacturing process: The level of manufacturing process of the equipment is also an important factor in determining its durability. Exquisite manufacturing technology can ensure the accuracy and fit of components and reduce failures and damage caused by manufacturing defects.
Maintenance: Regular maintenance of your equipment is key to ensuring its durability. This includes cleaning the equipment, checking the wear and tear of each component, replacing damaged components promptly, adjusting various parameters of the equipment, etc. Good maintenance can reduce the failure rate of equipment and extend its service life.

 

6. How to prevent large brick machines from rusting?

Avoid humid environments: Try to avoid placing large brick machines in humid and rainy environments. If conditions permit, you can build a rainproof shed or mobile cabin for the equipment to reduce the chance of rainwater directly contacting the equipment.
Keep ventilation and dry: Ensure that the equipment storage and working areas are well-ventilated to help reduce moisture accumulation and reduce the risk of rust.
Regular cleaning: Regularly clean dust, dirt, and other dirt on the surface of large brick machines to prevent this dirt from adhering to the equipment for a long time and forming a corrosion source.
Inspection and rust removal: Regularly check whether there is rust on the surface of the equipment, and once found, rust removal should be carried out in time. For minor rust, physical rust removal methods can be used, such as sandpaper, wire brushes, and other tools for grinding; for more serious rust, chemical rust removers may be required for treatment.
Select high-quality materials: When designing and manufacturing large brick machines, high-quality materials with good corrosion resistance should be selected, such as stainless steel, aluminum alloy, etc. These materials can effectively resist the erosion of the external environment and extend the service life of the equipment.

 

7. What material is the large brick machine made of?

Body: The body of a large brick machine is mostly made of steel plates, thickened steel plates, and other steel materials. This material has high hardness, compact structure, good stability, and reliability. At the same time, steel has good corrosion resistance and impact resistance, so it is suitable for various harsh working environments.
Molds, cutting knives, and pressure plates: These key components are made of high-quality alloy materials. The alloy material has higher hardness, wear resistance, and corrosion resistance, which can ensure that the brick machine can maintain efficient and stable production capacity under long-term high-load operation.

 

8. What fields can a large brick machine be applied to?

Construction field: Bricks produced by large brick machines are indispensable building materials in the construction field and can be used to build the basic structures of various buildings, such as walls, columns, foundations, etc. In residential construction, bricks produced by large brick machines are widely used for wall construction, paving, etc., providing a solid and stable building foundation. In addition to residential construction, large brick machines also meet the needs of commercial buildings for high-quality building materials, such as office buildings, shopping malls, hotels, etc.
Road and transportation field: Pavement bricks produced by large brick machines can be used to pave sidewalks, driveways, etc., to improve the durability and beauty of roads. In the construction of transportation facilities, such as parking lots, bus stations, etc., bricks produced by large brick machines also play an important role.

 

9. What factors affect the ease of use of large brick machines?

Humanized design: Whether the design of the equipment takes into account the comfort and convenience of the operator, such as whether the layout of the control panel is reasonable and whether the operating buttons are easy to reach.
Modular design: The modular design allows each part of the equipment to be replaced or repaired independently, reducing downtime and maintenance difficulty.
Automation level: The highly automated brick machine can automatically complete the processes of loading, pressing, and bricking, reducing manual operations and improving production efficiency and ease of use.

 

10. What are the disadvantages of large brick machines?

Environmental requirements: Large brick machines will generate certain noise and dust pollution during operation, which will have a certain impact on the surrounding environment. Therefore, when using large brick machines, it is necessary to consider their impact on the environment and take corresponding measures to control it.
Site requirements: Large brick machines occupy a large area and require a larger site for installation and operation. At the same time, the layout and installation of the equipment also need to consider factors such as production processes and logistics to ensure the smooth operation of the equipment.
Production flexibility: Large brick machines are usually suitable for large-scale, continuous production, and may be difficult to adapt to small batches and multiple varieties of production needs. This limits the application scope of large brick machines to a certain extent.

 

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