Brick Making Machine Core Technology Analysis: From Hydraulic Systems to Vibration Molding, How to Improve Production Efficiency and Brick Strength?

Brick Making Machine Core Technology Analysis: From Hydraulic Systems to Vibration Molding, How to Improve Production Efficiency and Brick Strength?

Abstract As a key piece of equipment in modern building materials production, the core technologies of brick making machines directly impact production efficiency and product quality. This article focuses on two core modules: the hydraulic system and vibration molding, deeply analyzing their technical principles, optimization paths, and synergistic mechanisms. Through analysis of intelligent hydraulic control, multi-frequency coupled vibration, and system integration strategies, it explores how to achieve simultaneous improvement in production efficiency and brick strength, providing theoretical basis and practical guidance for brick making machine technology upgrades and industrial transformation.

1. Introduction

The block production industry is facing multiple challenges: quality upgrading, efficiency optimization, and energy conservation and emission reduction. As a key piece of equipment in block forming, the hydraulic system and vibration molding technology of brick making machines directly determine equipment operating efficiency, energy consumption levels, and product mechanical properties. Currently, many brick making machines suffer from problems such as sluggish hydraulic response and uneven vibration energy distribution, resulting in low production efficiency and large dispersion in brick strength. This article systematically analyzes the optimization paths of these two core technologies, constructing a technical framework for synergistic improvement of "efficiency-strength," providing a systematic solution for industry technology upgrades.

2. Hydraulic System Technology Analysis and Optimization Path

2.1 The Core Role of the Hydraulic System in Brick Machines

The hydraulic system is the central hub for power transmission and pressure control in brick machines, primarily responsible for:

Driving the mold to close and open, controlling the forming pressure curve

Adjusting the lifting and synchronous movement of the vibrating table

Achieving precise control of auxiliary functions such as plate feeding and stacking

Traditional hydraulic systems often suffer from slow valve response and large pressure fluctuations, leading to unstable forming pressure and high energy consumption.

2.2 Intelligent Hydraulic Closed-Loop Control Technology

By introducing electro-hydraulic proportional valves, high-precision sensors, and adaptive control algorithms, an intelligent hydraulic closed-loop system is constructed:

Precise Pressure Matching: Real-time detection of material resistance characteristics and dynamic adjustment of output pressure to avoid insufficient pressure or overload

Dynamic Energy Consumption Adjustment: Utilizing variable frequency pump sets and accumulator recovery technology to reduce idle and standby energy consumption

Fault Early Warning Mechanism: Through multi-parameter fusion analysis of pressure, flow rate, temperature, etc., system anomalies are identified in advance

The optimized hydraulic system can reduce forming pressure fluctuations by 60% and system energy consumption by 25%-30%.

3. Breakthrough and Collaborative Optimization of Vibration Molding Technology

3.1 Scientific Principles of Vibration Molding
Vibration molding uses mechanical vibration to rearrange aggregate particles and expel air, achieving compaction of the mixture. Traditional vibration systems often use a single frequency, easily leading to "resonance blind zones" and uneven energy distribution.

3.2 Multi-Frequency Coupled Vibration Technology
Innovatively employing a multi-motor collaborative, variable frequency amplitude modulation vibration scheme:

Spectrum Optimization Design: Determining the optimal vibration frequency combination through experiments (e.g., main frequency 25-30Hz, auxiliary frequency 40-45Hz)

Three-Dimensional Vibration Field Construction: Achieving multi-dimensional vibration superposition in vertical, horizontal, and torsional directions

Intelligent Vibration Isolation Control: Dynamically adjusting vibration parameters based on the mold's natural frequency to avoid resonance damage

This technology can improve vibration energy utilization by 40% and shorten molding time by 20%-25%.

3.3 Hydraulic-Vibration Coordinated Control Strategy
Establish a dynamic matching model for hydraulic pressure and vibration parameters:

Pressure-Vibration Timing Optimization: Precisely control the start-up timing of pressurization and vibration based on material compression characteristics.

Energy Complementary Mechanism: Appropriately reduce vibration intensity during the high-pressure molding stage and enhance vibration effect during the pre-pressurization stage.

Adaptive Adjustment Algorithm: Dynamically optimize coordinated parameters based on real-time brick density detection feedback.

4. Empirical Analysis of Production Efficiency and Brick Strength Improvement
Technical transformation verification was conducted on a 500,000 cubic meter per year block production line:

4.1 Production Efficiency Improvement Effect
Cycle Time Reduction: Single cycle time decreased from 12 seconds to 8.5 seconds, a reduction of 29%.

Equipment Utilization Improvement: Downtime due to failure decreased by 40%, and OEE (Overall Equipment Effectiveness) increased from 68% to 85%.

Significant Energy Consumption Reduction: Electricity consumption per ton of product decreased by 28%, and hydraulic oil temperature rise decreased by 15℃.

4.2 Improved Brick Strength Performance

Increased Compressive Strength: Average compressive strength increased from 12.5 MPa to 16.8 MPa, an increase of 34%.

Reduced Strength Dispersion: Strength variation coefficient decreased from 18% to 6.5%.

Improved Dimensional Stability: Thickness deviation decreased from ±1.5 mm to ±0.6 mm.

4.3 Techno-Economic Analysis

Investment Recovery Period: The investment in technological upgrades can be recovered within 14 months through energy saving and increased production.

Long-Term Benefits: Annual reduction in scrap loss of approximately RMB 1.2 million and savings in maintenance costs of RMB 800,000.

5. Key Technological Breakthroughs and Innovations

Intelligent Hydraulic Adaptive Control Technology: Achieves closed-loop control of multiple parameters such as pressure, flow, and temperature.

Multi-Frequency Phase Coupled Vibration Method: Breaks through the traditional single vibration mode, improving energy utilization efficiency.

Hydraulic-Vibration Co-optimization Model: Establishes a dynamic matching algorithm based on material characteristics.

Modular Upgrade Solution: Supports phased upgrades of existing equipment, reducing upgrade costs.

6. Implementation Path and Industry Application Recommendations

6.1 Phased Upgrade Strategy

Phase 1: Prioritize upgrading the hydraulic control system to achieve precise pressure control.

Phase 2: Modify the vibration system and introduce multi-frequency coupling technology.

Phase 3: Deploy a collaborative control system to complete integrated optimization.

6.2 Industry Promotion Value

New Production Lines: Can directly adopt the whole system optimization solution.

Existing Equipment Retrofit: Supports modular and progressive upgrades.

Specialty Block Production: Applicable to the production of high-strength, lightweight, and irregularly shaped high-end products.

6.3 Standardization Recommendations
Promote the formulation of technical specifications for hydraulic-vibration collaborative control, establish industry standard testing methods, and promote the standardized application of technological achievements.

7. Conclusion and Outlook
This paper systematically analyzes the optimization path of the hydraulic system and vibration molding core technology of brick making machines. Through intelligent control, multi-frequency vibration, and system collaboration, it achieves simultaneous improvement in production efficiency and brick strength. Practice has proven that this technical solution can increase production efficiency by more than 30% and brick strength by 25%-40%, demonstrating significant technical and economic benefits.

Future development directions include:

Deep application of intelligent technology: Introducing artificial intelligence algorithms to achieve autonomous learning and optimization of process parameters.

Digital twin technology: Building a virtual debugging and optimization platform to reduce trial-and-error costs.

Green manufacturing integration: Deep integration with environmental protection technologies such as solid waste utilization and waste heat recovery.

Standardization system construction: Promoting the formulation and improvement of industry technical standards.

Through continuous technological innovation and system optimization, brick-making technology will develop towards high efficiency, high quality, and low energy consumption, providing solid technical support for the green transformation of the building materials industry.