Beginner's Guide to Avoiding Pitfalls: Understanding Common Terminology for Concrete Brick Making Machines

                       Beginner's Guide to Avoiding Pitfalls: Understanding Common Terminology for Concrete Brick Making Machines

For newcomers to the concrete brick making industry, equipment parameters and technical terms can often be confusing. Understanding these key terms can not only help you choose the right equipment but also help you avoid many pitfalls in production. This article will focus on explaining three core terms: capacity, pressure, and molding cycle, allowing you to quickly grasp the key points of purchasing and operating a concrete brick making machine.

I. Capacity – More Than Just "Hourly Output"

1. Theoretical Capacity vs. Actual Capacity

Theoretical Capacity: The maximum output of the equipment under ideal conditions of continuous operation, usually expressed in "blocks/hour" or "cubic meters/hour".

Actual Capacity: The actual output after considering factors such as preparation time, maintenance, and personnel operation.

Key Points to Avoid: Don't blindly trust the maximum capacity figures in brochures; actual capacity is usually only 60%-80% of the theoretical value. When inquiring with the supplier, be sure to understand the conditions under which the data was measured.

2. Key Factors Affecting Production Capacity
* Mold Replacement Frequency and Time
* Continuity and Stability of Raw Material Supply
* Operator Skill Level
* Equipment Maintenance Status
II. Molding Pressure: Matching Process Requirements, Avoiding "Over-Pressure"
* Misconception: Higher pressure is always better. In reality, excessive pressure leads to accelerated equipment wear, increased energy consumption, and even damage to the aggregate structure.

Principle:
* Static Pressing Process: Suitable for small products (e.g., standard bricks 240×115×53mm), requiring a pressure of 15-20MPa. However, when the pressing area exceeds 0.5㎡, the total pressure may exceed 100 tons, drastically increasing equipment costs.

* Vibration Pressing Process: High-frequency vibration (≥50Hz) initially compacts the mixture, then applies 5-10MPa pressure, ensuring strength while reducing energy consumption. For example, when producing 390×190×190mm hollow blocks, secondary pressing is used (…). Pre-compression at 3MPa followed by final compression at 8MPa can reduce pressure decay and improve the density of the finished product.

Select the pressure range according to product type:

1. Solid bricks: 5-8MPa

2. Hollow blocks: 3-6MPa

3. Aerated concrete blocks: 0.5-2MPa (dependent on chemical gas expansion)

Check the pressure regulation method: Prioritize equipment with multi-stage pressure regulation to avoid product quality fluctuations caused by a single pressure.

Pay attention to pressure transmission efficiency: Check whether the hydraulic system is equipped with a pressure compensation device to prevent pressure decay due to oil temperature rise.

III. Molding cycle: Balance speed and quality, reject "blindly pursuing speed"

Misconception: Pursuing short cycles (e.g., 10 seconds/plate), but an excessively fast pace may lead to insufficient compaction and surface defects.

Process analysis:
Molding cycle composition: Feeding (2-3 seconds) + Vibration compaction (5-8 seconds) + Pressurization (2-3 seconds) + Demolding (1-2 seconds).

Key Vibration Parameters: The vibration frequency (30-50Hz) and amplitude (2-5mm) must match the aggregate particle size. For example, when producing 390×190×190mm blocks, biaxial vibration (frequency 45Hz, amplitude 3mm) can achieve 95% density within 8 seconds.

Suggestions for Avoiding Pitfalls:

1. Request the manufacturer to provide a "molding cycle-density curve": High-quality equipment should achieve a density ≥1800kg/m³ within a 12-15 second cycle.

2. Observe the demolding effect: If honeycomb, cracks, or difficulty in demolding appear on the surface of the product, it indicates insufficient vibration time or uneven pressure distribution.

3. Consider the degree of automation: Fully automatic equipment (such as those equipped with robotic arms for palletizing) can shorten auxiliary time (such as pallet replacement), and the actual overall efficiency is 30%-50% higher than that of semi-automatic equipment. IV. Selection Recommendations and Practical Points

1. Prioritize Clear Needs: First, determine the main brick types to be produced, quality requirements, and daily output needs, then match equipment parameters accordingly.

2. Require On-Site Trial Runs: If possible, personally observe the equipment operation, measure the actual cycle time, and check the quality of the finished product.

3. Focus on Adjustability: Excellent equipment should have adjustable parameters such as pressure and cycle time to adapt to different production needs.

4. Consider Future Expansion: If you plan to increase product types, choosing equipment with a wider parameter range will provide more flexibility.

5. Emphasize After-Sales Service: Equipment maintenance and technical support are equally important.

Understand the supplier's response speed and service network. Understanding the core terminology of concrete brick making machines is not only the foundation for selecting equipment but also the key to optimizing efficiency and ensuring quality in daily production. Remember, there is no "best" equipment, only the "most suitable" equipment.