Research on a Process Path to Improve Block Demolding Strength by 35% through Vibration Spectrum Optimization

Research on a Process Path to Improve Block Demolding Strength by 35% through Vibration Spectrum Optimization

Abstract Block demolding strength is a key indicator affecting production efficiency and finished product quality. Traditional vibration molding processes often result in loose internal block structures and easy demolding damage due to a single spectrum and uneven energy distribution. This study proposes a process path based on multi-band coupled vibration and real-time spectrum optimization. By constructing a coordinated vibration mode of "high-frequency dispersion - low-frequency compaction" and combining it with an adaptive control system, the demolding strength of blocks can be improved by more than 35%. Experiments show that the optimized process can simultaneously reduce demolding time by 20% and mold wear rate by 18%, providing an efficient and energy-saving technical solution for high-quality block production.

Keywords Vibration spectrum optimization; block demolding strength; multi-frequency coupled vibration; real-time spectrum analysis; adaptive control; molding process; strength improvement path

1. Introduction

In the block molding process, insufficient demolding strength leads to increased block breakage rate, decreased production efficiency, and aggravated mold wear. Traditional vibration systems often use fixed frequencies, which are difficult to adapt to the dynamic requirements of different material ratios and molding stages, easily causing energy waste and structural defects. In recent years, spectrum optimization technology has shown potential in the field of material forming, but its systematic application in block production still lacks in-depth research. This paper uses vibration spectrum as the core variable and explores a quantifiable and replicable path to improve demolding strength through theoretical modeling, simulation analysis, and experimental verification.

2. Mechanism of the Relationship between Vibration Spectrum and Demolding Strength

2.1 Influence of Spectral Characteristics on the Internal Structure of Blocks
High-frequency vibration (80-120 Hz): Promotes uniform distribution of fine aggregate and slurry, reducing local porosity;

Low-frequency vibration (25-40 Hz): Enhances the interlocking effect between aggregates, improving overall density;

Frequency band coupling effect: Achieves energy gradient transfer through temporally alternating particle resonance.

2.2 Formation Mechanism of Demolding Strength
Demolding strength depends on the internal bonding force and structural integrity of the block. Optimizing the spectrum can enhance strength through the following methods:

Reducing porosity to below 8%, reducing structural weak points;

Increasing the density of the transition zone between cement paste and aggregate;

Optimizing the distribution of hydration products, shortening the initial strength formation time.

3. Vibration Spectrum Optimization Process Path Design

3.1 Multi-Band Coupled Vibration System Architecture
The system consists of three parts:

Dual-motor cooperative drive device: main motor (0-120 Hz frequency conversion), auxiliary motor (0-50 Hz frequency conversion), supporting phase synchronous adjustment;

Real-time spectrum monitoring module: built-in accelerometer and FFT analyzer, dynamically acquiring vibration energy distribution;

Adaptive controller: based on PID algorithm and material database, adjusting frequency, amplitude, and duration in real time.

3.2 Process Parameter Optimization Flow
Material adaptability analysis: matching the initial spectrum according to aggregate particle size and slurry rheology;

Stage vibration strategy:

Initial stage (0-3 s): high frequency dominant (100 Hz), promoting leveling;

Middle stage (3-8 s): low frequency dominant (35 Hz), achieving compaction;

Final stage (8-10 s): alternating high and low frequencies (50 Hz/90 Hz), enhancing structural homogeneity.

Closed-loop feedback regulation: Dynamically correcting spectral parameters using demolding resistance sensor data.

3.3 Key Technological Breakthroughs

Rapid Spectrum Switching Technology: Frequency switching response time < 0.1 s;

Energy Directional Transfer Algorithm: Optimizing vibration propagation path based on block geometry;

Anti-interference Synchronous Control: Solving phase drift problems in multi-motor coordination.

4. Experimental Verification and Effect Analysis

4.1 Experimental Design

Control Group: Traditional fixed-frequency vibration (50 Hz);

Experimental Group: Optimized spectrum vibration (multi-band coupling);

Test Indicators: Demolding strength (MPa), porosity (%), demolding time (s), mold wear (g/10,000 cycles).

4.2 Results Comparison

Indicators | Control Group | Experimental Group | Improvement

Demolding Strength (MPa) | 1.2 | 1.62 | +35%

Porosity (%) | 12.5 | 8.1 | -35%

Demolding Time (s) | 15 | 12 | -20%

Mold Wear (g/10,000 cycles) | 120 | 98.4 | -18%

Energy Consumption (kWh/1000 units) | 18.5 | 15.2 | -18%

4.3 Microstructure Analysis

Scanning electron microscopy (SEM) showed:

The thickness of the aggregate-slurry interface transition zone in the experimental group samples decreased by 30%;

The pore morphology changed from interconnected to isolated, and the uniformity of distribution improved;

The distribution density of hydration products (C-S-H gel) increased significantly.

5. Engineering Application and Economic Benefits

5.1 Production Line Adaptation Solution

Existing Production Line Retrofit: Add a variable frequency motor and control system; retrofit cycle ≤ 5 days;

New Production Line Integration: Directly configure a full-spectrum optimized vibration table;

Compatibility Design: Supports intelligent linkage with hydraulic systems, curing kilns, and other equipment.

5.2 Comprehensive Benefit Assessment
Taking a production line with an annual output of 10 million blocks as an example:

Direct Benefits: Reduces breakage losses by approximately RMB 450,000 annually; reduces mold replacement costs by RMB 300,000;

Energy Saving Benefits: Saves approximately 32,000 kWh of electricity annually; reduces carbon emissions by 25 tons;

Capacity Increase: Increases daily block production by approximately 5,000 blocks, resulting in an annual revenue increase of approximately RMB 600,000.

5.3 Industry Promotion Potential
This technology is suitable for:

Production of high-end products such as high-strength blocks, lightweight blocks, and decorative blocks;

Environmentally friendly block production with a high content of solid waste aggregates (fly ash, construction waste);

Highly automated intelligent block production lines.

6. Conclusions and Outlook

This study confirms that vibration spectrum optimization can improve the demolding strength of masonry blocks by more than 35%, while reducing energy consumption and mold wear. The combination of multi-band coupled vibration and adaptive control technology provides a refined and intelligent upgrade path for the block molding process. Future research directions include:

AI spectrum self-learning system: automatically optimizing vibration modes based on production data;

Cross-scale simulation technology: full-chain modeling from particle-level simulation to macroscopic strength prediction;

Green process integration: integrating spectrum optimization with technologies such as waste heat curing and low-carbon cementitious materials.

Through continuous innovation, vibration spectrum optimization technology is expected to become a core driving force for improving the quality and efficiency of the masonry industry, promoting the transformation and upgrading of building materials towards high performance and low energy consumption.