Secrets to Increased Production and Efficiency: A Manual for Daily Maintenance and Troubleshooting of Concrete Brick Machines

Secrets to Increased Production and Efficiency: A Manual for Daily Maintenance and Troubleshooting of Concrete Brick Machines
As a core piece of equipment in building materials production, the stable operation of concrete brick machines directly impacts brick quality, production efficiency, and equipment lifespan. This article, combining industry practice and technical specifications, systematically outlines key operational guidelines for increasing the production and efficiency of concrete brick machines from three dimensions: daily maintenance, periodic maintenance, and troubleshooting, helping enterprises achieve high-efficiency production.

I. Daily Maintenance: More Than Just Cleaning, It's an Investment in Efficiency

Daily maintenance of concrete brick machines is often simplified to "wiping and wiping," but it is actually a sophisticated efficiency assurance system. Daily hydraulic system pressure testing before work can prevent more than 30% of molding defects; weekly mold alignment calibration can increase the product qualification rate by 5 percentage points; and monthly vibrator amplitude testing directly affects brick density and compressive strength.

II. Periodic Maintenance: The Core Strategy for Extending Equipment Lifespan

1. Weekly Maintenance: Balancing Lubrication and Tightening

Lubrication Management: Apply lithium-based grease to moving parts such as bearings, gears, and chains; check the smoothness of the lubrication pump and oil pipes. For example, a brick factory experienced gear wear due to delayed lubrication, increasing replacement costs by 20,000 yuan.

Molding System Inspection: Adjust the parallelism of the pressure head and mold frame (deviation ≤ 0.5mm), and test whether the vibration motor frequency meets production requirements.

Connector Tightening: Tighten the bolts of the mold, vibration motor, and frame to standard torque using a torque wrench to prevent loosening during operation.

2. Monthly Maintenance: Deep Cleaning and Performance Calibration

 Hydraulic System Maintenance: Test the viscosity and pH of the hydraulic oil; if the indicators exceed the standards, completely replace the hydraulic oil and clean the oil tank and filter element; check the operating performance of the hydraulic pump and motor, and repair or replace them if necessary.

Electrical System Inspection: Clean the dust from the distribution box, check for contactor and relay contact erosion, and test the motor insulation resistance (≥ 0.5MΩ is acceptable).

Precision Calibration: Use a laser rangefinder to calibrate the machine body level, pressure head stroke, and mold frame positioning accuracy to ensure that the brick size deviation is ≤ 3mm.

3. Quarterly Maintenance: Structural Reinforcement and Wear Parts Reserve

Structural Component Inspection: Disassemble the conveyor belt roller bearings and replace worn parts; check the oil level in the material distributor gearbox and replenish with 46# machine oil.

Mold Replacement: If the mold cavity wear exceeds 2mm, it needs to be repaired by welding or replaced to prevent brick chipping and cracking.

 Rust Prevention: After derusting the frame and transmission components, apply anti-rust paint to extend the equipment's service life.

III. Common Fault Troubleshooting: Practical Guide to Quickly Restore Production

1. Brick Forming Defects

Uneven Density: Adjust feeding parameters or check the mixing device (e.g., worn mixing fork); replace the vibrating table/pressure head rubber pad or synchronous gear rack.

Cracks and Chips: Adjust material moisture (15%-20%) and extend the material distribution time; clean mold blockages and replace worn mold frames or side plates.

 Inconsistent Height: Adjust the round nuts on both sides to the same height to ensure the pressure head presses down parallel.

2. Hydraulic System Failure

Insufficient Pressure: Check for hydraulic pump cavitation (insufficient oil level in the tank, clogged suction filter), clean the filter and replenish hydraulic oil; check for jamming of the relief valve and solenoid valve, replace seals if necessary.

Overheating: Clean radiator fins, check cooling water pump circuit; appropriately reduce feed speed to lighten the load.

Oil Leakage: Tighten loose pipe joints, replace aged O-rings or gaskets; check for cracks in oil pipes, replace if necessary.

3. Electrical Control System Failure

Motor Not Starting: Check power supply voltage and terminal tightness, test motor winding resistance; adjust thermal relay and circuit breaker settings.

 PLC Logic Malfunction: Check sensor signals (e.g., proximity switch misalignment, aging wiring), recalibrate parameters; contact manufacturer technicians to fix program errors.

4. Vibration System Abnormality

Weak Vibration: Tighten bolts connecting the vibration motor to the frame, replace damaged bearings or eccentric blocks; check the synchronization of multiple motor control circuits.

• Abnormal noise: Adjust the vibration platform support springs, replace broken or fatigued springs; install anti-vibration pads to reduce resonance.

Daily maintenance and troubleshooting of concrete brick making machines are not independent processes, but rather complementary and synergistic. Comprehensive daily maintenance reduces the probability of malfunctions and the frequency of troubleshooting; efficient troubleshooting quickly resolves problems when they occur, reducing equipment downtime. Only by combining these two aspects can the goal of "increasing production and efficiency" be truly achieved.