Abstract: This article introduces the fully automatic multifunctional one-time forming brick making machine and T-shaped porous bricks developed by Shenyang Hongkun Mechanical Equipment Co., Ltd., and analyzes the characteristics and application scope of this equipment.
Keywords: one-time brick making machine; T-shaped porous bricks; Decoration; Wall energy-saving; heat preservation
1. background
Bricks and tiles are local bulk products with large quantities and wide production distribution. There are nearly 100000 state-owned brick and tile enterprises in China, and most of them have outdated production processes and equipment, single products, and poor quality. In recent years, with the rapid development of China’s economy, the brick and tile industry has made significant progress, and the level of technical equipment has been rapidly developed. New technologies and equipment such as high-performance brick machines, robot barcode systems, and automatic barcode machines have been vigorously promoted and applied, and a number of large-scale and high-tech brick and tile production enterprises have been built. At present, with the adjustment of China’s economic structure, on the one hand, there is overall overcapacity in the wall material industry, and on the other hand, there are few types of green products that meet the requirements of building energy conservation and environmental protection, resulting in insufficient performance. According to incomplete statistics, there are over 1000 enterprises in China that provide technical services and equipment for the production of sintered bricks and tiles, among which only a few dozen have influence in the industry. There are few enterprises that truly have innovation and competitiveness. Equipment enterprises imitate each other, with a clear tendency towards equipment homogenization, intensified competition, rising costs, and a significant decline in efficiency. The adjustment of industry structure is the development of soil conservation, energy conservation and emission reduction, waste utilization, environmental protection, insulation, and green products. The upgrading of the industry is the innovative development of equipment technology. Therefore, this article introduces the products of Shenyang Hongkun Mechanical Equipment Co., Ltd., which have been successfully tested and obtained national invention patents after years of research – a “fully automatic multifunctional one-time forming brick making machine” and a “T-shaped porous brick”.
2. multi-functional one-time brick making machine
2.1Principle and Function of Multifunctional Brick Machine:
Different from traditional extrusion molding machines, the multifunctional one-time brick making machine adopts a mold chain walking molding method. The principle is that the mold chain is driven in parallel by a cycle of parallel traction, and a single blank is continuously pressed into holes through an inclined track up and down. It can form porous bricks and hollow bricks with various hole shapes and holes arranged in different ways, especially brick shapes mixed with T-shaped holes and cross shaped holes, If the extrusion method is used to shape products with this special pore structure, it will cause the core frame and core rods to be arranged in a staggered manner, which is impossible to achieve; The total mass of the currently produced molding machine is 12 tons, as shown in Figure 1. Among the components, the structural parts composed of ordinary sheet metal and profiles account for 1/3 of the machine weight, the castings account for 2/4, and the general and standard parts account for more than 60% of the total number of components, indicating a high degree of standardization. The core technology is mold manufacturing, which uses a belt conveyor to transport raw materials into the guide groove and then enter the mold box separately. The active sprocket drives the mold box to move, the mold chain circulates, and the single billet is continuously formed. This avoids the drawbacks of high energy consumption, frequent replacement of mud holes and rib breaks, and leakage of mortar through holes in the molding machine. There are push plates, mold cores, and covers in the mold box, which are formed by the angle generated by the up and down rails during operation. At present, the molding machine can process two types of bricks, producing sintered bricks and concrete block bricks, with low production costs and easy promotion.
Figure 1 Multifunctional one-time forming brick machine
2.2 T-shaped porous bricks
Formed T-shaped porous brick size: long × wide × Height=240 mm × 115 mm × 90 mm; Hole type: T-shaped and cross shaped mixed; Void rate: ≥ 32%; Hole width 10 mm; Longitudinal 240 mm, conduction path 560 mm, transverse 115 mm, conduction path 169 mm; Thermal conductivity: ≤ 0.21 W/(m · K).
The characteristic of T-shaped porous bricks is that the porosity is above 32%; High thermal resistance, T-shaped hole structure, with a hole width of 10 mm, as shown in Figure 2. The T-shaped and cross shaped hole walls have the longest path, and the path through which heat transfer passes is 2.5 times the length of ordinary bricks, greatly improving insulation performance; It can increase the utilization of waste, mainly including industrial waste residue, coal gangue, fly ash, and construction waste.
Figure 2 T-shaped porous brick
Decorative: Clear water wall tiles, embossing, polishing, sandblasting, glazed
Taking the 370mm wall KP1 brick (T-shaped masonry method) in the cold northern region as an example, a T-shaped porous brick is used to add benzene plates in the longitudinal and transverse middle, with a thickness of 30 mm to 50 mm and a height of 100 mm to 300 mm. One or more layers are inverted according to the conventional masonry method, and after adding benzene plates in each layer or multiple layers, a 90 mm plate is added to the top × 20 mm × A 5mm iron clip is designed to prevent separation based on the benzene plate and hole spacing, to enhance the overall integrity of the wall and block the ash cold bridge, thereby improving the insulation effect of the wall.
In the southern region, taking the KP1 brick of a 240mm wall as an example, T-shaped porous bricks are used according to the conventional masonry method. Each layer has a 10mm thick ash opening, and a benzene plate with a width of 20mm~50mm is added longitudinally along the wall in the middle. This can block the cold and hot air conduction path of the ash opening, improving the energy-saving effect of the wall.
2.3 Technical parameters of multifunctional one-time brick making machine
The main technical parameters of the multifunctional one-time forming brick making machine are as follows: ① brick size: porous bricks that meet national standards; ② Hole rate: load-bearing porous bricks ≥ 33%, porous cut block bricks ≥ 50%; ③ Hole type: T-shaped, cross shaped mixed; ④ Hole width: ≤ 10 mm; Mud rib width: 10 mm; ⑤ Longitudinal (240 mm long) heat transfer path: 560 mm; ⑥ Thermal conductivity: ≤ 0.21W/(m · K); ⑦ Production efficiency: 6500 pieces/h (>11000 standard bricks/h); ⑧ Host size: long × wide × Height=5.6 m × 10 m × 2.4 m; ⑨ Body mass: 12 t; 10 Installed capacity: 7.5 kW~22 kW; Å Core replacement cycle: greater than annual production capacity.
2.4 Characteristics of multifunctional one-time brick making machine
a. Automation: No manual control is required, and mechanical control is used for feeding, forming, and discharging bricks.
b. Versatility: ① Capable of producing sintered brick T-shaped hole KP1 series porous bricks; ② Capable of producing sintered brick T-shaped hole DM series porous bricks; ③ Capable of producing sintered hollow block series bricks; ④ Concrete hollow block series bricks.
c. Uniqueness: The T-shaped porous brick is sealed with leak free mortar on top, and has a relative T-shaped hole depth of 3 mm, which has good shear resistance; Making a clean wall can prevent water seepage from the wall.
d. Energy efficiency: The main power of the entire machine is a 7.5 kW~22 kW motor, and there is no excess waste during the production process.
e. High production capacity: up to 7000~25000 pieces per hour (equivalent to standard bricks).
f. Forming rationality: The raw materials enter the mold box through a straight line operation of the cover, mold core, and push plate, which generate vertical movement through the up and down inclined tracks in the mold box, forming it. After forming, they are transported to the bottom and pushed out by the lower inclined track, and the brick blank can be formed.
g. Simple manufacturing process: This machine has a simple manufacturing process, using ordinary profiles and steel plates without the need for special raw materials; The mechanism is cast into shape without screws, preventing detachment, easy assembly, and safe operation.
In summary, the brick surface formed by this equipment is smooth and of good quality, which can meet the new national requirements for energy conservation and insulation. It is easy to operate, easy to promote, and suitable for technical transformation and upgrading of brick factories.
Formed products have incomparable advantages compared to traditional porous bricks:
①The holes can be dense or thin, and under the production conditions of existing brick factories in China, high porosity porous bricks that exceed national standards can be produced. The unique feature of the forming mechanism is that it is easy to form holes, with clear hole contours, complete and beautiful hole rib structures; ② The brick body has a long heat transfer path and low thermal conductivity. The staggered arrangement of holes can increase the heat conduction path and improve the insulation effect; Among the various hole types of porous bricks, circular holes have the worst heat resistance, not as good as rectangular strip holes or rectangular holes, while T-shaped holes have the best insulation effect, but it is difficult for the extruder core frame to achieve. The heat conduction path of the porous bricks produced by the multi-functional one-time molding brick making machine is more than 1.5 times that of the vacuum extrusion mud and extruded circular porous bricks, with a longitudinal length of 560 mm, which is more than 2.3 times that of solid bricks. The thermal conductivity of solid bricks is 0.81 W/(m · K), while the thermal conductivity of porous bricks produced using this equipment may decrease to 0.2 W/(m · K); ③ Saves mortar, saves labor in masonry, and is easily accepted by construction units. The porous brick produced by a multifunctional one-time brick making machine has a closed top surface that will not cause mortar leakage.
2.5 The application range of multifunctional one-time brick making machine
The multifunctional one-time forming brick making machine has obtained a national patent, developed and tested by enterprises, and is particularly suitable for the needs of brick factories in China to produce various types of porous bricks.
The patented technology of a multifunctional one-time brick making machine has strong scalability. It can be extended from producing current KP1 porous bricks to producing various modular bricks, which can meet the needs of China’s construction industry to gradually transform towards modular bricks for masonry. This brick machine can also form clean water walls, decorative bricks, and porous bricks with various decorative functions such as smooth, floral, and sandblasting.
3. Conclusion
The fully automatic multifunctional one-time molding brick making machine is a gratifying attempt at technological equipment innovation in the brick and tile industry, setting a model for the research and development of core technologies with intellectual property rights in the brick and tile industry. Practice has proven that only through continuous efforts and exploration can the industry develop. The application and improvement of multifunctional one-time brick making machines will definitely play a better role in expanding the variety of wall materials, improving product functions, and solid waste brick making.
