How to regularly maintain and service a brick-making machine?

How to regularly maintain and service a brick-making machine?

Maintenance and service of Exmork brick-making machine are key to ensuring stable production, extending equipment life, and reducing repair costs. The principle of "prevention first, combining maintenance and repair" must be adhered to.

The following is a detailed and practical guide to brick-making machine maintenance and service, covering daily, periodic, and component-specific measures:

1. Daily Maintenance (Before and After Each Shift)

This is the most basic and crucial step, performed by the operator.

Cleaning:

After-Shift Maintenance: After each shift, the machine must be thoroughly cleaned. Remove any remaining concrete from the hopper, mold, feed box, vibrating table, and any corners of the machine. Hardened concrete lumps can damage the equipment and affect the quality of the next molding.

Keep it dry: Wipe away oil and moisture from the surface of the equipment and keep it clean and dry.

Tightening Inspection:

Inspect and tighten all connecting bolts, especially the base bolts of the vibration motor and the mold fixing bolts. Bolts are prone to loosening due to the long-term high-frequency vibration of the equipment. Lubrication and Maintenance:

According to the equipment manual, fill all oiling points (such as bearings, guide rails, and chains) with the specified lubricant or grease. Note:

The guide pins and bushings of the mold and ram should be cleaned and greased every shift to prevent dry grinding and seizure.

Avoid spilling lubricant onto the pallet or mold cavity, as this may affect the quality of the bricks.

Operational Inspection:

Before starting the machine, check that the oil level in the hydraulic station is within the specified range.

After starting the machine, listen for any unusual knocking or grinding sounds to ensure smooth operation.

II. Regular Maintenance (Weekly, Monthly, or Hourly)

This is a more in-depth maintenance procedure and should be performed by professional maintenance personnel or experienced operators.

Hydraulic System Maintenance:

Hydraulic Oil: Check the oil quality regularly. If the oil becomes dark, thick, or foamy, it should be replaced promptly. It is generally recommended to replace the hydraulic oil and oil filter every 2,000-3,000 hours of operation or annually. Oil Line Inspection: Inspect all hydraulic oil lines and joints for leaks, wear, or signs of aging, and address them promptly.

Cleanliness: Keep the hydraulic station and its surroundings clean to prevent dust and debris from entering the oil lines.

Vibration System Maintenance:

Vibration Motor: Regularly inspect the bearing condition and wiring of the vibration motor for tightness. Use a megohmmeter to check its insulation resistance to ensure the motor is free of moisture.

Vibration Spring/Rubber Pad: Inspect the buffer device (spring or rubber pad) under the vibration table for breakage or permanent deformation, and replace it promptly.

Electrical System Maintenance:

Regularly inspect all wiring terminals for looseness.

Check the position, sensitivity, and reliability of limit switches, proximity switches, photoelectric sensors, etc., and clean their sensing surfaces.

Cleanse dust from the electrical control cabinet to prevent short circuits.

III. Special Maintenance of Key Components

These components are directly related to the health of the brick making machine and product quality, and require special attention.

Mold Maintenance and Care:

The mold is the "heart" of the brick making machine. Daily Cleaning: Before leaving each shift, remove any remaining material from the mold and apply oil to prevent rust.

Avoid air vibration: Prolonged vibration without material is strictly prohibited, as this will severely wear the mold.

Regular Inspection: Inspect the mold's inner wall, lining, and pressing head for excessive wear or scratches, which can cause inaccurate brick dimensions or difficulty in demolding. Repair or replace as necessary.

Pallet Maintenance: Pallets support bricks, so their flatness is crucial.

Timely Cleaning: Residual material should be removed from the surface after each cycle.

Regular Leveling: Regularly inspect pallets for warping and leveling. A warped pallet can cause uneven brick thickness and even damage the equipment.

IV. Establish Maintenance Records and Safety Procedures

Establish Records: Create a maintenance log for each piece of equipment, recording the time and content of each maintenance, repair, and parts replacement. This helps track equipment status and predict failures.

Safety First: All maintenance and repair work must be performed with the power completely disconnected and the hydraulic system depressurized. Hang a warning sign that reads "Maintenance in progress, do not close the switch."

Summary: Maintenance Tips

For easier memorization, you can follow the following tips:

"Check before starting the machine, clean after starting it" – Check before starting the machine, and clean after leaving the machine.

"Tighten the bolts, keep the oil lines open" – Tighten the bolts and maintain lubrication.

"Clean oil, stable hydraulics" – Keep the hydraulic oil clean and the system stable.

"Clean molds, high-quality products" – Clean molds ensure high-quality bricks.

Institutionalizing and regularizing maintenance tasks will not only minimize losses caused by sudden equipment downtime, but also keep your Exmork brick-making machine in a youthful state for a long time, creating greater economic benefits.