Advanced Semi-Automatic Brick

Manufacturing Machine
Gajanan Madhukar Kulkarni, Mayuresh Ganesh Gawali,
and Samarth Madhukar Kulkarni
Keywords Brick · Brick size and volume · Moulds · Compressing element ·
Transmission system · Hopper
1 Introduction
The construction sector is an important part of the Indian economy with the
contribution of 10% in GDP and is registering an annual growth of 9%. Bricks are
the backbone of this sector. The brick was historically manufactured by an ancient
method dating back to 6000 B.C. called the soft mud process in which relatively
moist clay is pressed into simple rectangular molds by hands. To keep the sticky clay
from adhering to the molds, the molds may be dipped in water immediately before
being filled, producing brick with a relatively smooth, dense, surface know as water
struck brick [1]. The time required for the manufacturing of bricks was more hence;
the needs of construction business cannot be fulfilled. So to avoid the problems
mentioned above& make bricks available in low cost, the ‘Advanced SemiAutomatic Brick
Manufacturing Machine’ has invented.
Olga et al. [1] studied the effects of agricultural solid waste (oat husk and barley husk
and middlings) on the physical and mechanical properties and porosity of fired clay
bricks. Neslihan and Adnan [2] studied the manufacturing phases of traditional clay
bricks in Diyarbakir’s local workshops. Their study identifies that the traditional
manufacturing of clay brick methods in Diyarbakır is similar in many regions of the
world. Stephen P. Luby et al. [3] studied the systemof brick manufacturing in
Bangladesh is an economic equilibrium with the manufacture of inexpensive bricks
supplying the demand for construction materials but at a high cost to the environment
and health of the population. From the literature survey, it is observed that many
researchers have focused on various materials used along with mud clay for the
G. M. Kulkarni (*)
A. G. Patil Polytechnic Institute, Solapur, Maharashtra, India
M. G. Gawali · S. M. Kulkarni
A. G. Patil Institute of Technology, Solapur, Maharashtra, India
© Springer Nature Switzerland AG 2020
P. M. Pawar et al. (eds.), Techno-Societal 2018,
https://doi.org/10.1007/978-3-030-16962-6_47
463
manufacturing of brick [4, 5]. None of the researchers has tried to develop any another
method or machine for brick manufacturing. Hence, there is the scope of further research
work by designing & developing a machine, which will give more profit to the
manufacturer by increasing productivity within the lesser time limit in less investment.
2 Machine Components
2.1 Introduction
The ‘Advanced Semi-Automatic Brick Manufacturing Machine’ looks like a small
vehicle; the main components of the machine are Mould Drum, Hopper,
Compressing Gear, Wheels, Transmission, Ejection System and Frame.
2.2 Frame
The frame is the most important part of the machine it is like a skeleton. From
available options; Mild Steel (Square Pipe) had selected for manufacturing of frame.
Mild Steel (Square Pipe) was very easily available and it was best wieldable material
amongst the two viz. Aluminum and Mild Steel. Different components of the frame
are made from the single square pipe of (40 feet) 12,192 mm, having different in
length. The comparison between these two materials are given in Table 1. İmage of
the frame has given in Fig. 1.
2.3 Mould
Mould is mounted on the periphery of two circular molddiscs. Mould has made up of
Medium-density fibreboard (MDF).
Hence by considering all these parameters and design requirements, MDF was
selected for the manufacturing of mold whose comparison is given in Table 2. The
different parts has been given in Fig. 2a, b.
Table 1 Comparison between mild steel and aluminum
Sr. No. Parameters
Material
Aluminum Mild steel
1. Weight Very less Moderate
2. Cost High Affordable
3. Strength Very weak Moderate
4. Availability Not easily available Very easily available
464 G. M. Kulkarni et al.
2.4 Mould Disc
Mould disc is the part of mold drum assembly. On the periphery of two discs
moldshas been mounted in a circular pattern. This two-disc has a bore of the required
diameter through which axle is passed Total 32moldshave been mounted on the disc.
The MDF sheet of thickness 18 mm was used for this. Picture of mold disc has given
in Fig. 3
Fig. 1 Frame
Table 2 Comparison between MDF, Ply wood and Sagwan
Sr. No. Parameters
Material
MDF Ply Wood Sagwan
1. Weight Very less Moderate Heavy
2. Cost Affordable Low Very high
3. Strength Very high Not enough High
4. Availability Easily available Easily available Low
5. Water proof Highly Moderate Highly
Fig. 2 Different components of mould (a) Top plate (b) Bottom plate
Advanced Semi-Automatic Brick Manufacturing Machine 465
2.5 Compression Gear
It has a shape like gear so it is called as compressing gear. It is supported with axle
separately provided for it and present at the upper side of the frame. Total 9 no. of
tooth’s are present on the gear. İt has manufactured from MDF. Picture of compression gear
has given in Fig. 4
2.6 Cam
Cam plays a very important role in the ejection of bricks from the mould. Mould
drum and axle on which it is mounted both are rotary but the cam is stationary. Cam
also has one bore situated at top of it which fixes the cam in its position, through that
bore axle passes, and mounted on the same axle on which mold drum has mounted.
Cam has manufactured from MDF. İmage of the camhas given in Fig. 5.
2.7 Road Wheels
Road wheels are nothing but the wheels connected to the bottom axle and in contact
with the ground. There are four wheels used in the machine. These four wheels are
Fig. 3 Mould disc
Fig. 4 Compression gear
466 G. M. Kulkarni et al.
connected to frame with help of axles. As per design requirement, 420 mm wheel
diameter has used. Wheels have been made up of rubber tire and metallic rim.
2.8 Axles
It is situated on the frame i.e. ends of axles are supported on frames and fixed their
position with the help of bushes. Total 4 axles of same diameter and length are
used in the machine of the same material. Hollow Pipe has used as axle because it
has more torque transmission capacity than the solid shaft and also it is light
weight. As per design requirement, mild steel pipehas used of circular crosssectional pipe as
an axle.
2.9 Hopper
In this machine, hopper acts as a storage place which containsa mixture of soil,
water, silica, ash, etc. is kept in the hopper and transferred it to the mold cavity.
Hopper is at topmost position of the frame. The opening of the hopper is just above
the mold cavity and hoper has supported by the bars welded to the frame and
connected to the walls of the hopper. A sheet metal of thickness 0.5 mm is used
for manufacturing of hopper. The sheet metal is of tin, it is light in weight, easy for
fabrication, has high strength and non corrosion property.
2.10 Ejection System
It consists of different parts such as, ejector, ejector pin, guiding pin, helical
compression spring. It is situated in mold and rested on a bottom plate, the ejector
is connected to the ejector pin and guiding pin. One helical compression spring is
Fig. 5 Cam
Advanced Semi-Automatic Brick Manufacturing Machine 467
present on the ejector. Ejector had made from MDF sheet of 12 mm thickness.
Ejector pins and guiding pins were made of mild steel and brass respectively. Spring
used in the slothas made from spring steel.
2.11 Sprockets
There are two sprockets present in the machine, one is large in size and another is
relatively small. Both are mounted on different axles respectively. Small sprocket
has present on a lower rear axle connected to the wheels, and another big sprocket
has present on a middle axle connected to the mold drum. Smaller sprocket is driver
sprocket and big sprocket is driven sprocket. Both sprockets have made up of
hardened steel.
By combining all parts of the machinean assembly of the machine had done.
Software image of the fully assembled machine has given in Fig. 6
Fig. 6 Assembled ‘Advanced Semi-Automatic Brick Manufacturing Machine’
468 G. M. Kulkarni et al.
3 Conclusion
As compared to traditional methods for brick manufacturing, the method of
manufacturing a brick by ‘Advanced Semi-Automatic Brick Manufacturing
Machine’ is simple and easy. Any unskilled operator can handle this machine.
Total 32 bricks can be laid down in one rotation of Mould Drum. The volume of
the hopper is designed to accommodate the required amount of mud i.e. 7 kg. The
various materials like Clay, Fly Ash can be used for brick manufacturing using this
machine. For one cycle, the time required is 5 min. It is compact in size and can
move in minimum space as per the requirement. The machine is mechanically
operated and hence no external power supply is needed. This avoids the problem
of pollution and hence machine becomes environment-friendly. The machine gives
very less fatigue to the operator. Therefore, the operator can work more effectively
and can give maximum productivity. The maintenance of the machine is also easy.
The cost of the machine is affordable and it has one-time investment for brick
manufacture. It will give maximum profit to the manufacturer with high
productivity.