# **Operation Process & Technology of Vibrator Terrazzo Machine**
## **1. Raw Material Preparation**
- **Aggregate Mixing**:
- Marble/granite chips (3-8mm size) mixed with cement/polymer resin (ratio depends on design).
- Additives (optional): Pigments, fiberglass reinforcement, waterproofing agents.
- **Moisture Control**:
- For cement-based terrazzo: Optimal water-cement ratio (0.4-0.5).
- For resin-based: Precise catalyst mixing for proper curing.
## **2. Machine Setup & Pre-Operation Checks**
- **Mold Installation**:
- Secure steel/polyurethane molds of desired tile size (e.g., 300x300mm to 600x600mm).
- Apply mold release agent (for easy demolding).
- **Vibration System Calibration**:
- Adjust eccentric weights on vibrator motors (typically 3000-6000 RPM).
- Set vibration duration (10-30 secs depending on mix thickness).
- **Control Panel Settings**:
- Program PLC for automatic cycles (filling → vibration → demolding).
- Set hydraulic pressure (if equipped, usually 10-20 MPa).
## **3. Production Process**
### **A. Material Loading**
1. **Automatic Feeding**:
- Conveyor belt transports premixed terrazzo into mold cavity.
- Sensors ensure uniform filling (avoid over/under filling).
2. **Manual Feeding Option**:
- Workers pour mix into molds, leveling with trowels.
### **B. Vibration & Compaction**
1. **High-Frequency Vibration**:
- Motors (2-4 units, 0.75-5 HP each) activate at 4000-7000 VPM (vibrations per minute).
- Eliminates air bubbles, ensures aggregate distribution.
2. **Secondary Compression (Optional)**:
- Hydraulic/pneumatic press applies 5-15 tons pressure for denser tiles.
### **C. Surface Finishing**
1. **Smoothing**:
- Trowel or roller levels surface during vibration.
2. **Embedded Reinforcement**:
- Wire mesh/fiberglass inserted (for large-format tiles).
### **D. Demolding & Curing**
1. **Ejection**:
- Hydraulic lift or manual removal of tiles from molds.
2. **Initial Curing**:
- Cement-based: 24hrs in humid room (90% RH).
- Resin-based: UV/heat curing (1-4 hrs at 50-80°C).
## **4. Post-Processing**
- **Grinding & Polishing** (after 7-28 days for cement-based):
- Diamond abrasive pads (50-3000 grit) for glossy finish.
- **Sealing**:
- Penetrating sealants (e.g., epoxy, polyurethane) for stain resistance.
## **5. Quality Control Checks**
- **Dimensional Accuracy**:
- Calipers measure thickness (±0.5mm tolerance).
- **Strength Testing**:
- Compression test (≥40 MPa for cement-based).
- **Visual Inspection**:
- No cracks, consistent color/aggregate distribution.
## **6. Automation & Advanced Tech**
- **Smart Sensors**:
- Monitor vibration frequency, material flow in real-time.
- **IoT Integration**:
- Remote diagnostics for motor performance, maintenance alerts.
- **Energy Recovery**:
- Regenerative braking in vibratory motors reduces power use.
## **Key Operational Parameters**
| Parameter | Typical Value |
|-----------|--------------|
| Vibration Frequency | 50-100 Hz |
| Compaction Time | 15-60 secs |
| Tile Density | 2.3-2.5 g/cm³ |
| Production Capacity | 100-500 tiles/shift |
**Maintenance Tips**:
- Daily: Clean molds, check motor mounts.
- Weekly: Lubricate bearings, inspect electrical connections.
Would you like details on optimizing the process for specific materials (e.g., recycled glass
terrazzo)?
