The fundamental reason is that the mechanism leakage plate production line
is an industrialized system that pursues high efficiency, high quality, and
large-scale continuous operation, and steel molds are the answer to meet all the
demanding requirements of this system.
Simply put, the supporting steel molds are the core components for
achieving automation, standardization, and efficient operation of the production
line.
Below are several key dimensions to explain in detail why it must be
"matching" and "steel":
Why must it be 'matching'?
The production line is a system, and the mold is a key link in the system
that must be coordinated with all equipment.
Accurate matching of size and positioning: The mold must be perfectly
matched with the interface size of the conveyor track, vibration table, flip
demolding machine, stacker crane and other equipment on the production line to
ensure smooth flow and precise positioning between various workstations.
Process matching: From concrete fabric, high-frequency vibration
compaction, to steam curing, automated demolding, each link has specific
requirements for the stress, fixing method, and thermal conductivity of the
mold. The matching mold is tailor-made for the process flow of this production
line.
Automation support: Modern production lines pursue "one click" operation.
The mold needs to be designed with standard lifting points, flipping axes, and
locking mechanisms so that the robotic arm or specialized equipment can
automatically grasp, flip, and demold, reducing manual intervention.
Why must it be made of "steel"? (The irreplaceable advantage of steel
molds)
a. Extremely high durability and lifespan
Wear resistant and impact resistant: The production of fecal leakage boards
uses dry and hard concrete containing sand and gravel, which causes significant
wear on the mold cavity under high-pressure vibration. The hardness, strength,
and wear resistance of steel (usually Q235 or manganese plate) are much better
than other materials (such as plastic, resin, or wood), and the service life of
a high-quality steel mold can reach tens of thousands or even hundreds of
thousands of times.
Resistance to deformation: Steel molds can maintain extremely high
dimensional stability under long-term concrete lateral pressure, vibration
force, and thermal expansion and contraction, without easily bending or
deforming, ensuring product consistency.
b. Excellent dimensional accuracy and surface smoothness
Precision machining: Steel molds can be manufactured through CNC cutting,
milling, and other methods to ensure precise and error free dimensions of each
hole and reinforcing rib, with extremely small tolerances.
Smooth surface: The inner cavity of the mold has been polished or specially
treated, making it very smooth. This makes demolding easy, and the surface of
the finished fecal leakage board has high smoothness, smooth pores, and is not
easy to accumulate dirt and grime, making it easy to clean. This is also a key
indicator of high-quality fecal leakage boards.
c. Excellent demolding performance
The surface of steel can undergo special treatment (such as spraying
release coatings such as Teflon) to further reduce the adhesion of concrete,
achieve rapid and complete demolding, not only improve efficiency, but also
reduce the rate of finished product damage.
d. Efficient thermal conductivity
The production line commonly uses "steam curing kilns" to accelerate
concrete hardening and shorten the production cycle. The good thermal
conductivity of steel enables molds and concrete to be heated quickly and
evenly, greatly improving maintenance efficiency. This is incomparable to
plastic or composite material molds.
e. Suitable for automation and mass production
Weight and strength balance: Steel provides sufficient strength while being
relatively controllable in weight, making it easy for automated equipment to
handle.
Maintainability: Even if there is local wear or damage, steel molds can be
repaired by welding, grinding, etc., with relatively low maintenance costs and
extended overall service life.
Why is it not possible to compare with other materials?
Plastic/composite material molds: not wear-resistant, short lifespan (may
only be a few hundred times); Poor thermal conductivity affects maintenance
efficiency; Low strength, easy to deform, difficult to ensure the accuracy of
large-scale products; The initial cost may be low, but the overall single cost
is much higher than that of steel molds.
Wooden mold: only suitable for extremely small quantities and handmade
workshop production. Easy to absorb water and deform, size cannot be guaranteed,
surface roughness, difficult demolding, extremely short lifespan, completely
unable to adapt to the high-speed rhythm of automated production lines.
