ULTRA-3000 Brick, Block and Paver Making Machine

Features & Benefits

For smaller capacity brick, block and paver making plants view the RE1400, RE1400-LITE, VB4X, VB4, VB1X, VB1, RE600, Twin UNI PLANT, UNI PLANT, UNI HYDRAULIC, UNI STATIC, UNI-ECO, PK300 CORNET and PK300-ECO.

PMSA^®’s ULTRA-3000 is Built to Last^® and has more than 40 top of range technology features, making it the market-leading ultra large capacity brick, block and paver making machine. Features of the ULTRA-3000 include:

Mechanical Features

• Robust heavy-duty tubular frame for long-life and machine rigidity which results in the consistent production of quality products for decades.
• Rigid machine and vibrator base frame contain the vibration and movement forces of the machine resulting in simpler flat slab foundations (without a pit) utilizing less concrete and lower civil costs.
• Bolted machine frame and vibration table base frame allows for any frame component on the machine to be replaced, this also allows for the future changing of the vibrator table to suit a different production board size if ever required.
• 120 mm hard chrome shafts provides a larger area for load bearing and no flexing which results in very stable guiding of both tamper and mould.
• The 4 hard chrome shafts are connected through a solid frame to provide stability and even lifting and lowering of the clamped mould assembly eliminates all lateral or longitudinal movement of the mould.
• Easily replaceable wear resistant guide shaft bushes for accurate tamper and mould box movement ensures dimensional consistency of products.
• Machine pins are held in place with power-locks for longer component life and ease of replacement.

Vibration System Features

• The Ultra-3000 comes standard with the UltraVibe CVS™ with fully adjustable vibration force up to 170 kN (approx. 17 tons).
• Heavy engineered construction of the vibration table and vibrator boxes making them with 3-years maintenance-free vibrator boxes.
• 4-motor UltraVibe CVS™ (continuous vibration system) with both instant force and frequency control independent from each other with both parameters adjustable in less than 0.2 of a second.
• The UltraVibe CVS™ provides faster cycle times, high vibration energy and smoother operation resulting in maximum product density and compaction, reduced cement consumption, lower energy consumption and less wear and tear on the block machine.
• UltraVibe CVS™ allows for specific vibration force and frequencies for each different product type resulting in optimal compaction to suit each product being manufactured as well as increased mould life.

Mould Filling and Feeder-box Features

• The concrete silo bin has a specially designed silo door to create even feeder-box filling resulting in more consistent mould filling.
• The concrete silo door is electrically operated with a variable speed drive to control the accuracy and speed of the dosing of concrete into the feeder-box.
• The height of the concrete silo and feeder-box assembly is easily adjustable by electrically driven operation for different mould heights and quick mould changes.
• A laser height sensor ensures accurate and consistent feeder-box filling.
• Feeder-box and agitator run in enclosed rails with smooth linear movement resulting in faster and consistent mould filling.
• The feeder-box and agitator have heavy-duty adjustable rollers for long-life and low wear.
• The enclosed rails have replaceable upper and lower wear plates for long-life and ease of maintenance.
• The feeder-box has moveable concrete dividers and bars to control filling for every different type of product being manufactured.
• The feeder-box and agitator are as strong and light as possible so that the forces, wear and energy requirement of moving the feeder-box is reduced resulting in lower running costs.
• High speed feeder-box agitator is fully controllable to optimise mould filling of a wide range of different products with varying heights.
• Abrasion-resistant spring loaded side scrapers and pneumatic independently controlled front and rear scrapers reduce concrete spillage.
• Topping/secondary feed options are available for kerbs, retaining wall blocks and ultra-smooth paving product surfaces.

Tamper and Mould Box Features

• The tamper head is fitted with solid spacers instead of anti-vibration mountings and a fixed mechanical tamper lock for the manufacture of high products to ensure consistent height of the products up to 500 mm high.
• Tamper rubbers are supported both in lifting and compression from over-travel to increase their lifespan.
• The tamper is free floating which results in superior compaction of the concrete products with less vibration force required resulting in lower energy consumption and longer component life.
• Heavy-duty mechanical tamper brake, fitted to the machine frame for easy maintenance, locks tamper movement during product de-moulding resulting in the highest quality products.
• Top tamper vibrators ensure increased product density and a smoother top surface for paving slabs and products.
• Tamper head low-friction bushes, spaced far apart, ensure maximum tamper stability and no lateral or longitudinal movement.
• Sensors can be fitted to determine which part of the tamper reaches the product height first, allowing for automatic control to compensate for unequal mould filling.
• The mould box and tamper are pneumatically clamped for fast mould changing as well as improved and focused vibration of the concrete product only (smart vibration system).

Hydraulic Features

• Powerful hydraulic system with accumulators, servo proportional valves and encoders for closed loop feedback with variable speed operation resulting in smooth and precise movement of tamper, mould, feeder-box and production board feeder for faster cycle times, lower maintenance costs and extended component life.
• The power pack has dual hydraulic pumps enabling the machine to run on a single pump in event of a breakdown.
• The power pack with cooling system is separate from the valve stand allowing for both to be positioned suiting any plant requirement including replacement of other makes of machines in existing production plants.
• The valve stand has a flexible hose connection to the machine for vibration damping to the valves.
• The hydraulic fittings have a double seal arrangement for improved sealing and maintenance free operation.

PLC and SCADA Features

• The PLC (Programmable Logic Controller) and SCADA (Supervisory Control and Data Acquisition) system include functionality for data storage, fault identification, programmed scheduled pre-emptive maintenance and timeous parts replacement, resulting in increased productivity and machine longevity.
• Immediate screen warnings for oil filter blockages, overheating, scheduled maintenance or faults, requires a password to override the warnings which are logged to assist management in operator accountability.
• All machine parameters can be changed using a touch-screen with graphic interface while the machine is in operation for instant adaptation to changing concrete mix characteristics without stopping the machine.
• Graphic representation of the UltraVibe CVS™ parameters indicate if the vibration frequency and/or force exceeds normal parameters, prompting a code to be entered, confirming that standard operating parameters will be exceeded.
• The controller is equipped with a modular dual communication system for all sensors, allowing for continuous communication in the event of cable fault or damage.
• The PLC components and IO modules are easily replaced and do not require pre-programming.

Production Board Handling Features

• Production board handling systems are designed to individual client requirements, capable of using steel, composite or wood production boards.