Fully Automatic Stationary ZENITH 1500

ZENITH designs, produces and delivers state-of-the-art Concrete Products Plants on highest quality standards. Plants are characterized by innovative German
Engineering, high robustness and high cost effectiveness. The well-known ZENITH quality and safety features stand for low maintenance and uninterrupted
productions process.

Hollow Block Making Machine, Paver Making Machine, Kerbstone Making Machine - Zenith 1500
  • The newly designed high-performance single pallet machine ZENITH 1500 forms the centerpiece of a state-of-the-art and efficiently working concrete block production. The wide range of production possibilities meets all customer requirements.
  • This is the machine with improved feeding technology and unique vibration technology.
  • Variable board size     → flexible investment possibilities
  • Vibration table with bolted fittings → better exchange in shortest time possible
  • Side walls with bolted fittings → better maintenance
  • Weight improved and therefore more energy-efficient than our competitors
  • Especially suitable for high products
  • Especially solid mould change design for a secure mould change
  • Bracing of the mould via bellow cylinders on the vibration table
  • Especially big moulding press opening of 1950 mm
  • The block machine can be delivered with a vibration table height of 700  – 850mm

Features

Main Features :

(1) Vibration

Vibration with servo control (“UltraDynamic“), automatic adjustment of the vibration power and speed by changing the respective amplitudes and frequencies via the visualization (servo motor ca. 4 x 6kW, no drive). This system is especially used for high performance plants with a great product variety.

  • All vibrations are working with pre- and main vibration.
  • Production on steel, wooden and plastic production supports possible.
  • With additional motor bearing, this releases the vibration drives and therefore increases the durability.
  • Separation of vibration supports from vibration table.
  • This avoids interferences by undesired transfer of vibration to the drives
(2) Vibration table

  • Good vibration behaviour
  • Good adjustment of nocker bars
  • Service-friendly owing to bolted fittings design.
  • Simple exchange of individual vibration supports.
  • With four additional bellow cylinders to reduce the clamping power in the case of difficult, thin-walled products.
  • In the case of repair, the screwed-in vibration table beam can be completely exchanged. No additional cutting, burning or welding is necessary.
  • The vibration motors can be individually controlled with mature, acoustic diagnostics.
  • The air pressure to be installed is chosen via the visualization and then stored product-related
(3) Top Vibrator

  • Top Vibrator with Inverter Technology.
  • Extremely quick braking is possible.
  • Variable frequency and adjustment.
(4) Machine Frame:

  • Robust and bolted – in machine frame consisting of side frame left and right, vibration table beam, vibration table motor beam and crosshead
  • Stable enough for the simultaneous pressure but also flexible enough to compensate the high vibration power.
  • Avoidance of cracking caused by an inflexible welding design.
(5) Feed Box Design:

  • Improved feed box design. Feed boxes for base and face mix in quick-change design.
  • The surrounding scraper frame is adjusted via rubber buffers.
  • Continuous monitoring of the feeding is possible.
(6) Platform Adjustment during Mould Change

  • Improved feed box design. Feed boxes for base and face mix in quick-change design.
  • The surrounding scraper frame is adjusted via rubber buffers.
  • Continuous monitoring of the feeding is possible.

Guide Columns

  • Improved feed box design. Feed boxes for base and face mix in quick-change design.
  • The surrounding scraper frame is adjusted via rubber buffers.

Block Height Control

  • Improved feed box design. Feed boxes for base and face mix in quick-change design.
  • The surrounding scraper frame is adjusted via rubber buffers.
  • Continuous monitoring of the feeding is possible.
(7) Hydraulic:

  • Use of output-controlled axial piston pumps instead of cell pumps.
  • The feed rate of the pumps adapts to the actual consumption of the machine.
  • During the short production breaks and during vibration, the pumps are set into standby mode, helping energy efficiency.
  • Use of proportional control valves with integrated electronics for a continuous pressure and speed adjustment.
  • Precise control, high repetition accuracy, best positioning accuracy.
  • Power station on hydraulic power pack for simple monitoring and adjustment.
  • By using improved quick valve technology a short reaction time for parameter changes is achieved.
  • All values are adjustable via the visualization and be product-related stored.
(8) Control Unit:

  • Use of Siemens S7 1500 control and switch technology TIA. Siemens is a Global Player world-wide supply of spare parts is therefore guaranteed.
  • Cross-Linking of the Plant with PROFINET and Ethernet.
  • Tool-free installation and simple troubleshooting.
  • All visualizations can be monitored and operated in the complete plant network
  • Path Measurement System installed in Absolute Encoder Technology
  • Very high positioning accuracy
  • Very robust, low-maintenance technology
  • No re-calibration after power breakdown necessary.
  • All positions are stored in the encoders.
  • Troubleshooting via Modem. Very quick reaction time in case of problems, solution within minutes

Tech Spec

Zenith 1500 operated with Steel pallets
Max. board size 1400 mm x 1200 mm x14 mm
Product height 50-500mm
Note: All the production parameters are subject to change without prior notice.
Product Size PCS/Mould Cycle Time (cycle/min) Production cap / 8hr
Hollow Block 400 x 200 x 200mm 15 4 3240 pcs
Rectangular Paver (with face mix) 200 x 100 x 60mm 60 4.2 272m2
Rectangular Paver (without face mix) 200 x 100 x 60mm 60 5.4 349m2
Kerb Stone 1000 x 250 x 150mm 4 3 720 pcs

Note: The capacity data are theoretical and are dependent on machine settings, mix design, aggregates used and other environmental conditions. All the production parameters are subject to change without prior notice

Production

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Finished Product