How to make a vibrator - step by step guide for the production of 3 stages

Under the influence of the vibrator even the most dense concrete mix becomes plastic and mobile.

Plan to carry out work on the concrete pouring? For high-quality concrete vibrator you need - this is a special device which is immersed in the concrete mix, and creates mechanical oscillations of high frequency. I will describe the principle of operation of the vibrator, and discuss how it can be made with your own hands.

Why do I need a vibrator

Concrete mortar is a mixture of coarse and fine aggregate, binder and water. All components consist of particles of different sizes. For qualitative monolithic concrete product, composite particles must solution tightly abut each other, and should not remain voids and air pockets between them.

After pouring the solution into the formwork immersed vibrator therein, the following processes occur:

1. The increase in plasticity:

• The high-frequency vibration transmitted solids and leads them to a continuous oscillatory motion;
• This increases the mobility and fluidity concrete solution, so it is well numb even in the deep and narrow formwork space.

1. Concrete Sealing:

• It is moving under its own weight particles tightly pressed against each other and to detail reinforcing strapping, which increases the density and strength of the concrete product;
• The increase in density can be seen with the naked eye, when the vibrator is lowered in front of the concrete begins to decrease in volume.

1. Removal of excess air:

• Due to severe vibrations solids under its own weight fall down, and the lighter air bubbles rise up and are removed from the concrete mix;
• Thus, vibrators for concrete to help reduce the porosity of concrete, and at the same time increase its cold resistance, water resistance and resistance to crack formation.

Concrete proper seal vibronasadku must be periodically removed from the solution, and only move vertically up and down.

The operating principle of the immersion vibrator

The device vibrators for concrete is very simple. It works on the principle of eccentric imbalance and consists of three main mechanisms:

1. drive mechanism It can be a gasoline or electric.

• In the private construction of vibrator is usually driven by an electric motor, a powerful electric drill or punch;
• An output shaft mounted drive coupling for connecting the flexible shafts vibronasadkoy.

1. flexible shaft It serves to transmit torque from the drive mechanism to the vibrating nozzle:

• It is made of a rigid metal cable, placed in a flexible outer casing;
• Shaft length is selected in such a way that it was in the 800-1000 mm longer than the deepest place in the formwork.

1. Vibronasadka or mace It is used directly to generate mechanical vibrations:

• Mace housing is made of stainless steel in the form of a sealed cup with a diameter of 40-60 mm;
• The lower and upper cups are arranged two rolling bearing;
• The freely rotating bearing steel shaft, which is attached to a flexible drive cable;
• The shaft is fixed eccentric imbalance with the displaced center of gravity, so the fast rotation mace starts to vibrate at a high frequency.

The figure shows the internal structure -tips deep vibrator.

Self-production of the vibrator

Considered the most reliable construction Percussive from the German company Wacker Neuson, but their main drawback - a high enough price. At the same time, a simple vibrator for concrete small amounts you'll be able to make in a home workshop.

Vibrators for concrete are of three types, but I continue to talk about the production of only the deep type.

Step 1: preparation of tools and materials

To make the high frequency vibrator, you will need a set of hand tools, a powerful motor and a pair of bearings and other materials can be found among scrap metal:

Illustration	List of tools and materials
	Hand tools: Metallic bench workbench; Two hammer weighing 200 grams and 500 grams; Powerful locksmith vise; Pliers or plier; An adjustable pipe wrench; Flat and shaped screwdriver; Measuring tools (ruler, calliper).
	Power: Powerful drill or drilling machine with a set of drills 3-16 mm; Bulgarian with cut-off and Grinding Discs for metal; Grinder with an abrasive stone; Welding apparatus with electrodes 3-4 mm.
	materials: Alternating electric motor 0.75-2 kW, with speed of 1500-3000 rev / min. Cut thick walled stainless steel tubes 300-500 mm in length and 40-60 mm in diameter; The steel rod with a diameter of 10-16 mm 300-500 mm - 2 pcs .; Hard steel wire with a diameter of 6-8 mm length of 1-2 meters (you can use the segment of cable fittings both on the left); Outer sheath for the cable (it is possible to use a rubber-reinforced high pressure hose; Bearings with an outer diameter equal to the inner diameter of the tube - 2 units .; Metal bushings, threaded cups, fasteners and other hardware. As an electric motor can be used a powerful electric drill or a hammer.

Step 2: production vibronasadki

Mace for compacting concrete produced separately and connected to the motor through the flexible drive shaft. This allows not only to increase the working length of the instrument, but also reduce the impact of the hands of mechanical vibrations, which create high frequency vibrators.

Illustration	Description of work
	The outer casing: Outside on the stainless steel tube from two sides cut threads; On the lower side inside the press in a rolling bearing; At the lower end of the tube cap screwed plug with a rubber gasket
	Shaft with an eccentric: Choose steel rod diameter such that it fits snugly into the inner race of bearings; rod length should be 50-60 mm greater than the length of the outer tube; Take another section of the same bar; Its length shall be 20 mm less than the distance between the bearings in the tube; Short bars welded laterally along the long axis of the shaft so that, after installation into the tube he was in the middle between the bearings.
	Build Clubs: Shaft with an eccentric welded stainless tube inserted into; The lower end of the shaft is pressed into the bottom bearing; On the projecting end of the shaft to suit the upper bearing and drive in the upper end of the tube.
	cable connection: By the protruding end of the shaft to fix a thin-walled stainless steel tube; Inside the tube inserted and riveted flexible drive cable.
	Vibrator assembly: An outer sheath of a cable with a clamp to fixedly secure the upper end cap; The cable length of the entire thread the inside of the outer shell; Top end cap with a fixed shell to fasten through the rubber gasket to the body of the mace.

Step 3: The flexible shaft connection

The flexible shaft must be added to the drive so that its outer shell was still attached to the motor housing. The inner cable must be attached to the motor shaft to rotate after turning it together with him. Shown below is the instruction from the image:

Illustration	Description of work
	Fixing the flexible shaft to the engine: Choose a thin-walled metal tube, inside which can pass freely the motor shaft; Below it weld a wide washer with mounting holes; On top of the tube to cut a plurality of radial segments; The flexible cable is rigidly secured to the motor shaft; The tube is put on the cable and attach screws to the motor housing through openings in the puck; The cut pitch to the pipe bend slightly inwardly, and insert them between the cable outer sheath; Petals on top to compress the metal hose clip.
	Nozzle attachment to the drill: From the steel plate and pipe manufacture interval bracket as shown in the figure; An outer sheath of a cable clamp by means of bolts inside the pipe.
	Fixing to the drill assembly: This bracket allows you to attach a vibrator conventional electric drill with a plastic side handle, which is supplied; Before installing the bracket, the free end of the flexible cable is necessary to clamp the chuck.

conclusion

You could make sure to make deep vibrator is a snap. I recommend to view the video in this article, but all suggestions and questions leave me in the comments.