استهداف عدم كفاءة التكسير الأولية: The High Cost of Compromise

Are your aggregate production or mining operations constrained by the primary crushing stage? Inefficient jaw crusher performance directly impacts your entire downstream process, manifesting as:

التوقف المفرط للصيانة: Frequent liner changes and unplanned stops for blockages can consume 1520% of available operating hours, تكلف عشرات الآلاف من الإنتاجية المفقودة.
تدرج المنتج غير المتوقع: Inconsistent feed opening dynamics and wear lead to poor size distribution, overworking secondary crushers and reducing final product yield.
تصاعد التكاليف التشغيلية: Premature component wear, ارتفاع استهلاك الطاقة لكل طن, and high labor intensity for routine servicing erode profit margins.
مرونة تغذية محدودة: Inability to handle a varied mix of feed materials (على سبيل المثال, البازلت الكاشطة, recycled concrete with rebar, highclay ores) forces production to slow down or stop.

Is your primary crusher a reliable asset driving profitability, or a recurring source of bottleneck and expense? The solution lies in specifying equipment engineered not just to crush, ولكن لتحسين التكلفة الإجمالية للملكية.

نظرة عامة على المنتج: JC5000 HeavyDuty Jaw Crusher

The JC5000 is a robust, singletoggle jaw crusher engineered for highcapacity primary crushing in demanding quarrying, التعدين, وتطبيقات إعادة تدوير الهدم. Its design focuses on delivering consistent throughput with minimized operational intervention.

سير العمل التشغيلي:
1. تناول الأعلاف: كبير (500mm x 250mm) feed opening accepts runofmine or runofquarry material directly from haul trucks.
2. سحق الضغط: A steep nip angle and aggressive crushing motion applies intense compressive force to fracture material against the fixed jaw plate.
3. تسريح & التخليص: The hydraulically assisted toggle system provides quick reversal of the moving jaw to clear blockages and assist in tramp metal release without stopping the crusher.
4. نقل المنتج: Crushed material exits at a consistent CSS (إعداد الجانب المغلق), typically between 75mm 150mm, جاهز للمعالجة الثانوية.

نطاق التطبيق & القيود:
مثالية ل: محاجر الصخور الصلبة (الجرانيت, البازلت), mediumscale mining operations, largescale construction waste recycling plants.
القيود: Not designed for ultrafine grinding or as a standalone solution for finished aggregate. الحد الأقصى لحجم التغذية الموصى به هو 80% من البعد فتح التغذية. Requires a stable foundation and appropriate upstream feeding equipment.

الميزات الأساسية: الهندسة للتفوق التشغيلي

نظام تعديل التبديل الهيدروليكي | الأساس الفني: Integrated hydraulic cylinder replaces mechanical shims | المنفعة التشغيلية: CSS adjustment takes minutes versus hours, performed safely from ground level | تأثير عائد الاستثمار: يقلل من وقت التوقف عن تغيير المنتج بنسبة تصل إلى 90%, increasing annual utilization.

المحجر رمح غريب الأطوار | الأساس الفني: Forged from highintegrity alloy steel, مدعومة بمحامل كروية كبيرة الحجم | المنفعة التشغيلية: Sustains peak load under shock conditions; bearings run cooler with extended L10 life | تأثير عائد الاستثمار: Eliminates premature shaft failure; field data shows bearing service intervals extended by 40%.

هندسة الغرفة الأمثل | الأساس الفني: Computermodeled kinematics create an aggressive nip angle and deep crushing chamber | المنفعة التشغيلية: Enhances throughput capacity and promotes slabby material breakage over flaking | تأثير عائد الاستثمار: يسلم ما يصل إلى 10% more tons per hour at equivalent power draw compared to previous generation designs.

بناء الإطار الثقيل | الأساس الفني: Fabricated from stressrelieved steel plate with reinforced ribbing at all highstress points | المنفعة التشغيلية: Provides longterm alignment stability under cyclical loading, حماية المكونات الداخلية | تأثير عائد الاستثمار: Mitigates risk of frame fatigue cracking, ضمان السلامة الهيكلية على مدى أ 15+ عمر الخدمة سنة.

تعزيز السلامة & إمكانية الخدمة | الأساس الفني: Centralized grease points; accessible cheek plate bolts; guarding integrated into structure | المنفعة التشغيلية| Routine maintenance tasks are faster and safer for technicians| تأثير عائد الاستثمار| Lowers scheduled maintenance labor hours by an estimated 25%, improving site safety compliance.

المزايا التنافسية: مكاسب الأداء القابلة للقياس

The JC5000 Jaw Crusher is designed to outperform conventional solutions across critical metrics.

| مقياس الأداء | معيار الصناعة (فئة قابلة للمقارنة) | الأداء الموثق لحل JC5000 | ميزة (% تحسين) |
| : | : | : | : |
| التوفر (الجهوزية) | ~85% (تعديل التخصيم & blockage downtime)| >92% (with hydraulic toggle & المقاصة) | +8% |
| حياة الخطوط الملاحية المنتظمة (الصخور الكاشطة) | ~ 120.000 طن لكل مجموعة (من14%)| ~150,000 tons per set (Mn18% optional) | +25% |
| كفاءة الطاقة (كيلوواط ساعة/طن)| يختلف على نطاق واسع; baseline = 1.0x factor| Field data shows consistent reduction averaging ~0.9x factor |10% |
| وقت تعديل CSS| 24 ساعات مع الطاقم| <30 minutes with single operator |87% |

المواصفات الفنية

فتح الأعلاف: 500mm x 250mm
الحد الأقصى لحجم التغذية: 400مم
نطاق الإعداد الجانبي المغلق: 75mm 150mm
نطاق السعة: 180 350 طن في الساعة (تعتمد على مواد التغذية وCSS)
متطلبات طاقة المحرك: 75kW /100HP electric motor (معيار)
وزن كسارة (باستثناء المحرك): تقريبًا 16 طن متري
مواصفات المواد الرئيسية:
Frame Fabrication Grade Steel
Jaw Plates Premium manganese steel (Mn14% standard; من18%, Mn22% optional)
Eccentric Shaft Forged EN24/34CrNiMo6 equivalent
محامل محامل كروية; Timken/SKF/FAG grade
نطاق درجة حرارة التشغيل: 20°C to +40°C with standard lubricants.
أبعاد (الطول × العرض × الارتفاع): ~3.5m x 2.8m x 2.9m

سيناريوهات التطبيق

Granite Quarry Expansion Project Challenge:

A quarry needed to increase primary circuit throughput by 30% without expanding its footprint or major civil works. Their existing crusher created bottlenecks due to slow adjustment times and frequent liner wear checks.

حل:

Implementation of one JC5000 Jaw Crusher as the new primary unit. Key features utilized were the hydraulic toggle for rapid product sizing changes between road base and rail ballast production runs.

نتائج:

Throughput goals were met within the first quarter. The site manager reported a 22% reduction in weekly labor hours dedicated to crusher maintenance and adjustments, reallocating personnel to other areas.

ج&D Recycling Plant Upgrade Challenge:

A recycling plant processing mixed demolition waste faced excessive downtime from uncrushable materials jamming the primary jaw, requiring full shutdowns and manual clearing several times weekly.

حل:

Replacement with a JC5000 Jaw Crusher equipped with an automatic hydraulic tramp release system integrated into the toggle mechanism.

نتائج:

Blockage events requiring full shutdown were virtually eliminated. The plant recorded a 17% increase in monthly processed volume due to reduced stoppages while protecting downstream conveyors from metal damage.

الاعتبارات التجارية

Equipment pricing is structured around core configuration:

1. Base Machine Tier Includes crusher frame assembly drive sheave flywheels standard manganese liners guards lubrication system

2 حزم الميزات الاختيارية
Hydraulic Toggle Adjustment Kit Automatic Tramp Release System HeavyDuty Skid Base Frame Belt Drive Guard Package HigherGrade Manganese Liners Mn18Mn22

3 Service Support Packages Proactive maintenance plans are available including scheduled inspections parts kits priority technical support Extended warranty options can be negotiated based on application review

4 Financing Options Flexible commercial terms are offered through partnered financial institutions including equipment leasing capital loan structures or rentaltopurchase agreements tailored to project cash flow

الأسئلة المتداولة

What power supply is required for the JC5000 A standard 75kW 400V50Hz3phase electric motor is supplied Can it be configured for diesel drive Yes skidmounted diesel drive packages are available as an option

How does the hydraulic toggle system affect reliability The system simplifies mechanics replacing dozens of manual shims It uses proven industrial hydraulic components designed specifically for highshock environments reliability data indicates no reduction in overall system uptime

What is the lead time on replacement wear parts Commonly used parts like jaw plates cheek plates are typically held in regional stock centers with availability within 48 weeks Nonstock items have a manufacturing lead time communicated upon order

Can the JC5000 handle wet sticky clayladen material While capable performance will be reduced compared to dry rock We recommend site evaluation For severe clay applications pre screening or grizzly feeding should be considered

What commercial terms are available Minimum order quantity is one 1 unit We offer comprehensive commercial support including FOB CIF DAP delivery terms based on customer location Full payment letters of credit are standard structured payment plans can be discussed