1. فتحة مدفوعة بنقطة الألم

تؤدي التكاليف التشغيلية المتزايدة ووقت التوقف عن العمل غير المتوقع إلى تآكل ربحية دائرة التكسير الأساسية لديك? لمديري المصانع والمقاولين الهندسيين, the primary jaw crusher is a critical—and often problematic—bottleneck. وتشمل التحديات المشتركة:
تكاليف قطع الغيار المفرطة: Premature failure of jaw dies due to improper kinematics or lowquality materials, مما يؤدي إلى كثرة, عمليات الاستبدال المكلفة والتغييرات كثيفة العمالة.
التوقف غير المقرر: Structural fatigue or bearing failures from uncrushable materials or shock loads, halting your entire processing line for days.
إنتاجية غير متناسقة & شكل المنتج: Inefficient crushing chamber designs that produce excessive fines or slabby product, reducing downstream efficiency and final product value.
استهلاك عالي للطاقة: Inefficient drive systems and heavy, powerintensive components that significantly increase your costpertonne.

How do you select a primary crusher that delivers not just promised capacity, but predictable operating costs and sustained availability? The solution requires a focus on engineered durability and intelligent design.

2. نظرة عامة على المنتج

الكسارة الفكية JC5000 ذات قدرة عالية, كسارة أولية أحادية التبديل مصممة للتعدين الأكثر تطلبًا, المحاجر, and heavyduty construction applications. Its robust design is built to process hard rock, خام, and demolition concrete with maximum reliability.

سير العمل التشغيلي:
1. يٌطعم & الضغط الأولي: مادة تغذية كبيرة (up to 1.5m cube) يدخل في العمق, غرفة سحق غير قابلة للاختناق.
2. السكتة الدماغية الساحقة العدوانية: تعمل آلية التبديل الفردي عالية القوة على تحريك الفك المتحرك في حركة بيضاوية, applying compressive force efficiently.
3. تسريح & التخليص: The steep nip angle and optimized discharge setting facilitate rapid material evacuation, preventing chokepoints and promoting high throughput.
4. تكامل النظام: The crusher interfaces with vibrating grizzly feeders and downstream conveyors for a continuous feed system.

نطاق التطبيق: Ideal for stationary primary crushing plants processing granite, البازلت, خام الحديد, خام النحاس, and recycled aggregates. It is suited for hightonnage operations (>800 متف) requiring a top feed size up to 1500mm.

القيود: غير مصممة لتطبيقات إعادة التدوير الكاشطة بدون خيارات بطانة محددة. Requires a solid foundation and appropriate feeding equipment to achieve stated performance.

3. الميزات الأساسية

مجموعة محمل الأسطوانة الثقيلة | الأساس الفني: محامل كروية ذاتية المحاذاة ذات أعمدة ذات قطر كبير | المنفعة التشغيلية: Handles high radial and thrust loads from tough crushing conditions; extends bearing life by up to 3x compared to standard bearings | تأثير عائد الاستثمار: Reduces risk of catastrophic bearing failure; lowers maintenance frequency and associated labor costs.

Hydraulic Wedge Adjustment System | الأساس الفني: Dualacting hydraulic cylinders replace manual shim adjustment | المنفعة التشغيلية: Allows closedside setting (CSS) adjustments to be made quickly, بأمان, and accurately in minutes versus hours | تأثير عائد الاستثمار: Maximizes plant uptime during product changeovers; improves operator safety by eliminating manual handling.

تحسين هندسة غرفة التكسير | الأساس الفني: Computermodeled kinematics with a steep nip angle and deep symmetrical chamber | المنفعة التشغيلية: Delivers higher reduction ratios per pass; produces a more consistent product shape with less slabby material | تأثير عائد الاستثمار: Increases effective capacity of downstream circuits; improves final product cubicity for higher market value.

بطانات ارتداء BoltOn | الأساس الفني: Modular liner design with replaceable cheek plates manufactured from abrasionresistant steel | المنفعة التشغيلية: يبسط استبدال الخطوط الملاحية المنتظمة; protects the main frame structure from wear indefinitely | تأثير عائد الاستثمار: Drastically reduces longterm capital asset depreciation; cuts liner changeout time by over 40%.

PLCIntegrated Overload Protection | الأساس الفني: Hydraulic toggle plate with pressure sensors linked to the plant control system | المنفعة التشغيلية: Automatically releases tramp metal or uncrushable material; resets without manual intervention | تأثير عائد الاستثمار: Prevents costly damage to the pitman and bearings; avoids hours of unscheduled downtime per event.

القيادة المباشرة عبر VBelts & TEFC Motor | الأساس الفني: Hightorque motor connected via multiple Vbelts to a heavyduty flywheel | المنفعة التشغيلية: نقل سلس للطاقة يمتص تقلبات الحمل; standard motor compatibility simplifies sourcing and replacement | تأثير عائد الاستثمار: Lower installed cost compared to fluid couplings; improved energy efficiency under variable load conditions.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (فئة قابلة للمقارنة) | كسارة الفك JC5000 | ميزة (% تحسين) |
| : | : | : | : |
| الفك يموت الحياة (الجرانيت الكاشطة) | ~ 450.000 طن لكل مجموعة (based on competitor data sheets)| ~550,000 tonnes per set (المتوسط ​​الميداني الذي تم التحقق منه)| +22% in wear material cost/tonne |
| تحمل الفاصل الزمني للخدمة (MTBF)| 8,000 10,000 ساعات العمل| 14,000+ ساعات العمل (المتوقع)| +40% in service life |
| وقت تعديل CSS (Mechanical to Mechanical)| 46 hours with crew of two| <1 hour with single operator| 80% in downtime for adjustment |
| استهلاك الطاقة لكل طن مطحون| Benchmark of 100%| متوسط 9295% (sitedependent)| 5% ل 8% in energy costs |
| الوزن الإجمالي / Structural Mass Index| Benchmark of 100% for rated capacity| Index of ~115% (higher masstocapacity ratio)| +15% in structural rigidity & fatigue resistance |

Mean Time Between Failures based on industry lubrication schedules.
Mass index compares total machine weight relative to throughput capacity as an indicator of robustness.

5. المواصفات الفنية

فتح الأعلاف: 1500مم × 2000 مم (59" س 79")
الحد الأقصى لحجم التغذية: Up to 1500mm cube (59")
نطاق الإعداد الجانبي المغلق: 200مم 300 مم (8" 12")
نطاق السعة: حتى 1650 متف (تعتمد على مواد التغذية & CSS)
متطلبات طاقة المحرك: 375 كيلوواط /500 HP TEFC electric motor
الوزن الإجمالي (كسارة فقط): Approximately ~145,000 kg (~320,000 lbs)
بناء الإطار الرئيسي: Fabricated steel plate with stressrelieved welds; بطانات فولاذية AR عند نقاط التآكل.
نطاق درجة الحرارة المحيطة للتشغيل: 20درجة مئوية إلى +45 درجة مئوية (4درجة فهرنهايت إلى +113 درجة فهرنهايت) مع التشحيم القياسي.
Discharge Conveyor Recommendation: Minimum width of 1800mm (72") at recommended speed.

6. سيناريوهات التطبيق

Hard Rock Quarrying – Granite & Basalt Primary Crushing

Challenge A major aggregate producer faced excessive downtime from jaw die changes every ~400k tonnes and frequent adjustments for product gradation changes.
Solution Installation of one JC5000 Jaw Crusher as the new primary unit featuring bolton liners and hydraulic wedge adjustment.
Results Field data shows jaw die life extended by approximately +22%, achieving over $50k annual savings in wear parts alone. CSS adjustments now take under one hour versus half a shift each time they occur.

معالجة المعادن - سحق خام الحديد الأولي

Challenge An iron ore operation required higher throughput after mine expansion but had space constraints limiting plant footprint increases.
Solution Replacing two older jaw crushers with one highercapacity JC5000 unit due its deeper chamber allowing greater volume reduction per pass.
Results Plant throughput increased by approximately +30%. The consolidated footprint reduced civil works costs by an estimated $200k USD while lowering overall energy consumption per tonne processed by nearly 7%.

Major Infrastructure – Tunnel Boring Muck Processing

Challenge A largescale tunneling project needed an ultrareliable primary crusher located underground to process mixed geology muck continuously under strict schedule constraints.
Solution Deployment of the JC5000 configured with PLCintegrated overload protection specifically sized for conveyor transport out of the tunnel shaft.
Results The hydraulic toggle system successfully cleared multiple uncrushable objects automatically preventing an estimated >120 hours of potential downtime over the project lifecycle maintaining critical path schedule integrity

7 الاعتبارات التجارية

The JC5000 Jaw Crusher is offered as part of a complete modular crushing station or as a standalone unit for integration into existing plants

مستويات تسعير المعدات:
1 Base Unit Includes crusher mainframe drive motor flywheel guards basic tool kit
2 Plant Ready Package Adds hydraulic power pack for adjustment integrated walkways ladders preinstalled lubrication system
3 Customized Application Package Includes applicationspecific jaw die metallurgy special guarding environmental packages dust suppression interfaces

الميزات الاختيارية:
• Automated Greasing System
• Rock Level Sensor Integration
• Special AR Steel Grades for Cheek Plates
• SkidMounted Modular Frame

حزم الخدمة:
• Commissioning Supervision Standard package includes field technician support during startup Extended package includes operator training performance verification testing
• Preventive Maintenance Contracts Tiered plans offering scheduled inspections parts kits priority support based on annual operating hours

Financing Options Available through our partners including equipment leasing capital loans rentaltoown structures tailored project financing

8 التعليمات

Q What are the foundation requirements for installing this crusher?
A Detailed civil drawings are provided requiring reinforced concrete foundations designed dynamic loads exceeding static weight Consult engineering specifications early site planning phase

Q Can this crusher handle recycled concrete brick asphalt?
A While capable processing these materials we recommend consultation our engineering team specify appropriate jaw die metallurgy potentially install additional scalping preclean scrap metal Prolonged processing highly abrasive recycled materials may impact wear life expectations

Q How does hydraulic wedge adjustment compare traditional shim systems?
A Hydraulic wedges allow remote controlled adjustment from outside crusher improving safety speed Process takes minutes versus hours required manually add remove steel shims providing precise repeatable control over product size

Q What is typical delivery lead time after order placement?
A Lead times vary based configuration current production schedule Standard Plant Ready Package typically ships within months order confirmation Customized packages may require additional engineering manufacturing time We provide firm delivery schedule upon order confirmation

س هل قطع الغيار متاحة بسهولة على مستوى العالم؟?
A We maintain regional inventory hubs key wear components structural parts Critical items like bearings shafts stocked strategic locations ensure availability Most standard wear parts shipped within business days emergency orders