1. فتحة مدفوعة بنقطة الألم

تؤدي تكاليف التشغيل المتصاعدة وفترات التوقف غير المتوقعة إلى تآكل ربحية مقلعك? لمديري المصانع والمقاولين الهندسيين, ballast production presents distinct challenges that directly impact the bottom line. تشمل نقاط الألم الشائعة:
توليد الغرامات المفرطة: حتى 1520% of processed material can fall below spec, turning potential revenue into waste stockpiles.
ارتفاع استهلاك أجزاء التآكل: The abrasive nature of trap rock, الجرانيت, and basalt leads to premature liner and hammer failure, causing frequent, costly maintenance stops.
Inconsistent Product Cubicity: Poor particle shape in the final product reduces track bed stability and can lead to product rejection.
عدم كفاءة الطاقة: Older crushing stages consume disproportionate power for the usable tonnage produced, inflating operational expenses.
قدرة غير مرنة: Fixed plants struggle to adapt to fluctuating demand, creating bottlenecks or underutilization.

Is your current setup equipped to maximize yield from every ton of feed while controlling maintenance costs and energy consumption? The right primary crushing equipment is the foundational answer.

2. نظرة عامة على المنتج: ODM QUARRY PRIMARY JAW CRUSHER FOR BALLAST PRODUCTION

This product line focuses on heavyduty primary jaw crushers engineered specifically for highvolume ballast production from hard, abrasive feed materials. As an ODM (الشركة المصنعة للتصميم الأصلي), we provide customized crushing solutions built to your precise operational parameters and site constraints.

سير العمل التشغيلي:
1. التخفيض الأولي: ذاكرة للقراءة فقط (RunofMine) صخرة المحجر, typically up to 800mm in size, is fed into the crusher's robust vibrating grizzly feeder (فجفف فجفف) section.
2. الفحص المسبق & سحق: يقوم VGF بإزالة الدقائق الطبيعية ويتجاوز المواد ذات الحجم الصغير, توجيه الصخور كبيرة الحجم فقط إلى غرفة التكسير. The deep,symmetrical jaw chamber performs the initial compressive break.
3. Product Shaping: The kinematics of the jaw plate motion are optimized to promote interparticle crushing, enhancing particle cubicity on the first pass.
4. تسريح & نقل: Crushed material is discharged at a consistent CSS (إعداد الجانب المغلق) onto the primary conveyor for transport to secondary screening and crushing stages.

نطاق التطبيق & القيود:
مثالية ل: Primary crushing of hard, صخرة نارية كاشطة (الجرانيت, البازلت) and dense limestone for railway ballast and construction aggregates.
القيود: غير مناسب للالتصاق, claybound materials without prescreening/scalping. Feed size is constrained by crusher model inlet dimensions.

3. الميزات الأساسية

HeavyDuty Rolled Steel Frame | الأساس الفني: قطعة واحدة, stressrelieved fabrication | المنفعة التشغيلية: يزيل تشققات إجهاد الإطار تحت التحميل الدوري; provides stable platform for precision bearing alignment | تأثير عائد الاستثمار: Extended structural life exceeding 20+ years reduces capital replacement risk.

هندسة الغرفة الأمثل & Kinematics | الأساس الفني: ST/DT (Steep/Deeper Toggle) cavity design with aggressive nip angle | المنفعة التشغيلية: يزيد من الإنتاجية بنسبة تصل إلى 10% at same power draw; promotes better particle shape for downstream processing | تأثير عائد الاستثمار: Higher yield of inspec product per operating hour directly increases revenue.

Hydroset CSS Adjustment System | الأساس الفني: Hydraulic cylinders support the toggle seat for safe setting adjustment | المنفعة التشغيلية: Closedside setting changes can be made in minutes under load or during clearing strokes, without manual shims | تأثير عائد الاستثمار: Reduces downtime for product size changes by over 80%, enhancing plant flexibility.

LongLasting Manganese Jaws with Clamp Systems | الأساس الفني: Isovitric supergrade manganese steel with reversible design; mechanical clamp system for fast replacement | المنفعة التشغيلية: Jaw life increased by 2530%; changeout time reduced from days to a single shift | تأثير عائد الاستثمار: Lowers costperton for wear parts and significantly increases plant availability.

Integrated PreScreening Grizzly Feeder | الأساس الفني: Boltin grizzly sections with adjustable slope and gap settings | المنفعة التشغيلية: يزيل ما يصل إلى 20% of fines prior to crushing chamber, reducing unnecessary wear and improving chamber efficiency | تأثير عائد الاستثمار: Directly lowers wear part consumption and power cost per ton of crushed material.

نظام التشحيم الآلي المركزي | الأساس الفني: Programmable lubrication unit serving all key bearing points | المنفعة التشغيلية: يضمن فترات تشحيم المحامل المثالية; prevents both under and overgreasing failures | تأثير عائد الاستثمار: Extends critical bearing service life by an average of 35%, preventing catastrophic downtime.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (متوسط) | ODM Quarry Jaw Crusher Solution | ميزة (% تحسين) |
| : | : | : | : |
| التوفر (الجهوزية) | ~8590% (المقرر & توقف غير مجدولة) |> 94% (based on field monitoring data) |> +5% تحسين |
| تكلفة التآكل لكل طن (الصخور الكاشطة) $0.12 $0.18/طن| 25% تخفيض |
| استهلاك الطاقة المحدد| يختلف على نطاق واسع; older units > 0.8 kWh/ton @ CSS 150mm| 19% تخفيض |
| توليد الغرامات (<22مم)| ~1822% of total feed| 30% تخفيض |
| Product Flakiness Index (هدف 30% after primary stage| Consistently Improved Shape |

5. المواصفات الفنية

سعة نطاق النموذج: 400 1,800 طن في الساعة (الهيدروكربونات النفطية في الساعة), depending on feed material and closedside setting.
فتح الأعلاف: من 1000 مم × 650 مم حتى 1500 مم × 1200 مم.
متطلبات الطاقة: Drive motor from 90 كيلوواط حتى 300 كيلوواط; total installed power including feeder hydraulics specified per model.
مواصفات المواد: إطار ملحوم عالي القوة (الفولاذ S355JR); Isovitric manganese crusher jaws; forged alloy steel eccentric shaft with largediameter spherical roller bearings.
الأبعاد المادية & وزن: الأوزان التقريبية من 35 طن ل 120 طن; رسومات تخطيطية مفصلة مقدمة لتخطيط الأساس.
نطاق التشغيل البيئي: مصمم لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +45 درجة مئوية; dust sealing compliant with ISO standard levels; noise emissions designed below 105 ديسيبل(أ) في محطات المشغل.

6. سيناريوهات التطبيق

Hard Rock Quarry Supplying National Rail Project

تحدي: A granite quarry needed to supply over 2 million tons of Type I ballast within a strict timeline but faced excessive wear costs and fines generation (>22%) from their existing primary crusher.
حل: Implementation of a customconfigured ODM heavyduty jaw crusher with an integrated aggressive grizzly feeder profile optimized for their specific granite blend.
نتائج: Fines generation reduced to below spec at <14%. Wear part lifecycle extended by approximately28%. The project was completed ahead of schedule due to sustained throughput rates averaging12% above target.

Aggregate Producer Expanding into Rail Ballast Market

تحدي: An established aggregate producer lacked a primary stage capable of producing the consistent cubicity required by rail authorities without excessive secondary recrushing.
حل: Installation of an ODM jaw crusher with a specially engineered chamber profile focused on firstpass shape optimization.
نتائج: Final product Flakiness Index achieved directly after primary crushing met rail specification (<25%), reducing load on secondary cone crushers by approximately15%. This allowed reallocation of secondary capacityto other product lines.

7. الاعتبارات التجارية

Our ODM approach provides structured commercial flexibility:

مستويات تسعير المعدات: Based on model size/capacity range:
الطبقة الأولى (1200 الهيدروكربونات النفطية في الساعة): Fully customized solutions with advanced monitoring packages included.

الميزات الاختيارية & الحزم:
Advanced PLC automation package with loadregulation logic
Wear part monitoring sensors
Dust suppression system integration
Modular skidbase design for faster installation

حزم الخدمة:
Basic Warranty Package
Comprehensive Service Agreement including scheduled inspectionsand parts discounts
تركيب تسليم المفتاح & دعم التكليف

خيارات التمويل:
We work with international export credit agenciesand equipment financing partners t o offer leasetoown arrangements , mediumterm loans , or tailored rentalpurchase agreements t o align w ith your project cash flow .

8.التعليمات

س:What level o f customization i s possible w ith your ODM jaw crushers?
A.We can modify several parameters including feeder dimensions ,grizzly bar configuration ,discharge conveyor interface points ,and motor mounting positions t o ensure compatibility w ith your existing plant layoutand feed system .

Q.How does this equipment improve our overall plant efficiency beyond justtheprimary stage?
A.B y deliveringa more consistent ,cubicalproductatthefirststage,yoursecondaryand tertiarycrushers operate more efficiently .This reduces circulating loadsand improves finalproductyieldwhile loweringtotalplantpowerconsumption .

س:What i sthetypical delivery lead timeforacustomized unit?
A.Forstandardmodels withinourTierI&IIrange ,lead timesaretypically1622weeksfromorderconfirmation .FullycustomizedTier IIIsolutionsrequire detailed engineeringand mayextendto28weeks .Proactive planningi srecommended .

Q.Arewearparts interchangeablewithothercrusherbrands?
A.No .Ourwearpartsaredesigned specificallyforourchambergeometryandkinematics t oensureoptimalperformanceand longevity .We providecomplete technicaldrawingsforinventory planning .

Q.What kindo f foundationi srequired ?
A.We providecomprehensivefoundationdrawingswitheachorderincludingallstaticand dynamicloaddata .Foundationsaretypicallyreinforcedconcrete ;our engineerscanreviewyoursitespecificplansuponrequest .

Q.Doyouoffertrainingforouroperatorsandmaintenancestaff ?
A.Y es.O nsiteoperationalandsafetytrainingduringcommissioningi sincludedwith everysale .Additionalmaintenancetrainingmodulesareavailableaspartofourservicepackages .

Q.Whatarethekeyfactorsin determiningthecorrectmodelsizeforourapplication ?
A.Capacityselectionisbasedonfourprimaryfactors :yourmaximumfeedsizematerialhardnessorBWI( BondWorkIndex ),desiredproductsize( CSS ),andrequiredhourlytonnage .Ourtechnicalteamwillanalyze yoursamplesandspecificationst orecommendtheoptimalmodel