1. فتحة مدفوعة بنقطة الألم

Are escalating operational costs and unpredictable downtime eroding your sand and gravel operation's profitability? تؤثر تحديات الصناعة الشائعة بشكل مباشر على أرباحك النهائية: inconsistent feed material causing frequent plant blockages and unplanned stops; excessive wear on crusher liners and screen cloths from abrasive, unscreened oversize; high energy consumption from processing alreadytospec material; and the significant labor cost of manual clearing and presorting. These issues translate to lost production hours, premature component replacement, and inefficient fuel or power use.

What if you could systematically remove these bottlenecks before they reach your primary processing circuit? How would a 1520% reduction in crusher liner wear change your annual maintenance budget? The solution lies in effective, highcapacity primary screening—the critical first line of defense for any efficient operation.

2. نظرة عامة على المنتج

The HeavyDuty Grizzly Feeder is a rugged, primary scalping unit designed to handle the initial size separation of runofquarry (ROQ) رمل, الحصى, وأطلقوا النار على الصخور. It operates as a robust filter at the very front end of your material handling system.

سير العمل التشغيلي:
1. Dump & يٌطعم: ROM material is dumped directly onto the feeder’s heavyduty deck from haul trucks or loaders.
2. الفصل الاهتزازي: An aggressive linear vibration moves material forward while allowing subdecksize particles to fall through the grizzly bars.
3. سلخ فروة الرأس & التوجيه: Undersize material (typically sand, الغرامات, and small gravel) passes through the grizzly openings onto an underlying conveyor for direct bypass to secondary circuits or stockpiling.
4. Oversize Conveyance: Oversize rocks (على سبيل المثال, +6", +8") are carried over the bars and discharged into the primary crusher.
5. حماية: The unit absorbs the impact of large rocks, protecting downstream conveyors and crushers from direct shock loading.

نطاق التطبيق: Ideal for hightonnage quarry face applications, river dredge feed points, and alluvial deposit operations where feed size is highly variable.
القيود: Not designed for fine screening or sorting; bar spacing is fixed or mechanically adjustable within a set range. Optimal performance requires controlled feed rates to prevent blinding of the grizzly deck.

3. الميزات الأساسية

بناء سطح السفينة الثقيلة | الأساس الفني: Highstrength, abrasionresistant steel alloy bars with reinforced support frames | المنفعة التشغيلية: Withstands direct impact from large rock (up to 48”+) and continuous abrasion without deformation | تأثير عائد الاستثمار: Reduces structural repair costs by up to 40% over standard decks, extending service life beyond 5 years in severe duty.

Adjustable Grizzly Bar Section | الأساس الفني: Modular section with manually or hydraulically adjustable bar spacing | المنفعة التشغيلية: Allows operators to change scalp size (على سبيل المثال, from 4” to 8”) في تحت 30 minutes to match deposit changes or product specs | تأثير عائد الاستثمار: Maximizes bypass of spec material, increasing plant throughput by 1025% by relieving the primary crusher.

Dual Mass Vibratory Drive System | الأساس الفني: Springcoupled system where one mass cancels out dynamic forces on the structure | المنفعة التشغيلية: Generates highstroke linear motion for positive material movement even with sticky clays; reduces transmitted forces to the support structure by up to 95% | تأثير عائد الاستثمار: Lowers foundation costs by up to 50% and reduces energy consumption per ton by approximately 1520%.

BoltIn Replaceable Wear Components | الأساس الفني: Modular wear shoes, deck liners, and grizzly bars secured with hardened bolts | المنفعة التشغيلية: Enables rapid component replacement during scheduled maintenance without major welding or cutting | تأثير عائد الاستثمار: Cuts downtime for wear part replacement from shifts to hours, improving plant availability.

Variable Speed Drive Control | الأساس الفني: Frequency inverter controlling vibratory motor speed | المنفعة التشغيلية: Allows finetuning of feed rate and stroke effectiveness for different moisture content and gradations in realtime | تأثير عائد الاستثمار: Optimizes crusher cavity level for maximum reduction efficiency, reducing power spikes and improving overall circuit stability.

Integrated Hopper & Apron Section | الأساس الفني: Fabricated hopper with bolton apron plates at the feed point | المنفعة التشغيلية: Contains surge loads from truck dumping and provides a controlled feed onto the vibrating deck | تأثير عائد الاستثمار: Eliminates spillage at the feed point and protects dump truck beds from direct impact with grizzly bars.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة | HeavyDuty Grizzly Feeder Solution | ميزة (% تحسين) |
|||||
| Deck Plate Wear Life | 612 months in abrasive applications | 1824 months with AR400 liners | +100% wear life |
| القدرة الإنتاجية | Subject to frequent bridging/blinding | Highstroke vibration prevents packing | +30% consistent feed rate |
| استهلاك الطاقة | Fixed speed drives running continuously | محرك التردد المتغير (VFD) تحسين| 18% average power draw |
| توقف الصيانة | Fullday shutdowns for weld repair | Boltin component replacement |75% component swap time |
| Crusher Liner Wear | Direct impact from fines & المواد الكاشطة | Removal of 80mm fines before crushing |20% on primary mantle/concaves |

5. المواصفات الفنية

نطاق السعة: Model dependent, من 500 الهيدروكربونات النفطية لأكثر من 2,500 TPH of sand & الحصى.
متطلبات الطاقة: Electric vibrator motors ranging from 30 HP ل 100 HP, typically operating on 480V/3phase/60Hz power.
مواصفات المواد: Main frame ASTM A36 steel; Deck & Grizzly Bars AR400 / هاردوكس 400 فولاذ مقاوم للتآكل; Liners Boltin AR500 sections.
الأبعاد المادية (نموذج نموذجي): طول (feed hopper to discharge): ~20 ft; عرض (over deck): ~8 ft; ارتفاع (underframe): ~6 ft; وزن: ~25,000 lbs.
نطاق التشغيل البيئي: مصممة لدرجات الحرارة المحيطة من 20 درجة مئوية إلى +50 درجة مئوية (4درجة فهرنهايت إلى +122 درجة فهرنهايت). Dust seals are standard; optional spray bars available for highmoisture applications.

6. سيناريوهات التطبيق

Alluvial Sand & Gravel Pit

Challenge A pit feeding both concrete sand and drainage gravel faced constant plugging at the jaw crusher due to high clay content in wet months, halting production for manual clearing twice per shift.
Solution Installation of a heavyduty grizzly feeder with a VFDcontrolled highamplitude stroke was implemented ahead of the jaw crusher.
Results The aggressive action broke apart clay balls while scalping off oversize cobbles. Crusher plugging incidents dropped by over 90%, increasing effective daily throughput by an average of 180 tons per operating day.

Granite Quarry Processing Shot Rock

Challenge Excessive fines (4") in shot rock were causing rapid wear on cone crusher liners and consuming unnecessary crushing energy while also degrading final product shape.
Solution A twostage grizzly feeder was deployed—a fixedbar section at 8" followed by an adjustablebar section set at 4".
Results Approximately 22% من إجمالي الأعلاف (ال 4"x0" مادة) was bypassed directly to a tertiary circuit conveyor. This reduced load on the primary cone crusher by over onefifth, extending liner life by an estimated three weeks per set and lowering specific energy consumption.

7. الاعتبارات التجارية

طبقات التسعير: Units are configured based on size/capacity:
واجب قياسي (2000 الهيدروكربونات النفطية في الساعة): Includes full Hardox lining, hydraulic bar adjustment,and premium vibrator drives for severeservice mines.

الميزات الاختيارية: Hydraulic bar spacing adjustment module; integrated metal detection system; automated lubrication system; customdesigned skid bases or trailer mounts for semiportability; أغطية تغليف الغبار.

حزم الخدمة: Threetiered offerings:
1. Basic Warranty covering parts/labor for one year.
2. Extended Protection Plan covering all major structural components plus annual vibration analysis inspection.
3. FullService Agreement including scheduled wear part replacements based on monitored tonnage data.

Financing Options Available through our partners include equipment leasing programs that allow payments out of operational cash flow,tradein valuation services,and projectspecific financing.

8.التعليمات

Q What is required under this equipment?
A A level concrete foundation pad designedto absorb static loads is standard.Field data shows that our dualmass drive system minimizes dynamic forces,but proper anchoring is critical.We provide full foundation drawingswith purchase

Q Can it handle extremely wet or sticky material?
A Yes.The combinationof an aggressive linear strokeand optional deck heating systemsor polyurethanecoated barscan mitigate sticking.Variable speed control allows operators totune themotionfor optimalmaterial flowin changing conditions

Q How does this integratewith my existingprimarycrusherand conveyor system?
A Our engineering team will reviewyour plant layoutto ensureproper interfacingfor height discharge angleand chutework We designfor seamless transferpoints tomaximize flowand minimize spillage

Q Whatis therealistic payback periodon this investment?
A Basedon documented case studiesin similar operations paybackis typically achievedwithin1218 monthsthrough gainsin throughput reducedcrusherwearand lowerdowntime Your specific geologyand product mixwill determineexact figures

Q Arewearparts readily available?
A Yes All criticalwearcomponentsare standardizedstock itemsin our globalnetworkof distribution centers Guaranteedavailabilityis partof ourextendedservice agreements

Q Do you offeronsiteoperator training?
A Yes Comprehensive trainingfor bothoperationsand maintenancecrews is includedwith installation We focuson safeoperation troubleshooting proceduresand daily inspection checklists