1. فتحة مدفوعة بنقطة الألم

تؤدي تكاليف التشغيل المتصاعدة وفترات التوقف غير المتوقعة إلى تآكل هوامش مشروعك? لمديري المصانع والمتخصصين في المشتريات, the core crushing stage is often the primary bottleneck. تشمل التحديات الشائعة مع آلات كسارة الحجر دون المستوى الأمثل:

ارتداء المفرط & Component Failure: Premature wear on liners, فكي, or cones leads to frequent, unplanned stoppages for replacement, costing thousands in parts and lost production daily.
إخراج غير متناسق & تلوث المنتج: Poor crushing chamber design or unstable operation results in offspec product gradation, increasing recirculation load and reducing saleable material yield.
استهلاك عالي للطاقة: Inefficient drive systems and poor power utilization directly inflate your kWhperton cost, a significant variable in highvolume operations.
Difficult Maintenance & مخاطر السلامة: معقد, timeconsuming maintenance procedures require extended downtime and expose technicians to unnecessary hazards during liner changes or clearing blockages.
Infrastructure Rigidity: الكسارات الثابتة تفتقر إلى القدرة على الحركة للمشاريع متعددة المواقع, while poorly designed mobile units compromise on stability and throughput.

Is your current equipment delivering predictable tonnage at a controlled cost per ton? The solution requires a machine engineered not just to crush rock, but to crush operational inefficiency.

2. نظرة عامة على المنتج

The FabriCore HD Series Jaw Crusher is a heavyduty, primary crushing station engineered for highabrasion quarrying, التعدين, وتطبيقات إعادة تدوير الهدم. لقد تم تصميمه ليكون قويًا, stationary solution for operations prioritizing maximum uptime and lowest costperton over mobility.

سير العمل التشغيلي:
1. تناول الأعلاف: Oversized raw feed (ذاكرة للقراءة فقط) is delivered via dump truck or loader into the vibratory grizzly feeder.
2. التخفيض الأولي: Material enters the deep crushing chamber where a powerful elliptical jaw motion applies compressive force against a fixed jaw plate.
3. التحكم في التدرج: تخرج المواد المكسرة من خلال فتحة تفريغ قابلة للتعديل (CSS), تحديد الحد الأقصى لحجم المنتج.
4. تسريح & نقل: Sized material is discharged onto the integral product conveyor for transport to secondary processing or stockpiling.

نطاق التطبيق: مثالية للصخور الصلبة (الجرانيت, البازلت), abrasive ore, وحطام الهدم الخرساني المسلح. Suited for fixedplant installations with expected annual production exceeding 500,000 طن.

القيود الرئيسية: Not designed as a mobile trackmounted unit. Requires stable concrete foundation and appropriate feed system engineering. Maximum recommended feed size is 85% of the feed opening dimension.

3. الميزات الأساسية

Monoblock Fabricated Frame | الأساس الفني: Highstrength, welded steel construction with finite element analysis (الهيئة الاتحادية للبيئة) تحسين | المنفعة التشغيلية: Eliminates stress points and frame fatigue cracking common in bolted designs; ensures longterm alignment of crushing components | تأثير عائد الاستثمار: يقلل من تكاليف الإصلاح الهيكلي بما يقدر 60% over the crusher's lifespan; extends service life beyond industry average.

نظام القيادة الهيدروستاتيكي | الأساس الفني: Direct hydraulic drive with variable displacement motors | المنفعة التشغيلية: Provides smooth startup under full load, reversible operation for clearing blockages, and infinite CSS adjustment under load | تأثير عائد الاستثمار: Lowers peak electrical demand; reduces mechanical transmission wear; increases operational availability by enabling quick clearing of stalls.

Toggle System with Pressure Relief | الأساس الفني: Hydraulic toggle cylinder with integrated nitrogen accumulator overload protection | المنفعة التشغيلية: Automatically releases tramp metal or uncrushables without shearing pins or requiring manual intervention | تأثير عائد الاستثمار: Prevents catastrophic damage to other components; field data shows a reduction in tramp ironrelated downtime by over 90%.

Liner Lifetime Optimization | الأساس الفني: Computeraided chamber profile design and reversible/interchangeable manganese steel liners | المنفعة التشغيلية: Promotes interparticle crushing for better shape; allows use of both liner ends before replacement; simplifies inventory | تأثير عائد الاستثمار: Increases liner life by 1530%; reduces consumable costs per ton crushed.

نقطة تشحيم مركزية | الأساس الفني: Singlepoint connection to a network of lubrication lines for all major bearings | المنفعة التشغيلية: تمكن آمنة, rapid greasing during scheduled stops without dismantling guards; ensures consistent bearing protection | تأثير عائد الاستثمار: Cuts routine lubrication service time by half; extends critical bearing service intervals.

جبل المحرك المتكامل & حارس الحزام | الأساس الفني: Factoryaligned motor base and fully enclosed,

bolton belt guard assembly | المنفعة التشغيلية: Eliminates field alignment issues; provides superior operator safety and contains dust around the drive | تأثير عائد الاستثمار: Reduces installation/commissioning time; minimizes risk of injuryrelated stoppages.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة (Competitive Jaw Crusher) | FabriCore HD Series Solution | ميزة (% تحسين) |
| : | : | : | : |
| وقت تغيير الخطوط الملاحية المنتظمة| 1824 ساعات (التوقف) | < 12 ساعات (التوقف) | ~45% faster |
| استهلاك الطاقة| Fixed speed motor / محرك Vbelt| Hydrostatic direct drive with loadsensing control| حتى 12% انخفاض كيلووات ساعة / طن |
| وقت استعادة الحديد المتشرد| Manual pin removal / cutting torch (24 ساعة)| Hydraulic toggle reversal from operator station (<10 دقيقة)| ~95% faster |
| Frame Structural Warranty| 13 years standard warranty on frame/weldments| Lifetime warranty against defects in materials/workmanship| Definitive longterm assurance |
| التوفر (الجهوزية)| Industry target ~8590% (مُقدَّر)| Fieldreported >94% in comparable applications| ~5% absolute increase |

5. المواصفات الفنية

Model Featured: FabriCore HD4862
فتح الأعلاف: 48" س 62" (1200مم × 1500 مم)
الحد الأقصى لحجم التغذية: 41" (1050مم)
إعداد الجانب المغلق (CSS) يتراوح: 6" 14" (150mm 350mm)
نطاق السعة (@ defined CSS): 450 1,200 STPH (تعتمد على مواد التغذية & تدرج)
متطلبات طاقة المحرك: المستوى الرابع النهائي / Stage V compliant diesel engine OR electric motor option:
Electric Motor Option: 300 HP (225 كيلوواط), 460فولت/60 هرتز/3PH
الوزن الإجمالي (محطم + المغذية + الناقل): تقريبا. 185,000 رطل (84,000 كجم)
مواصفات المواد الرئيسية:
Frame Steel: ASTM A572 Grade 50
Jaw Liners: الصلب المنغنيز الأوستنيتي (14%18%)
Main Shaft Forging: Highalloy steel, تم اختباره بالموجات فوق الصوتية
تحمل المساكن: Cast ductile iron
نطاق التشغيل البيئي: 20درجة مئوية إلى +50 درجة مئوية (4درجة فهرنهايت إلى +122 درجة فهرنهايت). Dust suppression kit recommended for arid environments.

6. سيناريوهات التطبيق

محطة تكسير محجر الجرانيت الأولية

تحدي:
A southeastern US granite quarry faced recurring frame weld failures on their primary jaw crusher after just four years of service. Unplanned downtime for repairs exceeded two weeks annually alongside high energy costs from an inefficient drive system.
حل:
Replacement with a FabriCore HD4862 Jaw Crusher featuring the monoblock fabricated frame and hydrostatic drive system.
نتائج:
Zero structural issues reported after five years of operation. Energy monitoring showed an average reduction of $18 per operating hour in power costs at peak rates. Annual availability increased from approximately $86\%$ ل $95\%$.

Urban Demolition Recycling Hub

تحدي:
A contractor processing reinforced concrete from urban demolition struggled with frequent stallouts due to uncrushable rebar mats embedded in slabs. Each event required a full shutdown and dangerous manual torchcutting work inside the chamber.
حل:
Installation of a FabriCore HD3650 Jaw Crusher equipped with the hydraulic toggle pressure relief system.
نتائج:
The system automatically detects overloads and reverses to eject uncrushables within one minute via remote control from the operator cabin. This eliminated an average of three manual interventions per week—reducing safety risk—and increased daily throughput by preventing extended stoppages.

7. الاعتبارات التجارية

Our pricing structure is based on transparent configuration:

طبقة المعدات الأساسية ($XXXk $XXXk): Includes core FabriCore HD crusher with standard manganese liners,
electric motor drive option,
والضوابط الأساسية.

Optional Feature Packages:
حزمة الأتمتة ($XXk): Includes CSS adjustment via PLC,
ارتداء أجهزة استشعار المراقبة,
remote diagnostics port.
حزمة التآكل الثقيلة ($XXk): Upgraded liner alloys,
additional wear plates at critical impact points,
ceramiclined feed chute sections.

Service Agreements:
1.Planned Maintenance Plan ($Xk/year): عمليات التفتيش المجدولة,
lubrication kits,
الأولوية للدعم الفني.
2.Comprehensive Uptime Plan ($XXk/year): Includes all planned maintenance plus discounted parts pricing up to $40\%$ off list price,
guaranteed emergency parts dispatch within $24$ ساعات.

Financing Options are available through our industrial partners including operating leases ($36$60 شروط الشهر),
قروض المعدات,
and leasetopurchase agreements designed to preserve capital expenditure budgets.

(ملحوظة: Specific pricing figures are omitted here as they vary based on final specification,
currency region,
and market conditions.)

8\. FAQ\\\\\\\\\\\\\\\\n\n\Q1\. How does this machine integrate into my existing plant flow\? \\nA\. The FabriCore HD Series is designed as a modular primary station\. We provide detailed interface drawings \(feed height\, discharge height\, footprint\, power connection points\) during the quotation phase\. Our engineering team can review your existing layout to ensure compatibility\.

\Q2\. What is the expected operational cost per ton crushed\? \\nA\. While site\specific\, industry testing demonstrates that operators typically achieve between \$10\%\15\%\$ lower total cost\per\ton compared to previous generation jaw crushers\. This stems from reduced energy consumption\, longer liner life\, higher availability\.

\Q3\. Are spare parts readily available internationally\? \\nA\. Yes\. We maintain regional inventory hubs on three continents\. For critical wear parts \(liners\) we guarantee stock availability against your serial number upon request\.

\Q4\. What training do you provide for our maintenance crew\? \\nA\. We include comprehensive onsite commissioning training covering operation\, daily checks\, routine maintenance procedures like greasing \,liner change protocols using our tooling system\.

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