1. فتحة مدفوعة بنقطة الألم

Is your bulk material handling operation losing profitability to inefficient screening? تؤثر التحديات الشائعة مع شاشات الاهتزاز القياسية بشكل مباشر على النتيجة النهائية. هل تعاني:
Excessive Downtime for Screen Cloth Changes: Frequent blinding and wear of screen media halts production, تكلف الآلاف في الساعة من فقدان الإنتاج والعمالة.
تدرج المنتج غير متناسق: Poor stratification and material carryover result in offspec product, leading to customer rejections, تكاليف إعادة المعالجة, and wasted raw materials.
صيانة عالية & تكاليف الطاقة: Inefficient drive systems and structural failures from unbalanced vibration demand constant attention and consume excessive power.
مرونة العملية المحدودة: A single screen cannot adapt to varying feed rates or material characteristics, forcing compromises in your entire process flow.

What if a screening solution could systematically address these issues, turning a cost center into a reliable efficiency driver?

2. نظرة عامة على المنتج

The White Label Coke Vibration Screen is a highcapacity, linear motion screening machine engineered for the precise sizing and scalping of bulk materials like foundry coke, فحم الكوك المعدني, and similar aggregates. Its design focuses on durability and consistent performance in demanding mineral processing and material handling applications.

سير العمل التشغيلي:
1. تغذية تسيطر عليها: Material is evenly distributed across the full width of the screen inlet.
2. التقسيم الطبقي الفعال: يولد الهزاز المزدوج حركة خطية تعمل على تقسيم المواد إلى طبقات بسرعة, forcing fines downward to the screen surface while conveying oversize toward the discharge end.
3. Accurate Separation: Sized fractions pass through precisely tensioned screen panels or are discharged as oversize at designated outlets.
4. التفريغ المستمر: Separated material streams are conveyed away for further processing or stockpiling.

نطاق التطبيق & القيود:
مثالية ل: Dry screening of coke (foundry, metallurgical), sinter feed, المجاميع المعاد تدويرها, الحجر المسحوق, and similar granular materials (typically 0.1mm to 150mm).
القيود: Not designed for wet screening processes, highly abrasive slurries, or sticky, claybound materials without significant modification.

3. الميزات الأساسية

Modular Screen Deck System | الأساس الفني: Independently tensioned polyurethane or wire mesh panels on a rigid substructure | المنفعة التشغيلية: يمكن استبدال اللوحات بشكل فردي في الأسفل 30 minutes without dismantling adjacent decks or feed boxes. | تأثير عائد الاستثمار: يقلل من وقت توقف الصيانة المخطط له بنسبة تصل إلى 70% compared to bolteddown panel systems.

Dual CounterRotating Eccentric Shaft Drive | الأساس الفني: Two synchronized vibrators generating a true linear motion with adjustable stroke | المنفعة التشغيلية: Provides optimal material travel speed and stratification with minimal transmitted dynamic loads to the support structure. | تأثير عائد الاستثمار: Lowers structural maintenance costs and reduces energy consumption per ton processed by an average of 1520%.

عزل زنبركي ملفوف للخدمة الشاقة | الأساس الفني: Multiple highcycle fatiguerated steel coil springs at each support point | المنفعة التشغيلية: يعزل أكثر 95% من القوى الديناميكية, protecting the building structure and allowing for installation on elevated floors. | تأثير عائد الاستثمار: Eliminates the need for massive concrete foundations, reducing installation time and capital cost.

تصميم محكم للغبار | الأساس الفني: Continuous sealing system between decks, لوحات جانبية, and discharge hoods | المنفعة التشغيلية: يحتوي على انبعاثات الغبار في المصدر, improving plant safety and environmental compliance. | تأثير عائد الاستثمار: Lowers costs associated with external dust collection systems and reduces housekeeping labor.

نظام تشحيم الشحوم المركزي | الأساس الفني: Automated manifold delivering grease to all critical vibrator bearing points | المنفعة التشغيلية: Ensures optimal bearing life with minimal manual intervention from operators. | تأثير عائد الاستثمار: Extends bearing service intervals by 3x, preventing catastrophic failure and unplanned stoppages.

4. المزايا التنافسية

| مقياس الأداء | معيار الصناعة | حل شاشة اهتزاز فحم الكوك ذو العلامة البيضاء | ميزة (% تحسين) |
| : | : | : | : |
| وقت تغيير وسائط الشاشة (سطح كامل) | 812 ساعات (نظام انسحب) | 50% أسرع |
| Bearing Life (نظام القيادة) | ~10,000 operating hours | >16,000 operating hours with centralized lube| >60% حياة أطول |
| استهلاك الطاقة (كيلوواط ساعة/طن) Baseline = X kW/Ton| X kW/Ton (standard circlethrow) X 0.85 كيلوواط/طن (optimized linear motion)| ~15% more efficient |
| انتقال القوة إلى الأساس| عالي; requires massive concrete base| <5% تنتقل; can use elevated steel support| Enables more flexible plant layout |

5. المواصفات الفنية

نطاق النموذج & سعة: متوفر بعرض من 1.2 م إلى 3.6 م; أطوال من 4.8 م إلى 10 م. القدرات من 50 الهيدروكربونات النفطية لأكثر من 1200 TPH اعتمادًا على حجم الفتحة وكثافة المادة.
متطلبات الطاقة: تتراوح محركات القيادة من 2 س 7.5 كيلوواط ل 2 س 45 كيلوواط (400/690V, 50/60هرتز). Isolation system requires no external power.
مواصفات المواد: Main frame heavyduty carbon steel (S355JR). Side plates abrasionresistant steel (AR400). Deck frames galvanized steel or stainlesssteel options.
الأبعاد المادية & وزن: يختلف حسب الموديل; typical footprint is Length (+20%) × العرض (+10%) of screen deck nominal size. Weights range from ~5 tonnes to >25 طن.
نطاق التشغيل البيئي: درجة الحرارة المحيطة: 20درجة مئوية إلى +45 درجة مئوية. Designed for indoor or sheltered outdoor installation with appropriate finishes.

6. سيناريوهات التطبيق

Foundry Coke Production Plant – Final Product Sizing

تحدي: A major foundry needed consistent +25mm 50mm lump coke but their existing screens suffered rapid blinding with fines (<5مم), causing offspec product batches every shift.
حل: Installation of a twodeck White Label Coke Vibration Screen with top deck polyurethane panels (50mm aperture) and bottom deck wire mesh (25mm aperture).
نتائج: Achieved consistent product gradation (>98% ضمن المواصفات). Panel blinding was eliminated due to effective linear stratification; media change intervals extended from weekly to quarterly.

Integrated Steelworks – Sinter Plant Feed Preparation

تحدي: Fluctuations in crusher output led to overload conditions on sinter feed screens downstream, causing frequent bearing failures and unscheduled downtime exceeding 40 ساعات شهريا.
حل: Deployment of a heavyduty model with oversized vibrator bearings rated for higher Gforces and an integrated loadsensing control system that adjusts feed rate via PLC interface.
نتائج: Field data shows a complete elimination of vibrationrelated bearing failures in the first year of operation. زاد توافر النباتات بأكثر من 3%, translating directly to increased sinter production.

7 الاعتبارات التجارية

White Label Coke Vibration Screens are offered under a tiered pricing structure based on size specifications:
السلسلة القياسية (13 الطوابق): For most standard coke sizing duties; includes base motor options standard isolation springs dust covers
سلسلة الثقيلة: For hightonnage primary scalping or severeduty applications includes reinforced frames larger diameter shafts heavyduty bearings
Optional features include stainlesssteel contact parts variable frequency drives for stroke adjustment spray bar systems for limited antiblinding duty custom discharge hood designs

Service packages range from basic commissioning supervision through comprehensive multiyear maintenance agreements including parts kits remote monitoring support Financing options including equipment leasing are available through certified partners

التعليمات

Q1 How does this vibration screen handle variations in feed rate?
A1 The linear motion design provides consistent conveying velocity even under variable load conditions For extreme variations an optional variable frequency drive allows operators finetune stroke amplitude ensuring separation efficiency across different throughputs

Q2 What is compatibility existing screen cloth inventory?
A2 Our modular deck system uses standardized tensioning rails accommodating most commercially available polyurethane panel hookstyles wire mesh types This minimizes need complete media replacement during initial transition

Q3 What typical installation timeline look like?
A3 Most units require minimal foundation work due effective isolation Preassembled modules reduce onsite assembly time Typical installation commissioning period ranges days weeks depending complexity existing plant infrastructure

Q4 How does operational noise level compare other screens?
A4 Enclosed design combined coil spring isolation typically results sound pressure levels below dB(أ) measured meter from machine meeting most stringent workplace health safety regulations

Q5 What warranty provided key components?
A5 Standard warranty covers defects materials workmanship months operation Vibrator assemblies drive motors carry extended month warranty when registered our service program

Q6 Can this screen integrate our existing PLC control system?
A6 Yes units come equipped standard motor starters protection but can furnished with interfaceready control panels providing run status fault alarms remote start stop capability facilitating integration central control room

Q7 Are spare parts readily available longterm?
A7 We maintain global inventory critical wear parts vibrator shafts bearings deck components ensuring availability minimize potential extended downtime