Dirigirse a los gerentes de planta, Especialistas en adquisiciones, y contratistas de ingeniería: Un técnico & Commercial Evaluation of the JC5000 Jaw Crusher

1. APERTURA IMPULSADA POR EL PUNTO DE DOLOR

Managing primary crushing stages presents persistent operational and financial challenges. Material de alimentación inconsistente, paradas de mantenimiento no planificadas, and rising energy costs directly impact your bottom line. ¿Estás experimentando:
Excessive Downtime for Wear Part Replacement? Frequent jaw plate changes halt entire processing lines, costando miles por hora en producción perdida.
Inconsistent Throughput and Product Gradation? Variable feed size and hardness lead to unpredictable output, bottlenecking downstream operations and compromising final product specifications.
Unscheduled Maintenance from Tramp Metal or Uncrusheables? A single unforeseen event can cause catastrophic damage, resulting in lengthy repairs and significant component costs.
Rising Operational Costs from Energy Inefficiency? Older crushing technology consumes excessive power per ton of material processed, erosionando los márgenes de beneficio.

The solution requires a primary crusher engineered not just for power, but for predictable performance and total operational cost management.

2. DESCRIPCIÓN GENERAL DEL PRODUCTO

El Trituradora de mandíbula JC5000 es de alta capacidad, Trituradora de mandíbulas de palanca única diseñada para las aplicaciones de trituración primaria más exigentes en minería, heavy construction, y producción agregada a gran escala. Its design focuses on delivering maximum availability and the lowest cost per tonne in its class.

Flujo de trabajo operativo:
1. Consumo de alimento: Material de gran tamaño de mina o cantera (hasta 1,5 m de longitud de borde) se dirige hacia lo profundo, nonchoking corrugated feed opening.
2. Acción aplastante: A robust eccentric shaft drives a dynamically balanced moving jaw in an aggressive elliptical motion, applying compressive force to reduce material against a fixed jaw.
3. Descargar: Crushed product exits at the bottom discharge point, con tamaño determinado por la configuración del lado cerrado (CSS), adjustable via a hydraulic wedge system.

Ámbito de aplicación: Ideal para roca dura (granito, basalto), minerales abrasivos, and recycled concrete/demolition waste. Suitable for stationary plants or large mobile tracked setups.

Limitaciones: Not designed for ultrafine grinding or as a secondary/tertiary crusher. Requires a properly sized feeding system to realize full capacity benefits.

3. CARACTERÍSTICAS PRINCIPALES

Marco resistente & Rodamientos de rodillos esféricos | Base técnica: Análisis de elementos finitos (FEA) distribución de tensión optimizada | Beneficio operativo: Resiste cargas máximas de material no triturable; eliminates frame fatigue failures | Impacto del retorno de la inversión: Extended structural life beyond the crusher’s service cycle; reduces risk of catastrophic plant shutdown.

Palanca hidráulica & Ajuste CSS | Base técnica: Cilindro hidráulico integrado para tensado y limpieza. | Beneficio operativo: Enables remote adjustment of discharge setting and automated clearing of chamber blockages in minutes | Impacto del retorno de la inversión: Minimiza el tiempo de inactividad por cambios de producto; improves operator safety by removing manual intervention.

ST47 Manganese Steel Jaw Plates | Base técnica: Highstrength alloy with optimal tooth profile design | Beneficio operativo: Extended wear life under high abrasion; maintains consistent product gradation throughout wear cycle | Impacto del retorno de la inversión: Reduces consumable inventory costs and changeout frequency by an average of 2535% versus standard plates.

Transmisión directa & Flywheel Mass | Base técnica: Hightorque motor coupled directly to eccentric shaft with optimized inertial mass | Beneficio operativo: Transmisión de potencia eficiente; maintains consistent crushing momentum under variable loading | Impacto del retorno de la inversión: Los datos de campo muestran 812% improvement in kWh per tonne crushed compared to comparable Vbelt driven units.

Intelligent Control System Interface | Base técnica: PLCbased monitoring of power draw, temperatura del rodamiento, y presión hidráulica | Beneficio operativo: Provides realtime operational data and prefailure alerts to prevent secondary damage | Impacto del retorno de la inversión: Permite la programación de mantenimiento predictivo, avoiding unplanned stops and reducing repair scope.

Quarry Duty Eccentric Shaft | Base técnica: Forged from highintegrity steel with precisionmachined bearing journals | Beneficio operativo: Unmatched resistance to bending fatigue under continuous highload operation | Impacto del retorno de la inversión: Core component designed for the lifetime of the crusher, eliminating replacement cost and downtime.

4. VENTAJAS COMPETITIVAS

| Métrica de rendimiento | Estándar de la industria (750mm x 500mm Class) | Solución de trituradora de mandíbulas JC5000 | Ventaja (% Mejora) |
| : | : | : | : |
| Average Wear Life (Roca abrasiva) | 180,000 220,000 toneladas por juego | 280,000 320,000 toneladas por juego| +35% |
| Liquidación de la cámara / Tiempo de ajuste de CSS| 45 90 minutos (manual) | < 10 minutos (hidráulico) |85% |
| Eficiencia energética (kWh/tonelada) Base| ~0,85 1.05 kWh/t| ~0,75 0.92 kWh/t| ~12% |
| Maximum Feed Size Acceptance Ratio| ~80% of gape width| ~85% of gape width| +6% intake capacity |

Ratio of acceptable topsize dimension to crusher gape width.

5. ESPECIFICACIONES TÉCNICAS

Capacidad de trituración: Arriba a 750 toneladas por hora (depende del material de alimentación y del ajuste del lado cerrado).
Apertura de alimentación: 1300mm x 1000 mm (51"x 40").
Potencia motriz: 132 kilovatios / 175 Motor eléctrico HP estándar.
Peso Total: Aproximadamente 48,500 kilos (crushing unit only).
Especificaciones clave de materiales: Fabricated heavyduty steel frame; Forged EN24/S355J2 eccentric shaft; ST47/ST52 fixed & moving jaws; Rodamientos de rodillos esféricos.
Rango de operación: Diseñado para temperaturas ambiente de 20°C a +45°C. Dust sealing is standard for harsh environments.

6. ESCENARIOS DE APLICACIÓN

Estación de trituración primaria de cantera de granito

Challenge A major aggregate producer faced excessive downtime from weekly jaw plate inspections and bimonthly changes due to highly abrasive feed.
Solution Installation of a JC5000 Jaw Crusher equipped with ST47 jaw plates and the hydraulic toggle system.
Results Wear part life extended to sixweek intervals. Combined with rapid hydraulic CSS adjustment for varying product demands, plant availability increased by an estimated 18%. The resulting increase in usable output provided a payback period on the crusher investment in under 14 meses.

Iron Ore Processing – Primary Reduction

Challenge An iron ore operation needed higher throughput from their primary circuit but was limited by frequent blockages from sticky feed material and fear of damage from tramp metal.
Solution A JC5000 was selected for its robust frame design and hydraulic clearing system.
Results The automated clearing cycle resolved blockages within one shift hour versus previous halfday manual efforts. The control system’s power monitoring now provides alerts on potential uncrushables, allowing operators to take preemptive action. Throughput increased by a consistent 15% due to reduced stall time.

7. CONSIDERACIONES COMERCIALES

The JC5000 Jaw Crusher is offered in configured tiers:
Configuración básica: Core crushing unit with motor drive guardsand basic controls.
Production Ready Package: Incluye base de motor integrada,vbelt drive guard assembly,lifting tools,and advanced PLC control system with touchscreen interface.
SiteSpecific Options: Custom wear plate profiles,fixed installation skid package,dust extraction ports,and various motor voltage/frequency configurations.

Service packages range from annual inspection plans to comprehensive scheduled maintenance agreements covering partsand labor.Financing options including operating leasesand equipment rentaltoown programs are available through authorized distributors to align capital expenditure with project cash flow.

8.Preguntas frecuentes

Q What is the typical installationand commissioning timelinefora JC5000?
A Fora stationary plant replacementwith prepared foundations,crane access,and utilities available,crusher commissioning typically requires57 working days.This includes mechanical setting,pourinplace epoxy grouting,and control system integration

Q How does theJC5000 handle recycled demolition concretewith rebar?
A The hydraulictoggle systemis designedto releas eautomaticallyif an uncrushable objectlike large tramp metalis encountered.This protects thecrusherfrom damage.The rebar will generally be cleanedfromthe chamberduringthe reversalcycleand ejectedwiththe product

Q ¿Hay piezas de desgaste fácilmente disponibles??
A Yes.Authorized distributorsstock criticalwear parts—jaw plates,toggleseats,s ide liners—ensuringavailabilityforplannedchanges.Field datasupports predictablewear lifeallowingforjustintimeorderingto minimizeyourinventoryholding

Q Can thiscrusherintegratewithourexistingPLCplant controls?
A Yes.TheJC5000'scontrolsystemprovess tandardhardwiredI/Oanda ModbusTCP/IPprotocolinterfacefor seamlessdataexchangewithmostcentralizedplant monitoring systems

Q Whatistheexpectedservice lifeforthemajor structuralcomponents?
A Thecoreframe,eccentricshaft,and bearinghousingsaredesignedand manufacturedfora minimumservice lif eof20+yearsundernormaloperatingconditionssubjecttoproper maintenance