1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L'augmentation des coûts opérationnels et les temps d'arrêt imprévisibles érodent-ils la rentabilité de votre circuit de concassage primaire? Pour les directeurs d’usine et les entrepreneurs en ingénierie, l'étape de concassage primaire est un goulot d'étranglement critique où les inefficacités se répercutent sur toute la chaîne de traitement. Les défis courants incluent:
Temps d'arrêt excessif pour la maintenance: Les changements fréquents de revêtement et les pannes mécaniques inattendues interrompent la production, coûtant des milliers de dollars par heure en perte de débit.
Consommation élevée de pièces d’usure: Aggressive or abrasive feed material leads to premature jaw plate wear, augmenter votre coût et créer des maux de tête en matière de gestion des stocks.
Gradation du produit incohérente: Fluctuations in feed size or hardness result in an uneven discharge product, placing stress on downstream screening and secondary crushers.
Rigid Setup Limitations: Fixed jaw crushers cannot adapt to changing project demands or feed characteristics, locking you into a single operational profile.

How do you secure consistent throughput while controlling maintenance costs and adapting to variable feed conditions? The solution requires a robust design focused on durability, facilité d'entretien, and sustained performance.

2. APERÇU DU PRODUIT

The Bulk JC5000 is a highcapacity, singletoggle jaw crusher engineered for primary crushing in demanding mining, carrière, et applications de construction à grande échelle. It processes runofmine rock, pierre de carrière dynamitée, and demolition concrete into a consistent, granulat grossier.

Flux de travail opérationnel:
1. Consommation alimentaire: Matériau surdimensionné (jusqu'à 1300mm) is directed into the deep crushing chamber by vibrating grizzly feeders.
2. Concassage par compression: The elliptical motion of the single toggle forces the movable jaw against the fixed jaw, appliquer une force de compression pour fracturer la roche.
3. Décharge & Autorisation: Le matériau broyé sort par l'ouverture de déchargement inférieure (CSS), with the aggressive stroke ensuring efficient clearing even under high load.

Champ d'application: Idéal pour le hard rock (granit, basalte), minerais abrasifs, and recycled concrete with strengths up to 400 MPa. It serves as the primary workhorse in stationary plants and large mobile tracked setups.

Limites: Non conçu pour être mouillé, sticky materials that may cause chamber packing without proper feed conditioning. For ultrafine output (<50mm), secondary or tertiary crushing stages are required.

3. CARACTÉRISTIQUES PRINCIPALES

Deep Chamber Design | Base technique: Optimized nip angle and long linear crushing path | Avantage opérationnel: Enables higher volume intake per cycle and reduces bridging risks | Impact sur le retour sur investissement: Increases potential throughput by up to 15% versus shallower chambers of similar inlet size

Système de réglage à bascule hydraulique | Base technique: Replaceable hydraulic cylinder for tensioning & overload release | Avantage opérationnel: Allows remote CSS adjustment under load and protects against tramp metal damage | Impact sur le retour sur investissement: Réduit les temps d’arrêt imprévus d’en moyenne 30 hours annually related to tramp iron incidents

Ensemble de roulement à rouleaux robuste | Base technique: Roulements à rotule sur rouleaux sur l'arbre principal | Avantage opérationnel: Supports higher radial loads and operates at lower temperatures than bronze bushings | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements d'environ 40%, diminution de la fréquence de remplacement des pièces

Doublures d'usure BoltOn | Base technique: Modular manganese steel liners on frame sides | Avantage opérationnel: Protects crusher frame from abrasion; replaced independently of jaw dies | Impact sur le retour sur investissement: Preserves structural integrity of main frame for decades, avoiding capital replacement costs

Points de graissage centralisés | Base technique: Automated or manual greasing lines routed to all major bearings | Avantage opérationnel: Permet de sécuriser, routine lubrication without direct operator access to moving parts | Impact sur le retour sur investissement: Standardizes preventive maintenance, reducing lubricationrelated failures by over 80%

Reinforced Swing Jaw Design | Base technique: Analyse par éléments finis (FEA) optimized cast steel structure with thick ribs | Avantage opérationnel: Provides maximum fatigue resistance under cyclic loading stresses | Impact sur le retour sur investissement: Minimizes risk of catastrophic jaw failure, ensuring multiyear structural service life

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Classe comparable) | Bulk JC5000 Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Average Jaw Plate Life (Granit abrasif) | ~180 000 MTON par ensemble (Standard Mn18) | ~250 000 MTON par ensemble (Premium Mn22) +38% |
| Il est temps d’ajuster CSS / Liner Turnover| 46 heures (manual shim adjustment) 900 TPH in field trials| >6% Sortie plus élevée |

5. SPÉCIFICATIONS TECHNIQUES

Ouverture d'alimentation: 1300mm x 1000 mm (51" x 40")
Taille maximale d'alimentation: Jusqu'à 1 100 mm de longueur de bord
Réglage du côté fermé (CSS) Gamme: 150mm 300mm
Plage de capacité: Jusqu'à 950 tonnes par heure (dépend de la matière première & CSS)
Exigence de puissance d'entraînement: 132 Moteur électrique kW
Poids total (Concasseur uniquement): Environ 62 tonnes
Spécifications des matériaux clés:
Cadre principal: Plaque d'acier robuste fabriquée
Mâchoire pivotante & Fixed Jaw Dies: Acier au manganèse de première qualité
Arbre excentrique: Acier allié forgé
Plage de température de fonctionnement: 30°C to +45°C with appropriate lubricants
Dimensions (L x l x H): ~4m x 3m x 3m

6. SCÉNARIOS D'APPLICATION

Hard Rock Quarry Expansion Challenge:

A granite quarry needed to increase primary circuit output by 25% without expanding its plant footprint or secondary crushing line.

Solution:

Two older jaw crushers were replaced with a single Bulk JC5000 unit configured with a wider CSS to produce optimal feed for existing cone crushers.

Résultats:

Le débit a augmenté de 28%. The consistent product gradation reduced cycling in downstream cones. Combined with longer wear life on jaw plates,the change lowered costpertonne by an estimated 18%.

LargeScale Mineral Processing Plant Challenge:

An iron ore operation faced excessive unplanned downtime due to tramp steel damaging its primary crusher,losing an average of $15k per incident.

Solution:

Implementation of the Bulk JC5000 with its hydraulic toggle system for automatic overload protection.

Résultats:

Field data shows three overload events were safely cleared without shutdown in one quarter.Planned maintenance intervals are now reliably met,directly saving over $60k in avoided downtime within six months.

7. CONSIDÉRATIONS COMMERCIALES

The Bulk JC5000 is positioned as a capital investment for operations focused on longterm total cost of ownership reduction.

Niveau de tarification de l'équipement de base: Comprend un broyeur,supports de moteur,and drive sheaves.Competitively structured against equivalent OEM offerings.
Fonctionnalités facultatives & Forfaits:

Forfait Performances: Includes automated grease system,démarreur de moteur,and wear part monitoring sensors.
QuickChange Package: Features hydraulic assist tools for jaw die replacement.
Modular Frame Guarding: Preassembled safety guards for faster installation.

Contrats de service:

1Year OnSite Warranty with factory commissioning support.
3Year /5Year Extended Protection Plans covering major components.
Scheduled Inspection Programs managed via predictive maintenance software.

Financing options include equipment leasing through partners,tailored rentaltoown structures for projectbased work,and fleet upgrade programs involving tradeins of legacy equipment.

8.FAQ

T1:What is the compatibility of the Bulk JC5000 with my existing vibrating grizzly feeder and discharge conveyor?
A1:The JC5000 is designed to standard industry mounting footprints.Its feed height and discharge trajectory can be engineered during quotation to match your current layout.Engineering support is provided for integration reviews.

T2:What is the expected operational impact during liner changeouts?
A2:The design prioritizes service access.Field reports indicate a full set of jaw dies can be changed by a threeperson crew in one shift,a significant reduction compared to older designs requiring torch work or complex dismantling.

T3:What commercial terms are available beyond upfront purchase?
A3.We offer several models including straight capital sale,fixedterm lease financing,and certified refurbished units from our rebuild program.Each has distinct cash flow implications we can detail based on your procurement process.

T4:What power supply infrastructure is required?
A4.The unit requires a dedicated supply compatible with its 132 kW motor.Full electrical schematics,suggested protection devices,and softstart recommendations are provided ahead of installation.A dieselhydraulic drive option exists for remote sites lacking grid power.

Q5:What training is provided for our maintenance team?
A5.Comprehensive training modules are included,covershing safe operation,procédures d'entretien courant,and basic troubleshooting.This can be delivered onsite during commissioning or at our regional technical centers.Documentation includes detailed parts manuals and taskspecific videos