1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent vos marges de production globales? Pour les directeurs d’usine et les entrepreneurs en ingénierie, core crushing challenges directly impact the bottom line. Consider these common, costly scenarios:
Temps d'arrêt imprévus: Bearing failures or component wear cause catastrophic stoppages, coûtant des milliers de dollars par heure en perte de production et de main d'œuvre.
Consommation élevée de pièces d’usure: Remplacement fréquent des doublures, mâchoires, or blow bars under abrasive conditions creates significant recurring expense and inventory burden.
Gradation du produit incohérente: Offspec material requiring recrushing or selling at a discount due to poor chamber design or unstable operation.
Consommation d'énergie excessive: Inefficient crushing action and outdated drive systems lead to power costs that consume profit.
Rigidity & Foundation Issues: Machine vibration and stress demand expensive, timeintensive civil works, delaying project starts.

La question centrale est: how can you achieve higher throughput of inspec aggregate while controlling maintenance costs and maximizing machine availability? The solution requires a machine engineered not just to crush, but to optimize total operational cost.

2. APERÇU DU PRODUIT

The modern commercial jaw crusher is a primary crushing workhorse engineered for hightonnage reduction of hard rock, such as granite, basalte, and abrasive ores. Its core function is to provide the first stage of size reduction in a quarry or mining operation.

Flux de travail opérationnel:
1. Consommation alimentaire: Runofmine (ROM) material is loaded into the vibrating grizzly feeder (VGFF VGF), which bypasses fines to the main conveyor and directs oversize to the crusher inlet.
2. Concassage par compression: Material enters the fixed and moving jaw plates. The elliptical motion of the moving jaw compresses rock against the stationary jaw, fracturing it along natural cleavage lines.
3. Réglage de décharge: The crushed material exits through the adjustable discharge opening at the bottom of the chamber. The closed Side Setting (CSS) precisely controls the maximum product size.
4. Transport du produit: Crushed product is discharged onto the main plant conveyor for transport to secondary crushing or screening stages.

Champ d'application & Limites:
Portée: Idéal pour le concassage primaire de matériaux durs, abrasive materials in stationary quarry plants, opérations minières, and largescale construction projects requiring consistent, highvolume output (typiquement 2001500+ TPH).
Limites: Not suitable for sticky or plastic materials. Requires a regulated feed size; oversize tramp metal can cause damage. Optimal performance is tied to proper feed arrangement and consistent material characteristics.

3. CARACTÉRISTIQUES PRINCIPALES

Chambre de concassage profonde | Base technique: Optimized nip angle and long linear crushing stroke | Avantage opérationnel: Increased capacity per stroke and reduced bridging; produces a wellshaped product with fewer flaky particles | Impact sur le retour sur investissement: Higher throughput of saleable product reduces costperton metric.

Construction de cadre robuste | Base technique: Fabricated from highgrade steel plate with reinforced stress points and finite element analysis (FEA) conception | Avantage opérationnel: Absorbs dynamic loads, minimizes operational stress fractures, and provides longevity in 24/7 environnements | Impact sur le retour sur investissement: Eliminates costly frame repairs/replacements, extending asset life beyond 20 années.

Bascule hydraulique & Système de réglage | Base technique: Replaces traditional mechanical toggle plates with a hydraulic cylinder for clearing blockages and adjusting CSS | Avantage opérationnel: Permet en toute sécurité, rapid clearing of stalled material in minutes versus hours; enables remote CSS adjustment for quick product changes | Impact sur le retour sur investissement: Drastically reduces downtime from tramp events and changeover time by over 70%.

Wedge Lock Jaw Plate Retention | Base technique: Utilizes mechanically locked wedges instead of traditional bolted systems | Avantage opérationnel: Enables faster, safer jaw plate changes with fewer loose parts; provides secure plate seating that reduces wear part failure risk | Impact sur le retour sur investissement: Cuts liner changeout time by up to 50%, augmentation de la disponibilité des plantes.

HighInertia Flywheels | Base technique: Precisely balanced cast iron flywheels store kinetic energy during each cycle | Avantage opérationnel: Smoothes peak power demands on the crusher drive motor, promoting efficient energy transfer throughout the crushing stroke | Impact sur le retour sur investissement: Reduces peak current draw, lowering energy costs by 510% versus standard designs.

Centralized Greasing Point | Base technique: Singlepoint connection linked to all major bearing lubrication points via internal grease galleries | Avantage opérationnel: Ensures consistent lubrication during routine maintenance without requiring multiple access points; improves bearing life significantly| Impact sur le retour sur investissement: Prevents premature bearing failure—a leading cause of major downtime—extending service intervals by 30%.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie | Commercial Jaw Crusher Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Temps de changement de doublure (Plaques à mâchoires) | 812 hours with manual bolt removal/retorquing | 50% plus rapide |
| Consommation d'énergie (kWh/tonne) | Varie considérablement; ligne de base fixée à 100% for comparison| Cinématique optimisée & highinertia flywheels reduce draw| 510% réduction |
| Bearing Life (L10 hours) under full load| ~30,000 40,000 hours with proper maintenance| >50,000 hours via precision machining & forced lubrication| ~25% longer life |
| Disponibilité (Annual Uptime %) hors maintenance planifiée| ~9294% factoring unscheduled stops| Field data supports >96% through robust design & hydraulic clearing| >2 percentage point gain |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de la gamme de modèles: 200 1,600 Metric Tons per Hour (MTPH), en fonction du matériau alimenté et du réglage du côté fermé.
Tailles d'ouverture d'alimentation: Ranging from 800mm x 550mm (32" x 22") up to 1600mm x 2000mm (63" x 79").
Exigences d'alimentation: Moteur du concasseur principal de 75 kW (100 HP) à 400 kW (530 HP). Plant auxiliary systems require separate power.
Spécifications matérielles: Fabricated main frame from ASTM A36 steel; critical wear parts available in multiple manganese steel grades (par ex., Mn14%, Mn18%, Mn22%) or optional premium alloys for specific abrasion/corrosion applications.
Dimensions physiques / Poids: Approximate machine weights range from ~25 tonnes for smaller models to over ~120 tonnes for largest units. Specific footprint dimensions are modeldependent.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C (4°F à +113°F). Sealed components protect against dust ingress in compliance with IP65 standards where specified.

6. SCÉNARIOS D'APPLICATION

Agrandissement de la carrière de granit

Challenge A quarry needed to increase primary circuit throughput by 25% without expanding its footprint or civil foundation due to space constraints.
Solution Implementation of a new generation jaw crusher featuring a deeper chamber and more aggressive stroke profile within an equivalent physical envelope to their old unit.
Results Achieved a sustained 28% increase in throughput at the same CSS due to improved efficiency. The existing feeder and infrastructure were retained directly impacting capital expenditure savings while meeting new production targets.

Basalt Aggregate Production for Rail Ballast

Challenge Strict product shape requirements (low flakiness index) for rail ballast were not being met consistently by an older primary crusher leading to excessive recirculation load
Solution Replacement with a jaw crusher designed specifically for optimal nip angle producing more cubical product at the primary stage
Results Flakiness index improved by over15%. This reduced load on secondary cone crushers increasing overall plant capacity by approximately12% while consistently meeting rail specification

7 CONSIDÉRATIONS COMMERCIALES

Equipment pricing tiers are typically structured around feed opening size capacity range:
Tier I Midrange models(up~500 MTPH): Positioned as highvalue replacements offering core features
Tier II Highproduction models(5001000 MTPH): Include advanced automation interfaces telemetry options
Tier III Superduty stations(1000+ MTPH): Feature custom engineering heavyduty configurations

Optional Features Premium alloy wear parts automated lubrication systems motorized discharge setting adjustment remote monitoring packages

Service Packages Standard offerings include commissioning supervision operator training extended warranty plans Critical component exchange programs ensure fast turnaround on major items

Financing Options Available through manufactureraffiliated partners include capital leases operating leases longterm rentaltoown structures tailored support project financing models

8 FAQ

What type of feeder works best with this jaw crusher?
A vibrating grizzly feeder VGF is strongly recommended It regulates feed rate removes fines scalp oversize rock protects against uneven loading which causes premature wear

Can we use this machine as a standalone unit without a full plant?
While possible it is not optimal For maximum efficiency it should be part integrated circuit including proper feed conveyance discharge systems Screening before secondary crushing highly recommended

How does hydraulic toggle adjustment translate into operational savings?
It eliminates manual shim adjustment saving12 hours per CSS change More importantly allows remote adjustment enabling optimization without personnel near moving parts enhancing safety productivity

What are typical lead times delivery installation?
For standard models lead time ranges814 weeks postorder Delivery installation commissioning typically require34 weeks site preparation including foundation must be completed prior arrival

Are wear parts interchangeable with other manufacturers' crushers?
No Wear parts are engineered specifically our chamber kinematics geometry Using nonOEM parts can reduce capacity increase power draw void warranty coverage critical components