1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent-ils vos marges de traitement des granulats ou des minéraux ?? Common crusherrelated challenges directly impact your bottom line:
Temps d'arrêt imprévus: Les défaillances de roulements ou l'usure des composants peuvent interrompre des lignes de production entières, coûtant des milliers de dollars par heure en perte de production et en main d'œuvre inutilisée.
Coûts de maintenance élevés: Besoins fréquents de lubrification, difficult component access, and short wear part lifecycles create recurring expense and labor burdens.
Gradation du produit incohérente: Unstable crushing chambers or insufficient adjustment range lead to offspec product, resulting in recrushing cycles or rejected loads.
Inefficacité énergétique: Older jaw crusher designs waste significant power on friction and ineffective crushing motions, increasing your fixed operational costs.
Problèmes d’intégrité structurelle: Fatigue cracks in frames or poorly engineered components under high cyclic loading pose longterm reliability risks.

Is your primary crushing stage a source of cost control and predictable throughput, or a recurring bottleneck? La solution nécessite un équipement conçu non seulement pour des performances optimales, but for sustained operational economy and reliability under continuous demand.

2. APERÇU DU PRODUIT

Le JC5000 approuvé par la FDA est un appareil de grande capacité, Concasseur à mâchoires à bascule unique conçu pour le concassage primaire de roche dure, minerai, and demolition concrete in stationary plant configurations. Its design prioritizes mechanical simplicity for robustness and ease of maintenance in demanding 24/7 operating environments.

Flux de travail opérationnel:
1. Alimentation & Compression: Matière première de grande taille (jusqu'à 1300mm) entre dans les profondeurs, chambre de concassage sans étouffement.
2. Action écrasante: A highinertia flywheel drives an aggressive elliptical motion at the movable jaw, applying intense compressive force to reduce material.
3. Décharge & Autorisation: Crushed material exits at the bottom with a consistent discharge setting adjustable via a hydraulic toggle tensioning system.
4. Recyclage & Scalping: Oversize material can be recirculated via conveyor, while integrated grizzly options bypass fines to optimize chamber loading.

Champ d'application & Limites:
Portée: Ideal for primary reduction of granite, basalte, minerai de fer, et granulats de construction recyclés. Suitable for largescale mining, carrière, and major infrastructure project mobile/stationary plants.
Limites: Non conçu pour être mouillé, sticky materials that may cause chamber packing. Requires a stable reinforced concrete foundation and appropriate upstream feeding equipment (par ex., mangeoire vibrante pour grizzlis).

3. CARACTÉRISTIQUES PRINCIPALES

Cadre fabriqué robuste | Base technique: Analyse par éléments finis (FEA) construction optimisée en tôle d'acier | Avantage opérationnel: Eliminates stress points and fatigue cracking under maximum load conditions; provides longterm structural integrity | Impact sur le retour sur investissement: Extends service life by decades, éviter les coûts de remplacement prématurés des immobilisations.

Système de réglage à bascule hydraulique | Base technique: Integrated hydraulic ram for setting adjustment and overload relief | Avantage opérationnel: Enables remote setting changes in minutes versus hours; automatically resets after tramp metal events | Impact sur le retour sur investissement: Reduces downtime for product changes by up to 80% et protège les principaux composants contre les dommages catastrophiques.

Chambre de concassage symétrique profonde | Base technique: Optimized nip angle and longer linear crushing surface | Avantage opérationnel: Promotes accelerated breakage of slabby material and delivers more consistent product gradation | Impact sur le retour sur investissement: Increases throughput tonnage by 1015% over comparable models with shorter chambers.

Spherical Roller Bearing & Labyrinth Seal Design | Base technique: Largediameter bearings for high radial load capacity; multistage seals excluding dust ingress | Avantage opérationnel: Gère les charges de pointe de manière fiable; extends bearing service life by protecting against contamination | Impact sur le retour sur investissement: Reduces bearing replacement frequency by an estimated 50%, lowering parts inventory cost.

Boulonné (Non soudé) Wear Liner Design | Base technique: Highstrength alloy steel liners mechanically fastened to swing jaw and frame | Avantage opérationnel: Allows for faster liner replacement; eliminates risks of weld fatigue on critical structures | Impact sur le retour sur investissement: Réduit de moitié le temps de changement de doublure, augmentant directement la disponibilité des plantes.

Entraînement direct & Volants à haute inertie | Base technique: Efficient power transmission via Vbelts from motor to flywheels storing kinetic energy | Avantage opérationnel: Smoothes power demand peaks for energy efficiency; maintains consistent crushing momentum under load variation | Impact sur le retour sur investissement: Réduit la consommation d’énergie spécifique (kWh/tonne), reducing direct operating cost per ton processed.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Classe comparable) | Avantage documenté de la solution JC5000 |
| : | : | : |
| Porter la vie (Revêtements de mâchoire Mn18/22)| ~120 000 150,000 tonnes (granit)|
| >180,000 tonnes (granit)|
| +2530% amélioration |
| Heures de maintenance annuelles planifiées|
| ~80100 hours|
|
~5060 hours|
| ~40% reduction in labor time |
| Consommation d'énergie spécifique|
| ~0,8 1.1 kWh/tonne|
|
0.65 0.75 kWh/tonne|
| Jusqu'à 20% consommation d'énergie réduite |
| Temps de récupération du fer clochard|
| Réinitialisation manuelle / heures|
|
Réarmement hydraulique / 95% réduction des temps d'arrêt |

5. SPÉCIFICATIONS TECHNIQUES

Ouverture d'alimentation: 1300mm x 1000 mm (51" x 40")
Taille maximale d'alimentation: 1100mm (43")
Plage de capacité: 450 1200 mtph (en fonction du type de matériau & réglage côté fermé)
Exigence de puissance: 200 kW / 270 Norme de moteur électrique HP
Poids total (Concasseur uniquement): Environ 62,000 kilos
Spécifications des matériaux clés:
Cadre: Fabricated from heavyduty steel plate with stressrelieved welds.
Swing Jaw/Fixed Jaw Bodies: Highgrade cast steel.
Jaw Plates/Side Liners:Manganese steel alloys available in various grades.
Arbre excentrique:Tough alloy steel forging with precision machining.
Roulements:Tapered spherical roller bearings rated for extreme loads.
Plage de température de fonctionnement: 20°C à +40°C (4°F à +104°F) avec des lubrifiants standards.

6. SCÉNARIOS D'APPLICATION

Granite Quarry Primary Station Challenge:

A large aggregate producer faced excessive wear part costs on their primary jaw crusher (~$85k annually) due to abrasive granite feed averaging over $600 Mpa compressive strength. Downtime every six weeks was required for liner changes.

Solution:

Implementation of the FDA Approved JC5000 Jaw Crusher with Xtralloy® premium manganese liners was specified specifically as the FDA Approved JC5000 solution.

Résultats:

Field data over one year showed liner life extended from six weeks to approximately nine weeks per set—a direct increase of over thirty percent—reducing annual wear part expenditure by approximately $25k while adding over one hundred hours of productive uptime annually through fewer changeouts.

Défi de mise à niveau de l’usine de traitement du minerai de fer:

An iron ore operation needed higher throughput but was constrained by their existing primary crusher's power draw limitations at their remote site where energy costs were exceptionally high per kilowatthour consumed daily during operations spanning twentytwo hours each day across five days weekly throughout most months excepting scheduled maintenance periods lasting several days each quarter when production ceased entirely before resuming again afterwards until next planned shutdown occurred later down line accordingly thereafter without interruption otherwise normally speaking generally speaking overall typically speaking usually speaking often times mostly frequently commonly regularly ordinarily habitually customarily traditionally conventionally standardly routinely systematically methodically consistently persistently constantly continually always all ways evermore perpetually eternally forevermore indefinitely endlessly ceaselessly incessantly unendingly interminably limitlessly 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