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 spécialistes des achats, the core challenges in primary crushing often stem from equipment that fails to meet the rigorous demands of continuous operation. Les points douloureux courants incluent:
Temps d'arrêt imprévus: Frequent mechanical failures and premature wear part replacement halt your entire processing line, coûtant des milliers de dollars par heure en perte de production.
Coûts opérationnels élevés: Excessive energy consumption per ton of processed material and the constant need for specialized maintenance crews directly impact your bottom line.
Sortie incohérente: Fluctuations in product gradation and capacity due to suboptimal chamber design or feeder control lead to bottlenecks downstream and quality rejections.
Configuration rigide: Fixed crushers that cannot adapt to varying feed materials or changing product specifications limit operational flexibility and contract bidding opportunities.

Is your current primary crusher a source of constant reactive maintenance rather than a reliable asset? What if you could specify a machine engineered from the ground up for total cost of ownership reduction? The following analysis details how a highquality, OEMfactory stone crusher machine is designed to address these exact operational and financial challenges.

2. APERÇU DU PRODUIT

This document details our toptier line of Concasseurs à mâchoires primaires, engineered as robust, stationary solutions for the initial reduction of hard, roche de carrière abrasive (par ex., granit, basalte) et béton recyclé. En tant qu'usine OEM, we control the entire manufacturing process from castings to final assembly, ensuring integrity at every stage.

Flux de travail opérationnel:
1. Consommation alimentaire: Dump trucks or wheel loaders deposit large feed material (jusqu'à 1200 mm) into a vibrating grizzly feeder (facultatif), qui contourne les amendes pour optimiser le chargement de la chambre.
2. Concassage primaire: La matière pénètre dans les profondeurs, nonchoking crushing chamber where a highinertia eccentric shaft drives a moving jaw plate against a fixed jaw plate, appliquer une force de compression pour fracturer la roche.
3. Décharge & Ajustement des paramètres: Crushed material exits at the bottom through an adjustable discharge opening (CSS). The setting is hydraulically adjustable for quick product size changes without manual shim manipulation.
4. Transfert en aval: The sized product is conveyed to secondary crushing or screening stages.

Champ d'application & Limites:
Portée: Idéal pour le concassage primaire de carrière à fort tonnage, opérations minières à grande échelle, and major infrastructure project aggregate plants processing hard, matériaux abrasifs.
Limites: Not designed for sticky or clayrich materials without prescreening. Requires a stable concrete foundation and significant capital investment justified by longterm, highvolume production needs.

3. CARACTÉRISTIQUES PRINCIPALES

Cadre soudé robuste | Base technique: Analyse par éléments finis (FEA) répartition optimisée des contraintes | Avantage opérationnel: Élimine les fissures de fatigue du cadre dans des conditions de charge maximale, garantir des décennies d’intégrité structurelle | Impact sur le retour sur investissement: Eliminates risk of catastrophic frame failure and associated replacement costs exceeding machine value.

Système à bascule hydropneumatique | Base technique: Replaces traditional mechanical toggle plates with hydraulic cylinders and accumulators | Avantage opérationnel: Provides automatic overload protection against tramp metal/uncrushables; permet une élimination rapide des blocages de la chambre | Impact sur le retour sur investissement: Empêche des dommages coûteux à Pitman, roulements, and shaft; reduces downtime from hours to minutes for clearing events.

Géométrie optimisée de la chambre de concassage | Base technique: Computermodeled kinematics based on feed material compression testing | Avantage opérationnel: Generates higher throughput with less wear per ton; produces a more consistent product shape with fewer slabby pieces | Impact sur le retour sur investissement: Increases overall plant yield of saleable product while extending jaw plate service life by up to 30%.

Base moteur intégrée & Garde-ceinture | Base technique: Unified steel fabrication housing motor and flywheel guards | Avantage opérationnel: Simplifie l'alignement de l'installation; provides superior safety compliance; reduces site fabrication work | Impact sur le retour sur investissement: Lowers installation time and cost by an estimated 1520%, accélération de la mise en service.

Point de graissage centralisé & Ports de surveillance de l'état | Base technique: Lube lines routed from singlepoint manifold to all major bearings; ports for temperature/vibration sensors | Avantage opérationnel: Permet de sécuriser, entretien courant rapide (<15 minutes); facilitates predictive maintenance scheduling | Impact sur le retour sur investissement: Reduces lubrication labor time by 60% and enables datadriven component replacement before failure.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Notre solution de concasseur à mâchoires primaire | Avantage documenté |
| : | : | : | : |
| Disponibilité (Temps de disponibilité) | 9294% in demanding applications| >96% based on 3year field data| ~34% d'amélioration |
| Tonnage par pièce d'usure Coût| Varie selon le type de roche; ligne de base = 1x| Achieves 1.25x 1.4x baseline| Jusqu'à 40% coût par tonne inférieur |
| Consommation d'énergie (kWh/tonne)| Dependent on CSS; ligne de base = 1x| Operates at 0.85x 0.9x baseline| 1015% amélioration de l'efficacité|
| Temps d'ajustement (Changement CSS)| Cales manuelles: 24 heures| Réglage hydraulique: <10 minutes| ~95 % de réduction des temps d'arrêt |
| Émission de bruit à 10 m| ~105 dBA typical unshielded|<95 dBA with integrated acoustic enclosures| Répond aux réglementations strictes du site |

5. SPÉCIFICATIONS TECHNIQUES

Capacité de la gamme de modèles: Depuis 350 MTPH en 1,200 MTPH (varie en fonction de la matière première & réglage de décharge).
Tailles d'ouverture d'alimentation: De 900 mm x 600 mm jusqu'à 1 500 mm x 1 200 mm.
Exigences d'alimentation: Moteur du concasseur principal de 75 kW jusqu'à 250 kW (400V/50Hz ou personnalisé). Includes softstart compatibility.
Spécifications matérielles: Châssis principal en acier moulé de haute qualité; Plaques à mâchoires en acier au manganèse (14%,18%,22% Mn disponible); Forged alloy steel eccentric shaft with precision machined bearings.
Dimensions physiques & Poids: Approximate installed weight ranges from ~25 tonnes for smaller models to over ~80 tonnes for largest units. Dessins de fondation détaillés fournis.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C. Dust sealing suitable for standard quarry environments; optional kits available for extreme dust/sand conditions.

6. SCÉNARIOS D'APPLICATION

Projet d'agrandissement de la carrière de granit

Défi: A large granite quarry needed to increase primary crushing capacity by over 40% but had limited space for new foundations within their existing plant footprint.
Solution: Implementation of our highcapacity singletoggle jaw crusher with a compact yet heavyduty design that fit the existing primary station footprint but offered significantly higher throughput due to its optimized stroke and speed.
Résultats: Achieved a sustained output increase of over 42%. The integrated motor base reduced installation complexity by three weeks versus projected schedule.

Recyclage urbain & Production globale

Défi: A contractor processing demolished concrete and asphalt faced extreme wear from rebar abrasion and needed rapid clearing capabilities when oversized metal was encountered.
Solution: Deployment of our jaw crusher equipped with the hydropneumatic toggle system and optional reinforced wear packages on specific components.
Résultats: Uncrushable material events now clear automatically within one minute versus previous multihour shutdowns. Wear life on liners adjacent to discharge increased by over 60%, drastically reducing operating costs per tonne of recycled material.

7. CONSIDÉRATIONS COMMERCIALES

Our pricing structure is based on model specification rather than optional markups on base units:
Niveau standard (ST): Includes core crusher with hydraulic CSS adjustment, garde de base, standard jaw plates/manganese steel grade.
Niveau de performances (TP): Adds integrated feeder motor support structure, upgraded bearing specifications for higher loads/duty cycles, centralized greasing system as standard.
Customized Tier (CT): Full engineering consultation for integration into greenfield sites or complex retrofits—includes custom skidding/packaging options like walkways/ladders prefitted.

Les fonctionnalités optionnelles incluent des systèmes de lubrification automatisés,variable frequency drive packages,and comprehensive dust suppression kits.Service packages range from basic commissioning support up through multiyear fullservice agreements covering parts,travail,and scheduled inspections.Financing options through partner institutions can structure payments aligned with projected production revenue streams

FAQ

T1: Are your crushers compatible with existing feeders,truck dump hoppers,and conveyors we have?
A1 Yes Our engineering team provides comprehensive interface drawings during the quotation phase We design discharge heights conveyor takeaway points etc.to match your existing layout minimizing retrofit costs

Q2 Quel est l'impact attendu sur la consommation énergétique globale de mon usine?
A2 Field data indicates our optimized drive train geometry results in lower specific energy consumption(kWh/tonne) Typically plants see measurable reductions at the primary stage contributing directly lower operating expense

Q3 How does your OEM factory status affect lead times parts availability?
A3 Direct manufacturing control allows us maintain critical inventory patterns We guarantee shipment genuine wear critical spare parts within hours not days weeks significantly reducing risk extended downtime

Q4 What are commercial terms payment structures?
A4 Standard terms involve progress payment tied major milestones(foundation approval shop test completion shipment) We also offer leasing structures capital preservation are priority

Q5 What level technical support provided during implementation?
A5 Commissioning supervised senior technician minimum five working days includes operator maintenance team training We provide detailed documentation digital formats