1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

Are you managing the recurring costs and operational bottlenecks associated with primary crushing and material sizing? Les défis courants incluent:
Dépenses élevées en pièces d’usure: Remplacement fréquent des marteaux, doublures, and impact aprons due to abrasive feed material, impactant directement votre coût par personne.
Temps d'arrêt imprévus: Unplanned maintenance stops to address wear or component failure, arrêter toute votre chaîne de traitement.
Gradation du produit incohérente: Variable output sizes leading to recirculating loads, reducing overall system throughput and efficiency.
Flexibilité d'application limitée: A crusher that cannot handle a range of materials or moisture contents forces compromises in your feed strategy.

How do you reduce total cost of ownership while maintaining reliable throughput and product quality? The solution lies in selecting a fabricated impact crusher engineered not just to crush, mais endurer.

2. APERÇU DU PRODUIT: FABRICATED IMPACT CRUSHERS

A fabricated impact crusher is a robust reduction machine utilizing highspeed rotors and durable impact elements to fracture material through kinetic energy. Its design is characterized by a heavyduty, welded steel frame (fabrication) that provides the structural integrity for demanding primary or secondary crushing duties.

Flux de travail opérationnel:
1. Consommation alimentaire: Material is directed into the crushing chamber via a reinforced feed hopper and apron.
2. Accélération & Impact: The highinertia rotor assembly hurls material against stationary impact aprons or curtains.
3. Réduction de taille: Fracturing occurs through repeated impacts, either rockonrock (within the rotor cascade) or rockonapron.
4. Éjection du produit: Le matériau calibré sort par l'espace réglable entre le rotor et les tabliers, determining final product gradation.

Champ d'application: Idéal pour le calcaire, béton/asphalte recyclé, débris de démolition, and other mediumtolow abrasiveness materials. Effective for producing a wellshaped, produit cubique.

Principales limites: Not typically suited for highly abrasive hard rock (par ex., granit, piège à pierres) as primary crushers without significant wear cost tradeoffs. Performance can be affected by very high moisture or clay content without proper configuration.

3. CARACTÉRISTIQUES PRINCIPALES

Cadre fabriqué robuste | Base technique: Allwelded steel plate construction with internal ribbing | Avantage opérationnel: Provides exceptional rigidity to withstand dynamic loads and vibration, extending bearing life and maintaining alignment | Impact sur le retour sur investissement: Reduces structural fatigue failures, lowering longterm maintenance costs by minimizing framerelated issues.

Système de réglage hydraulique | Base technique: Vérins hydrauliques intégrés pour le positionnement du tablier | Avantage opérationnel: Allows operators to adjust product size or clear blockages quickly from outside the machine | Impact sur le retour sur investissement: Cuts adjustment time by over 70% par rapport aux systèmes manuels, augmentation de la disponibilité des plantes.

MultiFacet Rotor Design | Base technique: Rotor discs with replaceable locking wedges securing hammer pins | Avantage opérationnel: Enables quick rotation or replacement of hammers/blow bars without full disassembly; maintains rotor balance | Impact sur le retour sur investissement: Reduces rotor service time by up to 50%, directly lowering labor costs and downtime.

Interchangeable Wear Components | Base technique: Standardized alloy steel castings for aprons, doublures, and blow bars in various metallurgies | Avantage opérationnel: Allows you to select wear part material (par ex., acier martensitique, fer chromé) based on your specific feed material’s abrasiveness | Impact sur le retour sur investissement: Optimizes wear life versus part cost, providing up to 30% longer service intervals when correctly specified.

Large Service Access Doors | Base technique: Hinged or sliding doors on the crusher housing | Avantage opérationnel: Fournit un coffre-fort, unobstructed access for routine inspection and maintenance tasks | Impact sur le retour sur investissement: Improves technician efficiency during preventative maintenance checks by providing easier access points.

Système de couplage à entraînement direct | Base technique: Fluid coupling or Vbelt drive options connecting motor to rotor | Avantage opérationnel: Smooths startup torque peaks and provides inherent overload protection under tramp iron events | Impact sur le retour sur investissement: Protects motor and drive components from shock loads, reducing electrical and mechanical failure risk.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Référence des normes de l'industrie | Our Fabricated Impact Crusher Solution | Avantage (% Amélioration) |
| : | : | : | : |
| Temps de changement des pièces d'usure (Primary Hammers) | 812 Heures (Manual Shim/Bolt) | 34 Heures (HydraulicAssisted/Wedge System) | ~65% Faster |
| Structural Frame Durability (in HighVibration Apps)| Welded Frame with Minimal Reinforcement| Computermodeled stress analysis with internal ribbing & gussets| Les données de terrain montrent 40% longer service life before weld fatigue |
| Forme du produit (Indice de cubique) Concassage secondaire| Varies Widely; Average CI of ~0.7| Consistent CI of 0.80.85 via optimized apron/rotor speed design| ~15 % de produit cubique en plus |
| Throughput per Installed HP (for Limestone)| 100120 TPH per 100 HP| 130150 TPH per 100 HP due to optimized chamber geometry & dynamique du rotor| Jusqu'à 25% Higher Efficiency |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèle dépendant de 150 TPH à plus 800 TPH in primary applications.
Exigences d'alimentation: Depuis 200 HP (150 kW) à 600 HP (450 kW), configured for either electric motor or diesel drive.
Spécifications des rotors: Solid steel rotor with bolton discs; diameters from ~40” (1000mm) to ~60” (1500mm); widths matched to feed opening.
Spécifications matérielles: Main frame fabrications from ASTM A36/A572 steel; wear components available in AR400 steel plate or highchrome cast iron alloys.
Dimensions physiques (Exemple de modèle): Feed Opening up to ~42” x ~48” (1065mm x1220mm); Machine weight approximately 25,000 – 55,000 livres (1125 tonnes métriques).
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; dust seals standard; optional Arctic packages or highdust environment kits available.

6. SCÉNARIOS D'APPLICATION

Production de granulats de béton recyclés

Défi: A recycling yard faced excessive wear costs from rebarcontaminated concrete and unpredictable downtime due to uncrushable material jams.
Solution: Implementation of a heavyduty fabricated impact crusher with hydraulic apron adjustment and a tramp iron relief system.
Résultats: Reduced unplanned downtime by 60% due to quick jam clearing. Durée de vie des pièces d’usure augmentée en moyenne de 35% through optimal alloy selection for the application.

Limestone Quarry Secondary Crushing

Défi: A quarry’s existing secondary circuit produced excessive fines (<5mm) while struggling with occasional claybound feed, causing throughput drops.
Solution Installation of an impact crusher configured with variable rotor speed control and a multistage apron configuration.
Results Achieved better product fraction control; reduced fines generation by approximately 20%. Throughput stabilized as the crusher handled occasional sticky material more effectively than the previous cone crusher setup.

7. CONSIDÉRATIONS COMMERCIALES

Our fabricated impact crushers are offered in three primary tiers:
1. Niveau de service standard: Pour une cohérence, nonabrasive materials like clean limestone. Focuses on core reliability at an entry price point.
2. Niveau robuste (Le plus courant): Includes features like hydraulic adjustment, enhanced wear packages, and heavier rotors for mixed/recycled materials and general quarry use.
3. Niveau d'usine modulaire/portable: Crushers integrated into wheeled or skidmounted frames with preengineered feed/discharge systems for mobile contracting.

Les fonctionnalités optionnelles incluent des systèmes de lubrification automatisés,
advanced bearing temperature monitors,
and different drive configurations
(fluid coupling vs Vbelt).

Service packages range from basic commissioning
to comprehensive annual inspection contracts
with guaranteed parts availability SLAs

Financing options include equipment leasing,
programmes de location en propre,
and projectbased financing solutions

8.FAQ

T1:What is your typical Minimum Order Quantity?
Our standard MOQ is one unit per order However we offer tiered pricing structures that provide discounts on orders for multiple units which is common for large contracting firms equipping several sites

Q2 Can your fabricated impact crusher replace our existing jaw cone setup?
In many secondary reduction applications yes Field data often shows an impact crusher can provide sufficient reduction at a lower capital cost than adding a secondary cone It requires analysis of your current feed size desired product specs

Q3 How do you ensure compatibility with our existing plant conveyor sizes discharge heights?
We require key interface dimensions during quotation Our engineering team designs discharge hoods support structures fit within your specified envelope ensuring smooth integration

Q4 What is the expected operational cost per ton for wear parts?
This varies significantly based on material abrasiveness We provide detailed estimates using industrystandard abrasion indices For example operating on clean limestone may yield $010$020/ton while recycled concrete could be $025$040/ton

Q5 Offrez-vous des garanties de performance?
Yes we provide guaranteed minimum throughput capacity based on agreedupon feed material specifications subject terms conditions outlined our commercial proposal

Q6 What is lead time from order placement delivery?
For standard heavyduty models lead time typically ranges between weeks depending current production schedule confirmed upon order placement Custom configurations require additional engineering time

Q7 What operator training provided?
We include comprehensive onsite operator maintenance training during commissioning covering safe operation routine checks basic troubleshooting procedures Documentation includes detailed parts manuals schematic diagrams