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, the primary jaw crusher is a critical linchpin, and its failures cascade through your entire operation. Considérez ces défis communs:
Temps d'arrêt imprévus: Premature wear of crusher jaws or failure of critical components can halt production for days, costing tens of thousands per hour in lost throughput.
Coûts de maintenance élevés: Besoins fréquents de lubrification, manual adjustment of settings, and the laborintensive process of replacing worn parts directly impact your bottomline maintenance budget.
Gradation du produit incohérente: An unstable or inefficient crushing chamber design leads to poor particle shape, increased recirculating load, et les goulots d'étranglement du traitement en aval.
Consommation d'énergie excessive: An inefficient drive system and nonoptimized kinematics can make the primary crusher one of the largest energy consumers on site.

Is your current solution equipped to deliver the mechanical reliability, operational simplicity, and longterm costpertonne efficiency required in today's market? The following analysis presents a datadriven approach to these challenges.

2. APERÇU DU PRODUIT

Le concasseur à mâchoires JC5000 est un broyeur à haute capacité, singletoggle primary crusher engineered for the most demanding mining and heavyduty quarry applications. Its design focuses on delivering maximum availability and reduced operating costs in hard rock processing.

Flux de travail opérationnel:
1. Alimentation & Compression: Matière première de grande taille (jusqu'à 1,4 m de longueur de bord) entre dans les profondeurs, chambre de concassage sans étouffement.
2. HighInertia Crushing: The heavyduty flywheels maintain momentum, forcing the aggressive elliptical motion of the jaw to apply immense compressive force.
3. Décharge & Autorisation: Crushed material exits at the bottom with a consistent discharge setting, aided by a large discharge area that minimizes risk of plugging.

Champ d'application: Ideal for stationary primary crushing plants processing hard rock (granit, basalte), minerai de fer, and abrasive feeds. It is suited for hightonnage operations requiring consistent product size for downstream cone crushers or milling circuits.

Limites: As a largecapacity primary machine, it is not designed for portable/skidmounted applications or for processing materials with very high clay or moisture content without proper feed system design.

3. CARACTÉRISTIQUES PRINCIPALES

Cadre robuste & Welded Construction | Base technique: Analyse par éléments finis (FEA) répartition optimisée des contraintes | Avantage opérationnel: Eliminates stress cracking under peak loads; provides stable platform for all components | Impact sur le retour sur investissement: Extended structural life reduces risk of catastrophic frame failure and associated capital replacement costs.

Chambre de concassage symétrique profonde | Base technique: Angle de pincement optimisé et géométrie de course d'écrasement longue | Avantage opérationnel: Favorise le broyage interparticulaire pour un rapport de réduction amélioré; generates better product shape with fewer fines | Impact sur le retour sur investissement: Increased yield of inspec product reduces recirculation load and downstream wear.

Hydrostatic Wedge Gap Adjustment System | Base technique: Hydraulic rams replace traditional manual shims | Avantage opérationnel: CSS adjustment takes minutes from a remote location without entering the crusher; enables quick compensation for wear | Impact sur le retour sur investissement: Réduit de plus les temps d’arrêt des réglages 80% par rapport aux systèmes manuels, augmenter les heures productives annuelles.

Spherical Roller Bearing Cartridge | Base technique: Selfaligning bearings housed in a singlepiece, machined cartridge | Avantage opérationnel: Handles high radial and axial loads; simplifies bearing replacement as a single unit | Impact sur le retour sur investissement: Standardized bearing service reduces parts inventory complexity and technician hours during maintenance events.

Toggle Seat Integrated Actuator | Base technique: Hydraulic cylinder replaces traditional toggle plates for uncrushable material relief | Avantage opérationnel: Automatic clearing of tramp metal or uncrushables protects the crusher from damage; se réinitialise automatiquement | Impact sur le retour sur investissement: Prevents costly damage to pitman, roulements, and frame from overload events, avoiding weeks of unscheduled downtime.

Point de graissage centralisé | Base technique: Singlepoint lube distribution network to all major bearings | Avantage opérationnel: Daily lubrication routine is completed safely in under 10 minutes without multiple access points | Impact sur le retour sur investissement: Ensures bearing longevity through consistent lubrication while reducing required operator labor time.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Classe compétitive) | Solution de concasseur à mâchoires JC5000 | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Annuel)| 88 92% (programmé & arrêts imprévus) |> 94% documented field availability| +36% une disponibilité plus productive |
| Temps d'ajustement CSS| 48 heures (système de cale manuel) |> <1 heure (hydrostatic wedge system)| ~85% faster adjustment |
| Durée de vie des roulements| 1218 months under severe duty |> Les données de terrain montrent 24+ months typical life| +33% intervalle d'entretien prolongé |
| Consommation d'énergie par tonne| Référence de base |> Jusqu'à 10% réduction grâce à une cinématique optimisée & conduire l'efficacité| Direct reduction in kWh/tonne cost |
| Durée de vie des pièces d'usure (Mn18/22 Mâchoires)| Sous réserve de matière première |> Documenté 1520% improvement from chamber geometry & even wear profile| Lower costpertonne for consumables |

5. SPÉCIFICATIONS TECHNIQUES

Ouverture d'alimentation: 1400mm x 1200 mm (55" x 47")
Taille maximale d'alimentation: Up to 1400mm edge length (55")
Réglage du côté fermé (CSS) Gamme: 150mm 300mm (6" 12")
Plage de capacité: Jusqu'à 1,750 tonnes par heure (dépend du matériel d'alimentation et du CSS)
Exigence de puissance d'entraînement: 200 kW / Options jusqu'à kW disponibles
Poids total (Concasseur uniquement): Approximately ~105,000 kg
Spécifications des matériaux clés:
Cadre: Tôle d'acier fabriquée avec nervures optimisées FEA.
Fixé & Moving Jaws: Acier au manganèse de haute qualité (Mn18Cr2/Mn22Cr2).
Arbre principal: Acier allié forgé.
Toggle Seat & Wedges: Alloy steel castings.
Plage de fonctionnement environnementale: Designed for ambient temperatures from 30°C to +45°C with appropriate lube oils. Dust seals are standard for harsh environments.

6. SCÉNARIOS D'APPLICATION

Agrandissement de la carrière de roche dure | Challenge A granite quarry expanding production faced excessive downtime from CSS adjustments and premature bearing failures on older plant equipment, limiting output growth. Solution Installation of a JC5000 Jaw Crusher as the new primary unit with hydrostatic wedge adjustment and cartridge bearing system. Results CSS changes reduced from a full shift to under an hour. Annual bearing inspections confirmed extended service life. Disponibilité des plantes augmentée de %, allowing the site to consistently meet new contracted tonnage targets.

Iron Ore Primary Crushing Upgrade Challenge An iron ore processing plant struggled with high recirculating load due to poor product gradation from an aging jaw crusher, creating bottlenecks in secondary crushing. Solution The JC5000 was selected for its deep chamber design capable of handling abrasive magnetite ore.Replacement focused on improving overall circuit efficiency Results Postinstallation data showed a more consistent mm product from primary stage.Recirculating load decreased by %, reducing energy consumption across the secondary circuit.Costpertonne for wear parts saw a measurable reduction due to improved chamber wear dynamics

Aggregate Producer Abrasive Feed Challenge A producer processing highly abrasive trap rock experienced unsustainable costs from frequent jaw plate changes every weeks,and associated labor.The manual shim system made proactive gap management impractical Solution Implementation of the JC5000 featuring symmetrical chamber wear profile and hydraulic wedge adjustment Results Wear part life extended by an average of weeks.Hydraulic adjustment allowed operators to perform weekly CSS checks in minutes maintaining optimal throughput.This translated directly into lower consumable costs per quarter

7 CONSIDÉRATIONS COMMERCIALES

The JC5000 Jaw Crusher is offered as part of a comprehensive material processing solution.Pricing is structured around core configuration packages

Base Equipment Tier Includes: Crusher mainframe pitman assembly standard jaws drive motor sheaves Vbeltsand base frame

Fonctionnalités facultatives:
Contrôle automatisé des écarts(CAG)systemfor continuous CSS monitoring
Motor Starter Package(VSD optional)
Custom discharge conveyor interface kits
Wear monitoring system sensors
Special alloy jaw platesfor specific abrasion/corrosion applications

Forfaits de services:
Extended Warranty Programscovering major components
Scheduled Inspection Planswith OEM technical support
Onsite Training Packagesfor operationaland maintenance crews

Financing Options are available including capital lease operating leaseand project financing terms tailoredfor largescale capital expenditure typically through partnered financial institutions

8 FAQ

What are the foundation requirementsforthe JC5000?
The JC5000 requiresa substantial reinforced concrete foundation designedto handle dynamic loads.Engineering drawingsand dynamic load data are providedfor your civil contractorsto ensure proper installation

How does the hydrostatic wedge system impact maintenance safety?
It eliminates the needfor technicians to handle heavy shims insideor adjacentto the crusher frame.All adjustmentsare made remotelyviaa control station significantly reducing safety risks associatedwith manual methods

Can you provide assistancewith integration into our existing plant layout?
Yes engineering supportis availableto reviewyour existing flow sheetand plant layout We can provide D layout modelsand integration studiesto ensure material transfer pointsfeed systemsand discharge conveyorsare properly aligned

What isthe typical lead timefrom orderto commissioning?
Lead timesvary basedon global manufacturing schedulesbut typically rangefrom monthsfor standard configurationsto monthsfor fully customized units Detailed project schedulingis provided upon inquiry

Des garanties de performance sont-elles offertes?
Yes we offer performance guarantees basedon agreed feed material characteristics These guarantees cover minimum throughput capacity maximum power consumptionand product gradation under defined test conditions