1. OUVERTURE ENTRAÎNÉE PAR POINT DE DOULEUR

L’augmentation des coûts opérationnels et les temps d’arrêt imprévisibles érodent les marges de votre projet? Pour les directeurs d’usine et les entrepreneurs en ingénierie, le concassage primaire est un goulot d'étranglement critique où les échecs se transforment en retards coûteux. Les défis courants incluent:
Usure excessive & Spare Parts Costs: Premature failure of jaw dies and components due to poor material selection or design, conduisant à de fréquents, expensive changeouts and parts inventory burdens.
Temps d'arrêt imprévus: Unplanned stoppages from mechanical failures or blockages disrupt the entire downstream process, coûtant des milliers de dollars par heure en perte de production.
Débit incohérent & Forme du produit: Fluctuations in feed material cause capacity drops and poor product gradation, impacting secondary crusher efficiency and final product specification.
Consommation d'énergie élevée: Inefficient crushing chambers and drive systems result in disproportionate power draw per ton of material processed.
Rigidité & Problèmes de fondation: Equipment vibration and dynamic forces necessitate overengineered, costly foundations and can lead to longterm structural fatigue.

How do you select a primary crusher that delivers predictable performance, minimise le coût total de possession, and provides the structural integrity for decades of service? The solution requires engineering focused on durability, efficacité, et simplicité opérationnelle.

2. APERÇU DU PRODUIT

Le Premium JC5000 est un robuste, Concasseur à mâchoires à bascule unique conçu pour le concassage primaire de grande capacité dans les exploitations minières exigeantes, carrière, et applications de construction à grande échelle. Its design prioritizes mechanical robustness and sustained throughput in continuous operation.

Flux de travail opérationnel:
1. Consommation alimentaire: Gros matériaux provenant de mines ou de carrières (jusqu'à 1300mm) est dirigé vers 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: The optimized discharge setting allows crushed material to exit freely without restriction, while the hydraulic toggle system provides instant unblocking capability.
4. Transport du produit: Sized product is discharged onto the primary conveyor for transport to the next stage of processing.

Champ d'application: Idéal pour le hard rock (granit, basalte), minerai de fer, et agrégats abrasifs. Convient aux usines stationnaires et aux grandes installations mobiles sur chenilles.
Limites: Not designed for recycling applications with high levels of rebar or tramp metal without appropriate prescreening protection. Requires a planned maintenance regimen consistent with all capital equipment.

3. CARACTÉRISTIQUES PRINCIPALES

Ensemble de roulement à rouleaux robuste | Base technique: Spherical selfaligning roller bearings on both eccentric shaft and swing jaw | Avantage opérationnel: Handles high radial and thrust loads with minimal friction; supports sustained high horsepower input | Impact sur le retour sur investissement: Proven bearing life exceeding 24,000 hours reduces replacement frequency by an estimated 40% versus standard bearings.

Bascule hydraulique & Système de réglage | Base technique: Integrated hydraulic cylinder replaces conventional mechanical toggle plates | Avantage opérationnel: Enables remote adjustment of crusher setting for product size changes and provides safe, rapid clearing of stalled chambers | Impact sur le retour sur investissement: Reduces downtime for clearing blockages from hours to minutes; eliminates manual shim adjustments.

Arbre excentrique forgé & Cadre robuste | Base technique: Highstrength alloy steel shaft; stressrelieved fabricated steel frame with reinforced ribs | Avantage opérationnel: Withstands peak shock loads from uncrushable material; maintains alignment under maximum load conditions | Impact sur le retour sur investissement: Élimine le risque de défaillance catastrophique de l’arbre; foundation costs can be reduced by up to 15% due to superior dynamic stability.

Géométrie optimisée de la chambre de concassage | Base technique: Computermodeled kinematics ensure steep nip angle and deep vertical chamber profile | Avantage opérationnel: Promotes aggressive bite and efficient reduction throughout the cycle; minimizes bridging and enhances throughput per stroke | Impact sur le retour sur investissement: Les données de terrain montrent une cohérence 812% increase in tons per hour compared to previousgeneration designs with equivalent power.

EasyMaintenance Design Philosophy | Base technique: Symmetrical frame design allows reversible mounting of jaw dies; accessible grease lines and centralized lube points | Avantage opérationnel: Extends wear part life by utilizing both ends of jaw dies; simplifies routine servicing tasks for technicians | Impact sur le retour sur investissement: Reduces liner inventory requirements; cuts planned maintenance time by an estimated 30%.

Volants à haute inertie | Base technique: Precisely balanced heavyduty flywheels store kinetic energy during each cycle | Avantage opérationnel: Smoothes out power demand peaks, ensuring consistent crushing force even under variable feed conditions | Impact sur le retour sur investissement: Protège les composants d'entraînement des charges de choc; contributes to lower overall specific energy consumption (kWh/tonne).

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Classe comparable) | Solution JC5000 haut de gamme | Avantage (% amélioration) |
|||||
| Mâchoire Die Vie (Roche Abrasive)| ~450 000 TM | Jusqu'à 600,000 MT | +33% |
| Disponibilité (Temps de disponibilité %) | 9092% | Constamment au-dessus 95% | +35% |
| Consommation d'énergie spécifique | ~0,85 kWh/tonne | Aussi bas que 0.78 kWh/tonne | 8% |
| Throughput @ CSS 200mm | ~750 MT/h | ~850 MT/h | +13% |
| Major Bearing Service Life | ~18,000 hours | >24,000 heures | +33% |

5. SPÉCIFICATIONS TECHNIQUES

Ouverture d'alimentation: 1300mm x 1000 mm (51" x 40")
Taille maximale d'alimentation: Up to 1100mm (43")
Plage de réglage côté fermé: 150 300mm (6" 12")
Plage de capacité (Varie selon le matériau & CSS): Jusqu'à 1100 MTPH
Exigence de puissance d'entraînement: 200 kW / Options jusqu'à kW disponibles
Poids total (Concasseur uniquement): Approximately kg
Spécifications des matériaux clés: Forged EN24/S155Cr3 Eccentric Shaft; HighStrength Fabricated Steel Main Frame; Manganese Steel Jaw Dies (14%,18%,22% disponible).
Plage de température de fonctionnement: 20°C à +45°C (4°F à +113°F) avec des lubrifiants appropriés.

6. SCÉNARIOS D'APPLICATION

Hard Rock Quarry Expansion – Australia

Défi: Une carrière de granit nécessaire pour augmenter le débit du circuit primaire de plus de % but was constrained by existing foundation limits and high wear costs on their legacy crusher.
Solution Installation of a Premium JC5000 jaw crusher with its optimized dynamic footprint replaced two older units.
Résultats obtenus a % increase in base layer production while reducing specific liner cost per ton by %. The stable operation allowed use of the existing feed structure with minimal reinforcement.

Iron Ore Primary Crushing – West Africa

Challenge Severe abrasion causing swing jaw bearing failures every months at a remote site logistics nightmare), coupled with excessive energy costs.
Solution Deployment of the JC5000 with its heavyduty roller bearing assembly optimized chamber geometry
Results Bearing service life extended beyond months eliminating two major changeouts per year Plant energy monitoring showed a % reduction in specific power consumption translating directly lower diesel generator fuel costs

7 CONSIDÉRATIONS COMMERCIALES

The Premium JC5000 is offered as capital equipment within established global pricing tiers based on final configuration

Base Configuration Includes crusher motor motor mounts flywheel guards basic tool kit Optional Features Hydraulic setting adjustment package automated grease lubrication system wear monitoring sensors various manganese steel grades special protective coatings

Service Packages Tiered offerings from basic commissioning supervision comprehensive multiyear planned maintenance agreements including parts kits financing Options Available through partnered financial institutions covering leasetoown operating leases traditional purchase structures tailored project finance

8 FAQ

Quelles sont les exigences de base pour le JC5000?
Detailed dynamic load drawings are provided Our design distributes forces effectively but a sitespecific civil engineering review is mandatory We supply all necessary interface data

Can this crusher handle very wet sticky material?
While capable modifications like steeper nip angles specific liner profiles can be specified However highly claybound material may require prescreening scalping for optimal performance

What is the expected delivery lead time?
Standard configurations typically have lead time between weeks subject current order book confirmation Customized builds require additional engineering time

Do you provide wear parts after purchase?
Yes we maintain full OEM spare parts support including genuine manganese dies bearings other critical components ensuring original performance specifications are maintained

Is operator training included?
Comprehensive onsite training covering operation daily checks routine maintenance troubleshooting is included standard commissioning package

What warranty applies?
The Premium JC5000 carries standard months warranty on materials workmanship extended warranties available purchase specific components