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, the primary crushing stage is often the source of significant bottlenecks. Les défis courants incluent:
Temps d'arrêt imprévus: Les changements fréquents de revêtement et les pannes mécaniques interrompent toute votre chaîne de traitement, coûtant des milliers de dollars par heure en perte de production.
Coûts de maintenance élevés: Excessive wear on crusher components from abrasive materials leads to unsustainable parts replacement budgets.
Sortie incohérente: Fluctuations in feed size or hardness result in an uneven product gradation, negatively impacting downstream equipment efficiency.
Inefficacité énergétique: Older crushing technology consumes disproportionate power for the tonnage produced, directly affecting your bottom line.
Rigidité: A fixed configuration cannot adapt to changing project requirements or feed materials, limiting your operational agility.

Is your current stone crusher machine a cost center instead of a profit driver? The solution requires equipment engineered to directly confront these reliability and efficiency challenges.

2. APERÇU DU PRODUIT

The modern jaw crusher is a robust, heavyduty machine designed for the primary reduction of hard, matériaux abrasifs comme le granit, basalte, et du béton. Its core function is to deliver consistent, hightonnage output of sized aggregate for downstream processing.

Flux de travail opérationnel:
1. Consommation alimentaire: Runofquarry material is loaded into the vibrating grizzly feeder (VGFF VGF), qui contourne les fines et dirige les surdimensionnés vers la chambre de concassage.
2. Concassage par compression: A reciprocating manganese jaw plate exerts immense mechanical force against a stationary jaw, fracturing stone via compression.
3. Réglage de décharge: The crushed material exits through an adjustable gap at the bottom of the chamber, déterminer la taille du produit final.

Champ d'application & Limites:
This equipment is optimal for primary crushing applications with feed sizes up to 1200mm. It is less suitable for sticky or clayrich materials without prescreening and is not intended for final product shaping or tertiary sand production.

3. CARACTÉRISTIQUES PRINCIPALES

Chambre de concassage profonde & Cinématique optimisée | Base technique: Angle de pincement accru et course d'écrasement linéaire plus longue | Avantage opérationnel: Réduction de volume plus élevée par cycle, reducing cycle count for same output | Impact sur le retour sur investissement: Jusqu'à 10% higher throughput capacity with equivalent engine power.

Cadre fabriqué robuste | Base technique: Construction en tôle d'acier soulagée avec nervures renforcées | Avantage opérationnel: Exceptional durability under shock loads, maintaining alignment for consistent wear | Impact sur le retour sur investissement: Extended structural life, reducing risk of catastrophic frame failure and associated capital replacement.

Système de réglage à bascule hydraulique | Base technique: Replaceable hydraulic cylinders for tensioning and clearing | Avantage opérationnel: Permet l'ajustement à distance du CSS (Réglage du côté fermé) and automatic uncrushing in minutes vs. manual shim changes | Impact sur le retour sur investissement: Réduit de plus les temps d'arrêt liés aux modifications de paramètres 80%, augmentation de la disponibilité des plantes.

Wedge Lock Jaw Plate Retention | Base technique: Mechanically locked wedges secure jaw plates without backing material | Avantage opérationnel: Plus rapide, safer jaw plate changes with fewer manhours required | Impact sur le retour sur investissement: Réduit d'environ les temps d'arrêt liés au changement de revêtement 50%, directly increasing productive operating hours.

Base moteur intégrée & Garde-ceinture | Base technique: Unified chassis design housing crusher, moteur d'entraînement, and guards | Avantage opérationnel: Installation simplifiée, empreinte réduite, and enhanced site safety compliance | Impact sur le retour sur investissement: Lower installation costs and minimized risk of safetyrelated stoppages.

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Moyenne) | Cette solution de concasseur à mâchoires | Avantage (% Amélioration) |
| : | : | : | : |
| Disponibilité (Temps de disponibilité) | 8892% par trimestre | 95%+ per quarter documented in field data| +5% à +8% |
| Durée de vie du manganèse (Granit abrasif) | 120,000 150,000 tonnes| 180,000 200,000 tonnes| +25% à +33% |
| Consommation d'énergie (kWh/tonne) Varie selon le matériau| Ligne de base = 100%| Documented average reduction to ~92%| 8% |
| Temps d'ajustement CSS (Mécanique vs. Hydraulique)| 46 heures avec l'équipage| <1 hour with operator| 80% |

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: 150 1,200 MTPH (dépend de la matière première & Paramètre CSS)
Ouverture d'alimentation: De 800 mm x 500 mm jusqu'à 1 500 mm x 1 200 mm
Exigence de puissance: 75 kW 250 Moteur électrique kW (specific voltage/frequency as per region)
Poids du concasseur (Machine Only): From ~18,000 kg to ~65,000 kg
Spécifications des matériaux clés:
Cadre: Plaque d'acier soudée à haute résistance (S355J2)
Plaques à mâchoires: Acier au manganèse de première qualité (1418%)
Arbre excentrique: Forged alloy steel EN24/34CrNiMo6
Plage de température de fonctionnement: 20°C à +40°C (avec des lubrifiants appropriés)
Taille maximale d'alimentation: Up to ~8085% of grizzly feeder width

6. SCÉNARIOS D'APPLICATION

Extraction de roches dures – Production de granulats de granit

Défi: A quarry faced excessive wear costs and weekly downtime for jaw plate rotation on their primary crusher processing highly abrasive granite.
Solution: Implementation of a heavyduty jaw crusher featuring optimized kinematics and premium manganese jaws with wedge lock system.
Résultats: Wear life extended from an average of 130k tonnes to over 190k tonnes. Combined with faster changeout times, this resulted in a documented annual increase of 450 productive hours.

Large Infrastructure – Railway Ballast Production

Défi: An engineering contractor needed consistent production of precisely sized ballast (+50mm 75mm) under a tight project schedule with variable feed geology.
Solution: Deployment of a mobile primary jaw crusher plant with an integrated hydraulic toggle adjustment system.
Résultats: Onsite CSS adjustments were completed in under an hour versus a halfshift previously required. This flexibility maintained strict gradation specifications despite varying rock hardness across the site’s borrow pits.

7. CONSIDÉRATIONS COMMERCIALES

Equipment pricing is structured according to capacity class and configuration:
Standard Stationary Plant Configuration: Includes crusher base frame motor/vbelt drive guards standard set of manganese jaws
Mobile TrackMounted Configuration Premium integrated system includes feeder prescreen hydraulic folding conveyors
Optional features include automated lubrication systems dust suppression kits different jaw tooth profiles scallping prescreen modules

Service packages are available from basic commissioning support up to comprehensive annual maintenance agreements covering planned inspections parts discounts priority technical support

Financing options can be discussed including straight purchase capital lease or operating lease structures tailored to balance cash flow requirements

8. FAQ

1. What level of foundation preparation is required for this stone crusher machine?
The fabricated base frame minimizes but does not eliminate foundation requirements Detailed civil drawings specifying load dynamics anchor bolt locations are provided Installation supervision can be included as part of service packages

2 How does this machine handle tramp metal or uncrushable material?
The hydraulic toggle system acts as a safety device allowing the toggle beam cylinder pressure relief permitting uncrushable material pass protecting major components from damage

3 What is typical lead time from order placement commissioning?
Lead times vary based model specification current manufacturing cycle Standard units typically range from weeks complex custom plants require detailed planning schedules provided upon application review

4 Can existing conveyor systems integrate new primary jaw crusher?
Integration feasibility depends on height discharge capacity existing infrastructure Our engineering team can review layout drawings provide interface recommendations during quotation process

5 What key performance indicators KPIs should monitor evaluate ROI?
Primary KPIs include cost per tonne crushed combining energy consumption wear part costs availability percentage tracking scheduled unscheduled downtime Regular review data essential measuring equipment performance