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 entrepreneurs en ingénierie, the primary crushing stage presents persistent challenges that cascade through your entire operation. Considérez ces points douloureux courants:
Coûts élevés de remplacement des pièces d’usure: Frequent shutdowns to replace hammers, barres de soufflage, and liners in abrasive applications directly impact your bottom line.
Temps d'arrêt imprévu pour la maintenance: Reactive repairs to critical components like rotors or bearings halt production, delaying projects and missing delivery windows.
Gradation du produit incohérente: Poor control over final product shape and size leads to excess fines or outofspec material, réduire le rendement vendable.
Consommation d'énergie élevée par tonne: Inefficient crushing chambers and drive systems make electricity a major, uncontrollable variable cost.
Rigidité dans le champ d’application: A crusher that cannot adapt to varying feed materials or product requirements forces compromises in efficiency.

What if your primary or secondary crushing solution could directly address these issues? The right impact crusher is not just a machine; il s'agit d'un investissement stratégique dans un débit prévisible, controlled operating expense, and superior product quality.

2. APERÇU DU PRODUIT

Le concasseur à percussion à arbre horizontal moderne (HSI) is engineered for highvolume reduction of medium to low abrasion materials like limestone, béton recyclé, asphalte, et débris de démolition. Its core function is to fracture material via sharp, highvelocity impact against rotating blow bars and durable breaker plates.

Flux de travail opérationnel:
1. Consommation alimentaire: Le matériau est dirigé vers la trémie d'alimentation robuste et sur le convoyeur d'alimentation régulé.
2. Accélération & Impact: The centrifugal force of the highinertia rotor accelerates material into the adjustable primary curtain.
3. Controlled Fracturing: Material rebounds between the rotor blow bars and adjustable secondary aprons/curtains for further reduction.
4. Éjection du produit: Correctly sized material exits through the adjustable gap between aprons, while larger pieces recirculate for further impact.
5. Contrôle des gradations: Final product size and shape are precisely managed by adjusting apron gaps and rotor speed.

Champ d'application & Limites:
Idéal pour: Calcaire, granulats recyclés (béton/asphalte), scories, charbon, nonabrasive quarry rock.
Bien adapté pour: Primary or secondary crushing duties where a cubical product shape is paramount.
Limites: Not recommended for highly abrasive igneous rock (par ex., granit, basalte) as primary crushers without significant operational cost planning for wear parts.

3. CARACTÉRISTIQUES PRINCIPALES

Système de réglage hydraulique | Base technique: Integrated hydraulic cylinders controlling rear apron position | Avantage opérationnel: Permet aux opérateurs d'ajuster la gradation du produit ou d'éliminer les blocages en quelques minutes sans changement manuel des cales | Impact sur le retour sur investissement: Réduit les temps d’arrêt des réglages jusqu’à 80%, augmentation de la disponibilité des plantes

Conception de rotor monobloc | Base technique: Solid steel rotor disc forged/welded into a single unit with high inertia | Avantage opérationnel: Provides stable operation under uneven feed conditions and withstands high shock loads | Impact sur le retour sur investissement: Prolonge la durée de vie des roulements jusqu'à 40% and reduces vibrationrelated structural stress

Système de pièces d'usure QuickChange | Base technique: Wedgelocked or cartridgeheld blow bars and apron liners | Avantage opérationnel: Enables safe replacement of key wear components from outside the machine | Impact sur le retour sur investissement: Cuts wear part changeout time by over 50%, réduire les coûts de main d'œuvre

Plaques de disjoncteur multipositions | Base technique: Repositionable/wrappable primary curtains or breaker plates | Avantage opérationnel: Maximizes wear material utilization by offering multiple wear surfaces before replacement | Impact sur le retour sur investissement: Can extend time between plate replacements by 23x, decreasing part consumption cost per ton

Système d'entraînement direct | Base technique: Vbelt or direct coupling from motor to rotor without gear reducers | Avantage opérationnel: Delivers higher power transmission efficiency (>95%) with fewer mechanical components | Impact sur le retour sur investissement: Réduit la consommation d’énergie de 812% compared to crushers with indirect drives

Interface d'automatisation basée sur un API | Base technique: Integrationready control system monitoring amp draw, vibration, température | Avantage opérationnel: Provides realtime operational data for predictive maintenance scheduling and load optimization | Impact sur le retour sur investissement: Empêche les pannes catastrophiques; enables output optimization for estimated 35% throughput gain

4. AVANTAGES CONCURRENTIELS

| Mesure de performances | Norme de l'industrie (Competitive HSI) | Notre solution de concasseur à percussion | Avantage (% Amélioration) |
| : | : | : | : |
| Temps de changement de pièce d’usure (Barres de soufflage) | 68 heures (équipage de 23) | 23 heures (équipage de 2) | ~65 % plus rapide |
| Consommation d'énergie (kW per ton/hr)| Based on specific models; benchmarked value = X kW/tph| Les données de terrain montrent une réduction constante| Jusqu'à 12% inférieur |
| Rotor Service Life (Abrasive Apps)| ~600k tons before major rebuild| Documenté >900k tons with proper maintenance| +50% longévité|
| Rapport de cubique du produit (% Cubique)| Typiquement 7585% produit cubique| Achieves consistent >90% produit cubique| Improved particle shape|
| Émission de bruit à 10 m (dB(UN))| ~110 dB(UN) typical operation|<105 dB(UN) with standard housing| Reduced environmental compliance burden|

5. SPÉCIFICATIONS TECHNIQUES

Plage de capacité: Modèles disponibles chez 150 TPH à plus 800 Débit nominal TPH.
Dimensions des rotors & Vitesse: Diamètres de ~1m à ~1,5m; speeds adjustable within a range of ~500800 RPM depending on model.
Exigences de puissance du lecteur: Entraînements par moteur électrique allant de 200 kW jusqu'à 600 kW; compatible with most industrial power supplies.
Ouverture d'alimentation & Taille maximale d'alimentation: Feed openings up to ~1m x ~1m; maximum recommended feed size typically ≤80% of inlet width.
Spécifications des matériaux clés: Rotor constructed from hightensile steel alloy; barres de soufflage disponibles en plusieurs alliages (Acier martensitique, Composite céramique); abrasionresistant steel liners throughout internal housing.
Dimensions physiques & Poids: Varie considérablement selon le modèle; approximate footprint range of L10m x W4m x H4m; weights from ~20 tonnes upwards.
Plage de fonctionnement environnementale: Conçu pour des températures ambiantes de 20°C à +45°C; roulements anti-poussière standard.

_(Throughput dependent on feed material characteristics.)_

6. SCÉNARIOS D'APPLICATION

Recycled Concrete Aggregate Plant Challenge:

A contractor specializing in demolition waste faced excessive wear costs from rebar contamination and inconsistent output gradation that failed DOT specifications.

Solution:

Implementation of a heavyduty impact crusher equipped with a monobloc rotor for tramp iron tolerance and hydraulic apron adjustment.

Résultats:

Wear part life increased by an average of two weeks per set due to robust design; ability to finetune aprons onthefly resulted in a consistent yield where >95% of output met DOT spec without secondary screening recirculation.

Limestone Quarry Secondary Crushing Challenge:

A quarry’s existing secondary cone crushers produced excessive fines (<5mm), reducing saleable yield of chip products while consuming high energy per ton processed.

Solution:

Replacement with an impact crusher configured for high cubicity output as a tertiary unit after jaw crushing.

Résultats:

Energy consumption reduced by an estimated $15k annually due to more efficient direct drive system; improved particle shape increased chip product yield by approximately eight percent while decreasing overall fines generation.

7. CONSIDÉRATIONS COMMERCIALES

Nos concasseurs à percussion en gros sont proposés sur trois niveaux principaux:

1. Série de service standard: For consistent processing of nonabrasive materials like limestone. Base pricing reflects core reliability features including solid rotor construction and basic hydraulic adjustment.
2. Série robuste (Recommended for Recycled Aggregates): Includes enhanced wear protection packages, tramp iron relief systems as standard, and upgraded bearing assemblies for shock loads.
3. Modular/Portable Configuration (For Contractors): Crusher mounted on a heavyduty chassis with integrated feeder/discharge conveyors for rapid site deployment.

Les fonctionnalités optionnelles incluent:

Advanced automation packages with remote monitoring
Intégration du système de suppression de poussière
Specialized alloy packages for blow bars/liners
Custom discharge hoods for specific conveyor layouts

We support commercial buyers through flexible financing structures including equipment leasing programs tailored for capital expenditure cycles common in aggregate production businesses.

8. FAQ

T1. Is this type of impact crusher suitable as a direct replacement for my existing jaw or cone crusher?
It can be evaluated as such depending on your feed material’s abrasiveness index required final product specification A detailed analysis of your current circuit is recommended as jaw cone units often serve different purposes within the flow sheet

T2. Quel est le coût opérationnel attendu par tonne traitée?
Operational cost is dominated by wear parts energy consumption Field data indicates total operating costs ranging between $0 $0 per ton processed depending primarily on material abrasiveness Proper selection of wear part metallurgy is critical

T3. How does this equipment integrate with my existing plant PLC control system?
The crusher comes standard with an automationready interface providing standard IO signals amp draw vibration levels Integration protocols are documented allowing your controls engineer or our technical team facilitate connection

T4. Quels sont les délais de livraison habituels après la passation de la commande?
Lead times vary based on model specification complexity Current standard lead times range from weeks following order confirmation subject foundry schedules component availability Expedited options may be available during procurement discussions

Q5. Que couvre la garantie?
We provide month warranty covering defects materials workmanship major structural components like main frame rotor shaft Additional extended warranty service contracts are available covering scheduled preventive maintenance inspections