1. PEMBUKAAN PAINPOINT DRIVEN

Adakah peningkatan kos operasi dan masa henti yang tidak menentu menghakis agregat atau margin pemprosesan mineral anda? Untuk pengurus loji dan kontraktor kejuruteraan, peringkat penghancuran utama selalunya menjadi punca kesesakan kritikal. Cabaran biasa termasuk:
Masa Henti Berlebihan untuk Penyelenggaraan: Perubahan pelapik yang kerap dan kegagalan mekanikal yang tidak dijangka menghentikan keseluruhan barisan pengeluaran anda, menelan belanja beribu-ribu sejam dalam pengeluaran yang hilang.
Penggunaan Bahagian Haus yang Tinggi: Aggressive or abrasive feed material leads to premature jaw plate wear, menaikkan costperton anda dan mencipta masalah pengurusan inventori.
Penggredan Produk Tidak Konsisten: A worn or poorly designed crusher chamber fails to maintain a consistent CSS (Tetapan sampingan tertutup), resulting in offspec product and recrushing cycles.
Rigid Infrastructure Demands: Many jaw crushers require extensive, costly foundations and are not suited for modular or semimobile plant designs, mengehadkan fleksibiliti operasi.
Ketidakcekapan Tenaga: Older designs with inefficient kinematics consume more power per ton of processed material, secara langsung memberi kesan kepada keuntungan anda.

What if your primary crusher could deliver predictable maintenance intervals, reduce wear costs by a measurable percentage, and adapt to evolving site requirements? The solution requires an engineered approach focused on reliability and total cost of ownership.

2. GAMBARAN KESELURUHAN PRODUK

The Bespoke JC5000 is a heavyduty, penghancur rahang tunggal yang direka bentuk untuk penghancuran primer berkapasiti tinggi dalam kuari, perlombongan, dan aplikasi kitar semula perobohan. Reka bentuknya mengutamakan keteguhan mekanikal dan kecekapan operasi untuk memproses batuan keras, bijih, dan konkrit.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Bahan suapan besar (sehingga 1300mm) is delivered via dump truck or wheel loader into the vibratory grizzly feeder (pilihan), yang memintas denda untuk mengoptimumkan pemuatan ruang.
2. Tindakan Menghancurkan: Bahan masuk ke dalam, kebuk penghancuran tidak tercekik. The aggressive elliptical stroke of the singletoggle mechanism applies high inertia forces to reduce material by compression.
3. Pelepasan & Pengangkutan: Crushed product exits at the bottom discharge point with a consistent gradation, ready for secondary processing via conveyor.

Skop Permohonan: Ideal for hightonnage primary crushing stations processing granite, basalt, bijih besi, dan konkrit kitar semula. Tidak disyorkan untuk melekit, plastic clays or as a standalone unit for producing fine sand specifications without downstream crushing stages.

3. CIRI TERAS

Geometri Ruang Dalam | Asas Teknikal: Sudut nip yang dioptimumkan dan lejang penghancuran yang panjang | Faedah Operasi: Peningkatan kapasiti setiap lejang dan mengurangkan risiko merapatkan/tercekik pada pembukaan suapan | Kesan ROI: Purata daya pemprosesan yang lebih tinggi (tph) maximizes plant utilization

Reka Bentuk Galas Gelek Tugas Berat | Asas Teknikal: Galas penggelek penjajaran sendiri berbentuk sfera pada aci utama | Faedah Operasi: Mengendalikan beban jejarian dan tujahan yang tinggi dengan kecekapan yang lebih tinggi daripada sesendal gangsa | Kesan ROI: Lower friction reduces power draw by approximately 812% versus comparable bushing designs

Pelarasan CSS Hidraulik & Perlindungan beban | Asas Teknikal: Silinder hidraulik bersepadu untuk penegangan plat togol | Faedah Operasi: Closed Side Setting can be adjusted quickly under load; system automatically releases to clear tramp metal | Kesan ROI: Minimizes unplanned stops for clearing blockages; allows rapid product size changes with less operator intervention

BoltIn Wedge Lock Jaw Plate System | Asas Teknikal: Mechanically locked wedge system without epoxy backing material | Faedah Operasi: Jaw plate changeout time reduced to under 4 hours with standard site tools | Kesan ROI: Direct labor savings during maintenance windows; meningkatkan ketersediaan tumbuhan

Pembinaan Rangka Modular | Asas Teknikal: Bahagian keluli yang difabrikasi dengan pad pengesan dimesin ketepatan | Faedah Operasi: Memudahkan pengangkutan, mengurangkan keperluan asas, and allows for future relocation or plant reconfiguration | Kesan ROI: Lower capital expenditure on civil works; preserves asset value through redeployability

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Kelas Setanding) | Bespoke JC5000 Solution | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Kehidupan Pelapik Purata (Granit Lelas) | 180,000 220,000 tan | 260,000 300,000 tan | +30% hayat perkhidmatan yang dilanjutkan |
| Penggunaan Kuasa setiap Tan Hancur| ~0.85 kWj/t | ~0.75 kWh/t| ~12% reduction in energy cost |
| Masa Min Antara Kegagalan (MTBF) Komponen Utama| ~2,000 jam| ~2,800 jam| +40% peningkatan dalam kebolehpercayaan |
| Jumlah Jam Penyelenggaraan setiap Tahun Dijadualkan & Tidak berjadual| Dianggarkan 120150 jam| Dianggarkan 80100 jam| Hingga 33% reduction in labor |

5. SPESIFIKASI TEKNIKAL

Pembukaan suapan: 1300mm x 1000mm (51" x 40")
Saiz suapan maksimum: 1100mm panjang tepi (43")
Tetapan sampingan tertutup (CSS) Julat: 150mm 300mm (6" 12")
Julat Kapasiti (Berbeza mengikut Bahan & CSS): 450 850 tan sejam
Keperluan Kuasa Pandu: 200 kw (268 Hp) motor elektrik
Jumlah Berat (Penghancur Sahaja): Kira -kira 62,000 kg
Spesifikasi Bahan Utama:
Bingkai utama: Plat keluli tegangan tinggi (Grade S355J2)
Swing Jaw Die: Keluli mangan (14% Mn), reversible
Aci eksentrik: Forged alloy steel EN24T
Julat Suhu Operasi: 25°C hingga +45°C (13°F hingga +113°F)

6. SENARIO APLIKASI

Projek Pembesaran Kuari Granit

Cabaran: An existing quarry needed to increase primary circuit output by 35% but had limited space for new foundation works. Downtime during installation was also a critical constraint.
Penyelesaian: Implementation of a modular Bespoke JC5000 jaw crusher on a prefabricated support structure with a lowprofile hopper.
Keputusan: Installation was completed in 40% less time than traditional methods due to simplified foundations. The plant achieved the target throughput increase of 35%, with energy monitoring showing a 9% reduction in specific power consumption compared to the older unit.

Naik Taraf Loji Pemprosesan Bijih Besi

Cabaran: Excessive wear on jaw plates from highly abrasive ore resulted in liner changes every six weeks at significant cost and production loss.
Penyelesaian: Replacement of an older doubletoggle crusher with the Bespoke JC5000 featuring its boltin wedge system and optimized chamber geometry.
Keputusan: Field data shows jaw plate life extended from an average of six weeks to nine weeks—a 50% improvement—reducing annual liner costs by onethird. The hydraulic adjustment system also allowed operators to compensate for wear more effectively between changes.

7. PERTIMBANGAN KOMERSIL

The Bespoke JC5000 is offered in three configured tiers:
1. Tier Unit Asas: Includes core crusher assembly with standard motor drives and basic instrumentation.
2. Peringkat PlantReady: Integrates matched grizzly feeder product conveyor walkways ladders safety guards motor starters PLC control panel
3. Modular SkidMounted Tier Full semimobile package on a heavyduty skid frame requiring only hookup to power utilities

Optional features include automated lubrication systems dust suppression kits various jaw plate tooth profiles feed chute extensions

Service packages are available from annual inspection plans comprehensive partsandlabor maintenance agreements Extended warranty coverage up five years is offered subject specific operating conditions Financing options including operating lease capital lease loan structures can be structured over terms three seven years align investment cash flow generation

8 Soalan Lazim

Q What existing secondary tertiary equipment compatible JC5000?
A The JC5000 designed produce well graded feed material typical cone impact crushers Its discharge setting range gradation curve data provided ensure compatibility your downstream circuit

Q How does hydraulic adjustment system affect daily operation?
A Operators can check adjust crusher setting minutes using remote station reducing need enter equipment area making product size adjustments responsive market demands

Q Apakah pentauliahan penghantaran masa utama yang tipikal?
A Standard units have lead time months from order confirmation Full modular plants require additional engineering Site commissioning supervised our engineers typically requires five seven working days

Q Are wear spare parts readily available globally?
A Yes standardized components common consumables like jaw plates side liners held regional distribution centers ensuring availability Critical bearing shaft assemblies available under expedited shipping programs

Q Can this crusher integrated into existing automated control system?
A Yes the JC5000 equipped standard Modbus RTU communication protocol allowing integration most SCADA PLC systems monitoring key parameters like power draw hydraulic pressure provide performance data