1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang meningkat dan masa henti yang tidak menentu menghakis keuntungan litar penghancur utama anda? Untuk pengurus loji dan kontraktor kejuruteraan, peringkat penghancuran utama adalah kesesakan kritikal di mana ketidakcekapan mengalir melalui keseluruhan barisan pemprosesan. Cabaran biasa termasuk:
Masa Henti Berlebihan untuk Penyelenggaraan: Perubahan pelapik yang kerap dan kegagalan mekanikal yang tidak dijangka menghentikan pengeluaran, 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: Fluctuations in feed size or hardness result in an uneven discharge product, placing stress on downstream screening and secondary crushers.
Had Persediaan Tegar: Fixed jaw crushers cannot adapt to changing project demands or feed characteristics, locking you into a single operational profile.

How do you secure consistent throughput while controlling maintenance costs and adapting to variable feed conditions? The solution requires a robust design focused on durability, kebolehkhidmatan, and sustained performance.

2. GAMBARAN KESELURUHAN PRODUK

The Bulk JC5000 is a highcapacity, singletoggle jaw crusher engineered for primary crushing in demanding mining, Penggalian, dan aplikasi pembinaan berskala besar. It processes runofmine rock, batu kuari yang diletupkan, and demolition concrete into a consistent, agregat kasar.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Bahan besar (sehingga 1300mm) is directed into the deep crushing chamber by vibrating grizzly feeders.
2. Penghancuran mampatan: The elliptical motion of the single toggle forces the movable jaw against the fixed jaw, menggunakan daya mampatan untuk memecahkan batuan.
3. Pelepasan & Pembersihan: Bahan hancur keluar melalui bukaan pelepasan bawah (CSS), with the aggressive stroke ensuring efficient clearing even under high load.

Skop Permohonan: Sesuai untuk batu keras (granit, basalt), bijih kasar, and recycled concrete with strengths up to 400 MPa. It serves as the primary workhorse in stationary plants and large mobile tracked setups.

Batasan: Tidak direka untuk basah, sticky materials that may cause chamber packing without proper feed conditioning. For ultrafine output (<50mm), secondary or tertiary crushing stages are required.

3. CIRI TERAS

Deep Chamber Design | Asas Teknikal: Optimized nip angle and long linear crushing path | Faedah Operasi: Enables higher volume intake per cycle and reduces bridging risks | Kesan ROI: Increases potential throughput by up to 15% versus shallower chambers of similar inlet size

Sistem Pelarasan Togol Hidraulik | Asas Teknikal: Replaceable hydraulic cylinder for tensioning & overload release | Faedah Operasi: Allows remote CSS adjustment under load and protects against tramp metal damage | Kesan ROI: Reduces unplanned downtime by an average of 30 hours annually related to tramp iron incidents

HeavyDuty Roller Bearing Assembly | Asas Teknikal: Galas penggelek penjajaran sendiri berbentuk sfera pada aci utama | Faedah Operasi: Supports higher radial loads and operates at lower temperatures than bronze bushings | Kesan ROI: Memanjangkan hayat perkhidmatan galas lebih kurang 40%, menurunkan kekerapan penggantian bahagian

Pelapik Pakai BoltOn | Asas Teknikal: Modular manganese steel liners on frame sides | Faedah Operasi: Protects crusher frame from abrasion; replaced independently of jaw dies | Kesan ROI: Preserves structural integrity of main frame for decades, avoiding capital replacement costs

Titik Greasing Berpusat | Asas Teknikal: Automated or manual greasing lines routed to all major bearings | Faedah Operasi: Membolehkan selamat, routine lubrication without direct operator access to moving parts | Kesan ROI: Standardizes preventive maintenance, reducing lubricationrelated failures by over 80%

Reinforced Swing Jaw Design | Asas Teknikal: Analisis Unsur Terhingga (FEA) optimized cast steel structure with thick ribs | Faedah Operasi: Provides maximum fatigue resistance under cyclic loading stresses | Kesan ROI: Minimizes risk of catastrophic jaw failure, ensuring multiyear structural service life

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Kelas Setanding) | Bulk JC5000 Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Average Jaw Plate Life (Granit Lelas) | ~180,000 MTON setiap set (Standard Mn18) | ~250,000 MTON setiap set (Premium Mn22) +38% |
| Masa untuk Pelarasan CSS / Liner Turnover| 46 jam (pelarasan shim manual) 900 TPH in field trials| >6% Output Lebih Tinggi |

5. SPESIFIKASI TEKNIKAL

Pembukaan suapan: 1300mm x 1000mm (51" x 40")
Saiz suapan maksimum: Panjang tepi sehingga 1100mm
Tetapan sampingan tertutup (CSS) Julat: 150mm 300mm
Julat Kapasiti: Hingga 950 tan sejam (bergantung kepada bahan makanan & CSS)
Keperluan Kuasa Pandu: 132 kW Motor Elektrik
Jumlah Berat (Penghancur Sahaja): Kira -kira 62 tan
Spesifikasi Bahan Utama:
Bingkai utama: Fabricated heavyduty steel plate
Swing Rahang & Fixed Jaw Dies: Keluli Mangan Premium
Aci eksentrik: Keluli aloi palsu
Julat Suhu Operasi: 30°C to +45°C with appropriate lubricants
Dimensi (L x W x H): ~4m x 3m x 3m

6. SENARIO APLIKASI

Hard Rock Quarry Expansion Challenge:

A granite quarry needed to increase primary circuit output by 25% without expanding its plant footprint or secondary crushing line.

Penyelesaian:

Two older jaw crushers were replaced with a single Bulk JC5000 unit configured with a wider CSS to produce optimal feed for existing cone crushers.

Keputusan:

Daya tampung meningkat sebanyak 28%. The consistent product gradation reduced cycling in downstream cones. Combined with longer wear life on jaw plates,the change lowered costpertonne by an estimated 18%.

LargeScale Mineral Processing Plant Challenge:

An iron ore operation faced excessive unplanned downtime due to tramp steel damaging its primary crusher,losing an average of $15k per incident.

Penyelesaian:

Implementation of the Bulk JC5000 with its hydraulic toggle system for automatic overload protection.

Keputusan:

Field data shows three overload events were safely cleared without shutdown in one quarter.Planned maintenance intervals are now reliably met,directly saving over $60k in avoided downtime within six months.

7. PERTIMBANGAN KOMERSIL

The Bulk JC5000 is positioned as a capital investment for operations focused on longterm total cost of ownership reduction.

Peringkat Harga Peralatan Asas: Termasuk penghancur,lekap motor,and drive sheaves.Competitively structured against equivalent OEM offerings.
Ciri Pilihan & Pakej:

Pakej Prestasi: Includes automated grease system,penghidup motor,and wear part monitoring sensors.
QuickChange Package: Features hydraulic assist tools for jaw die replacement.
Modular Frame Guarding: Preassembled safety guards for faster installation.

Perjanjian Perkhidmatan:

1Year OnSite Warranty with factory commissioning support.
3Year /5Year Extended Protection Plans covering major components.
Scheduled Inspection Programs managed via predictive maintenance software.

Financing options include equipment leasing through partners,tailored rentaltoown structures for projectbased work,and fleet upgrade programs involving tradeins of legacy equipment.

8.Soalan Lazim

S1:What is the compatibility of the Bulk JC5000 with my existing vibrating grizzly feeder and discharge conveyor?
A1:The JC5000 is designed to standard industry mounting footprints.Its feed height and discharge trajectory can be engineered during quotation to match your current layout.Engineering support is provided for integration reviews.

S2:What is the expected operational impact during liner changeouts?
A2:The design prioritizes service access.Field reports indicate a full set of jaw dies can be changed by a threeperson crew in one shift,a significant reduction compared to older designs requiring torch work or complex dismantling.

S3:What commercial terms are available beyond upfront purchase?
A3.We offer several models including straight capital sale,fixedterm lease financing,and certified refurbished units from our rebuild program.Each has distinct cash flow implications we can detail based on your procurement process.

S4:What power supply infrastructure is required?
A4.The unit requires a dedicated supply compatible with its 132 kW motor.Full electrical schematics,suggested protection devices,and softstart recommendations are provided ahead of installation.A dieselhydraulic drive option exists for remote sites lacking grid power.

S5:Apakah latihan yang disediakan untuk pasukan penyelenggaraan kami?
A5.Comprehensive training modules are included,covershing safe operation,prosedur penyelenggaraan rutin,and basic troubleshooting.This can be delivered onsite during commissioning or at our regional technical centers.Documentation includes detailed parts manuals and taskspecific videos