1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang meningkat dan masa henti yang tidak menentu menghakis margin pengeluaran agregat anda? Untuk pengurus loji dan kontraktor kejuruteraan, the core of these challenges often originates at the primary crushing stage. Titik kesakitan biasa termasuk:

Masa Henti Tidak Berjadual: Kegagalan mekanikal yang kerap dan perubahan komponen yang panjang menghentikan keseluruhan baris pemprosesan anda, menelan belanja ribuan sejam dalam kehilangan pengeluaran dan buruh.
Excessive Wear Costs: Abrasive feed material rapidly degrades crusher liners and wear parts, leading to high consumable expenses and frequent maintenance windows.
Output Tidak Konsisten & Bentuk produk: Variable feed size or hardness results in poor yield control and substandard product gradation, reducing the value of your final aggregate.
Penggunaan Tenaga Tinggi: Inefficient crushing chambers and drives consume excessive power, making energy one of your largest, most volatile operational costs.
Keselamatan & Operational Complexity: Manual adjustment processes and inaccessible service points increase risk for your crew and extend routine maintenance time.

Is your primary crusher a constant source of reactive maintenance rather than a reliable foundation for your operation? The solution lies in selecting a machine engineered not just to crush rock, but to crush your operational costs.

2. GAMBARAN KESELURUHAN PRODUK: COMMERCIAL JAW CRUSHER

A commercial jaw crusher is a heavyduty, compressiontype primary crusher designed to reduce large, quarried rock (up to 1.5m in size) into manageable feed for secondary processing. Its robust design is built for continuous, hightonnage operation in stationary plants or largescale mobile setups.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Large dump trucks deposit runofquarry rock into the vibratory grizzly feeder, yang memintas bahan subsize dan mengarahkan saiz terlalu besar kepada penghancur.
2. Penghancuran mampatan: The rock enters the fixed Vshaped chamber between a stationary jaw die and a moving jaw die. The moving jaw exerts immense mechanical pressure, fracturing the rock against the stationary surface.
3. Pelarasan Tetapan Pelepasan: The crushed material exits at the bottom opening. The size of this closedside setting (CSS) is hydraulically adjustable to precisely control final product top size without stopping the machine.
4. Pengangkutan Produk: Crushed material is discharged onto a main conveyor belt for transport to the next stage of screening or secondary crushing.

Skop Permohonan & Batasan:
Skop: Ideal for primary reduction of hard abrasive materials (granit, basalt, kuarzit), mediumhard stone (batu kapur, batu pasir), dan konkrit/asfalt kitar semula.
Batasan: Tidak sesuai untuk melekit, plasticclay materials that may cause chamber packing. Maximum reduction ratios are typically 6:1 ke 8:1, making secondary crushing necessary for most fine aggregate specifications.

3. CIRI TERAS

Ruang Penghancuran Dalam & Sudut nip agresif | Asas Teknikal: Kinematic geometry of swing jaw motion | Faedah Operasi: Enables higher throughput capacity per stroke and effective grip on slabby material | Kesan ROI: Increases potential revenue output by 1015% within same machine footprint

HeavyDuty Fabricated Steel Frame with StressRelieving | Asas Teknikal: Analisis Unsur Terhingga (FEA) reka bentuk yang dioptimumkan dengan rawatan haba postweld | Faedah Operasi: Provides exceptional durability against shock loads and fatigue over a 20+ jangka hayat tahun | Kesan ROI: Menghapuskan risiko kegagalan rangka bencana; protects longterm capital asset value

Hydraulic Toggle Adjustment & Clearing System | Asas Teknikal: Silinder hidraulik dualaks menggantikan plat togol mekanikal tradisional | Faedah Operasi: Allows remote adjustment of CSS for product control and automatic clearing of chamber blockages in minutes | Kesan ROI: Reduces downtime for settings changes by over 80% versus manual systems

QuikChange Jaw Die Wedge System | Asas Teknikal: Mechanically locked wedge design for liner retention | Faedah Operasi: Membolehkan selamat, fast replacement of manganese jaw dies without backing material or resin pouring | Kesan ROI: Cuts liner changeout time by half, meningkatkan ketersediaan tumbuhan

Roda Terbang Inersia Tinggi & Aci Sipi Teguh | Asas Teknikal: Balanced rotational mass energy storage | Faedah Operasi: Smoothes peak power demands, maintains momentum under load fluctuations for consistent crushing action | Kesan ROI: Reduces cyclical stress on drive motor, mengurangkan kos tenaga dengan 57% and extending component life

Penindasan Habuk Bersepadu & Water Spray System | Asas Teknikal: Manifold with nozzles targeting feed entry and discharge points | Faedah Operasi: Effectively controls airborne particulate at source for compliance with site health regulations | Kesan ROI: Mitigates risk of regulatory fines and reduces housekeeping labor

Sistem Gris Automatik Berpusat | Asas Teknikal: Programmable pump delivering precise grease volume to all key bearings | Faedah Operasi: Ensures optimal bearing lubrication without manual intervention during operation | Kesan ROI: Prevents premature bearing failure; data lapangan menunjukkan a 40% extension in bearing service intervals.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri (Purata) | Penyelesaian Jaw Crusher Kami | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Pertukaran Pelapik (Rahang Mati) | 1224 jam (mechanical/welded) | 68 jam (QuikChange Wedge) | ~50% lebih pantas |
| Adanya (Masa aktif %) Berakhir 12 berbulan-bulan| ~8590% (including adjustments/stoppages)| >94% (purata medan yang didokumenkan) |>45 mata peratusan |
| Penggunaan Tenaga Khusus (kWj/tan)| Varies; garis dasar = 100%| Pengurangan purata yang didokumenkan kepada ~93%| ~7% more efficient |
| Pakai Life of Jaw Dies (Granit Lelas)| Based on standard manganese grade| Upgraded Manganese Steel Alloy available| +1520% dipanjangkan umur |

5. SPESIFIKASI TEKNIKAL

Penamaan model: JC1500HD
Pembukaan suapan: 59” x 47” (1500mm x 1200mm)
Saiz suapan maksimum: Up to 47” (1200mm) panjang tepi
Julat Tetapan Sisi Tertutup: 6” – 12” (150mm – 300mm)
Julat Kapasiti (@ CSS): 550 – 950 STPH (500 – 860 MTPH), bergantung kepada jenis bahan & penggredan suapan.
Keperluan Kuasa Pandu: Peringkat IV Akhir / Stage V compliant dieselelectric or direct electric drive options available.
Crusher Drive Power: Hingga 400 Hp /300 motor elektrik kW.
Jumlah Berat (Penghancur Sahaja): Approximately ~125,000 lbs (~56,700 kg).
Spesifikasi Bahan Utama: Main frame fabricated highyield strength steel; Jaw dies premium manganese steel alloy; Eccentric shaft forged alloy steel; Galas jenis penggelek sfera.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C (4°F hingga +113°F). Enclosed lubrication system with heating/cooling options available.

6. SENARIO APLIKASI

Hard Rock Quarry Expansion Project

Challenge A granite quarry needed to increase primary circuit throughput by over 30% without expanding their plant footprint or primary feed conveyor infrastructure.
Solution Implementation of our JC1500HD jaw crusher with its deepchamber design allowed processing larger average feed size at a higher tonnage rate within existing civils.
Results Plant achieved a sustained throughput increase of 32%. The hydraulic adjustment system enabled operators to optimize CSS daily based on blast fragmentation data.

HighAbrasion Aggregate Processing

Challenge A producer processing highly abrasive trap rock faced excessive wear costs from other OEMs’ components requiring liner changes every six weeks at significant cost/downtime.
Solution Our jaw crusher was specified with optional premiumgrade manganese alloy jaws combined with an automated greasing system ensuring perfect bearing alignment under load.
Results Wear part life extended by an average of three weeks per set (+22%). Combined with faster changeout times total annual availability increased by approximately five days.

Recycled Concrete Aggregate Production

Challenge A contractor required reliable primary crushing capable handling large reinforced concrete slabs while managing tramp metal risks minimizing damage from uncrushable objects like rebar mats
Solution The JC series’ hydraulic toggle system was critical allowing automatic release clearing uncrushable objects protecting main components from overload damage
Results Zero incidents major structural damage due tramp metal over twoyear period Unplanned stoppages cleared typically under five minutes maintaining high utilization rates

7. PERTIMBANGAN KOMERSIL

Our commercial jaw crushers are offered through flexible models designed meet varying budgetary operational needs:

Peringkat Harga:
Base Configuration Includes core crusher drive motor basic lubrication system standard manganese jaws
HighProduction Package Adds hydraulic adjustment/clearing automated greasing upgraded premium jaws integrated water spray
Turnkey SkidMounted Unit Crusher premounted on heavyduty skid complete with integrated feeder discharge conveyor walkways ladders electrical starters ready connect power source

Optional Features Premium alloy wear parts extended warranty coverage remote monitoring telematics package dust enclosure kits cold climate packages (30°C)

Pakej Perkhidmatan:
Standard Warranty Comprehensive parts labor coverage first twelve months operation includes commissioning supervision
Planned Maintenance Contracts Fixed annual cost covering scheduled inspections lubrication consumables condition monitoring reporting priority technical support
FullService Agreements Covers all scheduled unscheduled maintenance including wear parts providing predictable cost per tonne crushed over multiyear term

Financing Options Available through our partners include capital lease operating lease leasetopurchase structures tailored match project cash flow timelines typical terms range three seven years

8. Soalan Lazim

What are my power connection options? Units can be configured direct electric drive requiring highvoltage plant connection or as dieselelectric hybrid standalone unit ideal greenfield sites lacking established grid power reducing initial infrastructure cost

How does this machine handle variations feed material hardness? The combination highinertia flywheels robust eccentric shaft allows machine absorb shock loads maintain consistent throughput even when transitioning between softer harder stone layers within same face minimizing need operator intervention adjusting feeder rates frequently

What typical lead time delivery installation? For standard configurations lead time averages sixteen twenty weeks exworks Commissioning installation supervised our engineers typically requires five ten working days depending site readiness complexity

Are wear parts readily available globally? Yes We maintain regional inventory hubs North America Europe AsiaPacific ensuring critical wear components like jaw dies available express shipment minimize any potential logisticsrelated downtime Most common parts stocked locally our dealer network

Can existing plant controls integrate new crusher’s automation systems? Yes Our control system designed communicate via standard industrial protocols Modbus TCP/IP OPC UA allowing seamless integration into your central SCADA plant management system providing operators realtime performance data alarm notifications directly familiar interface