1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang semakin meningkat dan ketersediaan yang tidak dapat diramalkan menghakis keuntungan litar penghancur utama anda? Untuk pengurus loji dan kontraktor kejuruteraan, peringkat penghancuran utama adalah kesesakan kritikal di mana ketidakcekapan mengalir melalui keseluruhan proses hiliran. Cabaran utama termasuk:

Masa Henti Tidak Berjadual: Premature failure of critical components like mainshafts or concaves leads to production halts costing tens of thousands per hour in lost throughput.
Kos Penyelenggaraan Berlebihan: Kerap, laborintensive liner changes and unpredictable wear life consume maintenance budgets and divert skilled personnel from other critical tasks.
Saiz Produk Tidak Konsisten: Poor feed distribution or worn crushing chambers yield an inconsistent feed for secondary circuits, mengurangkan kecekapan loji keseluruhan dan kualiti produk akhir.
Penggunaan Tenaga Tinggi: Inefficient crushing action and outdated drive systems result in unsustainable power draw, secara langsung memberi kesan kepada keuntungan anda.
Limited Feed Flexibility: Inability to handle varying ore hardness or occasional tramp metal without causing significant damage.

Bagaimanakah anda mencapai daya pengeluaran yang lebih tinggi dengan kebolehpercayaan yang lebih tinggi sambil mengawal jumlah kos pemilikan? The answer lies in advanced gyratory crusher design focused on durability, intelligence, dan kecekapan.

2. GAMBARAN KESELURUHAN PRODUK: PENGHANCUR GIRATOR UTAMA TUGAS BERAT

This heavyduty primary gyratory crusher is engineered for the first stage of comminution in hightonnage mining and aggregate operations. It is designed to accept runofmine feed directly from haul trucks, menyampaikan secara konsisten, coarse product to downstream conveying and processing systems.

Aliran Kerja Operasi:
1. Penerimaan Suapan: Direct dump from haul trucks into the rugged feed hopper, guided by a onepiece spherical spider cap for optimal entry.
2. Tindakan Menghancurkan: The eccentrically mounted mainshaft gyrates within the concave liners, applying compressive force to reduce large rock (often +1m) kepada saiz yang boleh dikawal.
3. Pelepasan produk: Crushed material exits through the discharge opening at the bottom of the crushing chamber, dictated by the selected crusher setting (CSS).

Skop Permohonan & Batasan:
Skop: Sesuai untuk kapasiti tinggi (5,000 15,000+ tph) primary crushing of abrasive hard rock (bijih besi, bijih tembaga, granit), batu kapur, and other minerals. Sesuai untuk pemasangan loji tetap.
Batasan: Not designed for portable plants or lowtonnage operations (< 500 tph). Requires significant capital investment and a reinforced concrete foundation. Less effective on clayrich or highly plastic materials that may cause packing.

3. CIRI TERAS

Reka Bentuk Cekung yang Dipatenkan | Asas Teknikal: bersegmen, alloyoptimized liner system with mechanical locking | Faedah Operasi: Mengurangkan masa henti penggantian sehingga 40% versus bolted designs; allows mixing liner profiles for optimal chamber geometry | Kesan ROI: Lower labor costs per changeout and maximized liner utilization increase annual available crushing hours.

Sistem Kawalan Pintar Bersepadu | Asas Teknikal: Tekanan pemantauan sensor masa nyata, suhu, Cabutan kuasa, dan pakai | Faedah Operasi: Provides predictive analytics for maintenance scheduling and alerts operators to abnormal conditions like bridging or overload | Kesan ROI: Mencegah kegagalan bencana; enables conditionbased maintenance over scheduled intervals.

Pelepasan Gelandangan Hydroset® & Pelarasan CSS | Asas Teknikal: Hydraulic piston supporting the mainshaft for remote adjustment of the Closed Side Setting (CSS) | Faedah Operasi: Allows quick compensation for wear or product size changes without stopping the crusher; secara automatik melepaskan tramp iron | Kesan ROI: Mengekalkan konsistensi spesifikasi produk; protects internal components from damage by uncrushables.

HighPrecision Spiral Bevel Gear & Pinion | Asas Teknikal: Computermodeled gear geometry manufactured to AGMA 14 kualiti | Faedah Operasi: Ensures smooth power transmission with minimal vibration and noise; extends gear life significantly under hightorque loads | Kesan ROI: Reduces risk of catastrophic drive system failure; lowers longterm spare parts inventory cost.

Pelinciran Automatik Berpusat | Asas Teknikal: Programmable system delivering precise oil volumes to key bearings at set intervals | Faedah Operasi: Menghapuskan ralat pelinciran manual; ensures optimal bearing temperature and longevity even in dusty environments | Kesan ROI: Secara langsung memanjangkan masa min antara kegagalan (MTBF) for critical bearings; reduces lubricant consumption.

Robust Mainshaft & Head Center Design | Asas Teknikal: Forged from highstrength alloy steel with precision machining on bearing journals | Faedah Operasi: Provides exceptional resistance to bending fatigue and shock loads from oversized feed | Kesan ROI: The core component's extended lifecycle defers major capital overhaul expenses for years.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Penyelesaian Gyratory Crusher Kami | Kelebihan Berdokumen |
| : | : | : | : |
| Masa Pertukaran Pelapik (Major) | 48 72 jam | 24 36 hours with tooling package| ~50% pengurangan |
| Ketersediaan Operasi (tahunan) | 92 94%| >96% (with Intelligent Control System)| +24 mata peratusan |
| Penggunaan Tenaga Khusus (kWj/t) Berbeza mengikut bahan.| Garis dasar = 100%| Pengurangan purata bagi 58% melalui kinematik yang dioptimumkan & kecekapan memandu| ~7% peningkatan |
| Wear Life of Concaves (Bijih Pelelas) MTons/Set| Varies widely by ore.| Data lapangan menunjukkan peningkatan yang konsisten terhadap 1525% via material science & design.| ~20% increase |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Model boleh dikonfigurasikan daripada 3,000 ke atas 15,000 Ton metrik sejam (tph), bergantung pada bahan suapan dan tetapan sisi tertutup.
Kuasa motor: Pilihan pemacu elektrik daripada 450 kW sehingga 1,200 kw (600 1,600 Hp). Dual pinion drives available for highest horsepower models.
Pembukaan suapan: Saiz gape dari 1,300 mm ke 1,800 mm (54" ke 72").
Spesifikasi Bahan Utama: Main frame of fabricated hightensile steel; concaves in manganese steel or optional alloy composites; mainshaft forged from NiCrMo alloy steel.
Dimensi Fizikal / Berat: Approximate total installed weight ranges from 400 tan hingga lebih 800 tonnes depending on model size. Foundation forces are provided for detailed civil engineering.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C. Dust seals and pressurized housing options available for extreme environments.

6. SENARIO APLIKASI

Pengembangan Lombong Tembaga Berskala Besar

Challenge A tierone copper miner required a primary crusher solution for a new pit expansion capable of processing highly abrasive sulfide ore at >10,000 tph while minimizing planned downtime.
Solution Installation of a superduty gyratory crusher featuring our patented concave system and intelligent controls.
Results Achieved sustained throughput of 10,500 tph. Liner life increased by an average of 22%, reducing planned changeouts from three to two per year. The control system predicted a bearing anomaly months in advance, allowing planned intervention during a conveyor shutdown.

Kuari Granit Pengeluaran Tinggi

Challenge An aggregate producer needed consistent (8 inci) product size for their rail loadout facility but faced bottlenecks due to frequent maintenance on older equipment.
Solution Replacement with a midsize gyratory crusher equipped with Hydroset® automation.
Results CSS adjustments are now made remotely in minutes versus hours of manual work. Product consistency improved such that secondary cone crusher throughput increased by an estimated 9%. Annual maintenance hours decreased by 30%.

7. PERTIMBANGAN KOMERSIL

Our gyratory crushers are offered under a transparent commercial framework designed for longterm partnership:

Peringkat Harga Peralatan: Pricing is modelspecific based on size/capacity. Standard packages include crusher assembly motor drive auxiliary lubrication unit basic controls foundation drawings
Ciri Pilihan & Naik taraf: Intelligent Control System premium wear material packages automated mantle positioning tool automated lubrication system special environmental sealing kits
Pakej Perkhidmatan Tersedia
Basic Warranty covers defects in materials/workmanship
Extended Service Agreement includes scheduled inspections parts discounts technical support
Full Performance Contract guaranteed availability wear part consumption service crew support
Financing Options We work with leading industrial finance providers to offer competitive leasing longterm rental or purchase plans tailored to your capital expenditure cycles

8.Soalan Lazim

Q What infrastructure is required prior installation?
A A reinforced concrete crusher foundation designed per our supplied load drawings is mandatory Access for heavy lift cranes during installation/maintenance must be considered Electrical substation capacity must match motor requirements

S Bagaimanakah ini berintegrasi dengan sistem PLC/SCADA kami yang sedia ada?
A The crushers intelligent control system communicates via standard industrial protocols OPC UA Modbus TCP/IP providing key data points health status alarms It can function as standalone unit interface seamlessly

S Apakah penghantaran masa utama yang biasa?
A Lead times vary by model complexity current manufacturing load Standard models typically have lead time months Custom configurations may require additional time Detailed schedule provided upon project initiation

Q Are training operator manuals provided?
A Yes comprehensive training program conducted at your site covers safe operation routine maintenance basic troubleshooting Detailed digital paper manuals parts books are supplied standard

Q Can you supply compatible downstream equipment conveyors bins?
A While we specialize primary crushing equipment we can provide interface specifications coordinate with preferred partners ensure complete circuit compatibility through project engineering phase