1. PEMBUKAAN PAINPOINT DRIVEN

Are you managing the recurring costs and operational bottlenecks associated with primary crushing and material sizing? Cabaran biasa termasuk:
Perbelanjaan Bahagian Haus yang Tinggi: Penggantian tukul yang kerap, pelapik, and impact aprons due to abrasive feed material, memberi kesan secara langsung kepada costperton anda.
Masa Henti Tidak Berjadual: Unplanned maintenance stops to address wear or component failure, menghentikan keseluruhan baris pemprosesan anda.
Penggredan Produk Tidak Konsisten: Variable output sizes leading to recirculating loads, reducing overall system throughput and efficiency.
Fleksibiliti Aplikasi Terhad: A crusher that cannot handle a range of materials or moisture contents forces compromises in your feed strategy.

How do you reduce total cost of ownership while maintaining reliable throughput and product quality? The solution lies in selecting a fabricated impact crusher engineered not just to crush, tetapi untuk bertahan.

2. GAMBARAN KESELURUHAN PRODUK: FABRICATED IMPACT CRUSHERS

A fabricated impact crusher is a robust reduction machine utilizing highspeed rotors and durable impact elements to fracture material through kinetic energy. Its design is characterized by a heavyduty, welded steel frame (rekaan) that provides the structural integrity for demanding primary or secondary crushing duties.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Material is directed into the crushing chamber via a reinforced feed hopper and apron.
2. Pecutan & Kesan: The highinertia rotor assembly hurls material against stationary impact aprons or curtains.
3. Pengurangan saiz: Fracturing occurs through repeated impacts, either rockonrock (within the rotor cascade) or rockonapron.
4. Pelepasan Produk: Sized material exits through the adjustable gap between the rotor and aprons, determining final product gradation.

Skop Permohonan: Sesuai untuk batu kapur, konkrit kitar semula/asfalt, serpihan perobohan, and other mediumtolow abrasiveness materials. Effective for producing a wellshaped, hasil kubus.

Had Utama: Not typically suited for highly abrasive hard rock (mis., granit, batu perangkap) as primary crushers without significant wear cost tradeoffs. Performance can be affected by very high moisture or clay content without proper configuration.

3. CIRI TERAS

Bingkai Fabrikasi Tugas Berat | Asas Teknikal: Allwelded steel plate construction with internal ribbing | Faedah Operasi: Provides exceptional rigidity to withstand dynamic loads and vibration, extending bearing life and maintaining alignment | Kesan ROI: Reduces structural fatigue failures, lowering longterm maintenance costs by minimizing framerelated issues.

Sistem Pelarasan Hidraulik | Asas Teknikal: Silinder hidraulik bersepadu untuk kedudukan apron | Faedah Operasi: Allows operators to adjust product size or clear blockages quickly from outside the machine | Kesan ROI: Cuts adjustment time by over 70% berbanding sistem manual, meningkatkan ketersediaan tumbuhan.

MultiFacet Rotor Design | Asas Teknikal: Rotor discs with replaceable locking wedges securing hammer pins | Faedah Operasi: Enables quick rotation or replacement of hammers/blow bars without full disassembly; mengekalkan keseimbangan rotor | Kesan ROI: Reduces rotor service time by up to 50%, directly lowering labor costs and downtime.

Komponen Pakai Boleh Tukar | Asas Teknikal: Standardized alloy steel castings for aprons, pelapik, and blow bars in various metallurgies | Faedah Operasi: Allows you to select wear part material (mis., keluli martensit, besi krom) based on your specific feed material’s abrasiveness | Kesan ROI: Optimizes wear life versus part cost, providing up to 30% longer service intervals when correctly specified.

Large Service Access Doors | Asas Teknikal: Hinged or sliding doors on the crusher housing | Faedah Operasi: Menyediakan selamat, unobstructed access for routine inspection and maintenance tasks | Kesan ROI: Improves technician efficiency during preventative maintenance checks by providing easier access points.

Sistem Gandingan Pemacu Terus | Asas Teknikal: Fluid coupling or Vbelt drive options connecting motor to rotor | Faedah Operasi: Smooths startup torque peaks and provides inherent overload protection under tramp iron events | Kesan ROI: Protects motor and drive components from shock loads, reducing electrical and mechanical failure risk.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Garis Dasar Piawaian Industri | Our Fabricated Impact Crusher Solution | Kelebihan (% Penambahbaikan) |
| : | : | : | : |
| Masa Tukar Bahagian Pakai (Primary Hammers) | 812 Jam (Manual Shim/Bolt) | 34 Jam (HydraulicAssisted/Wedge System) | ~65% Lebih Pantas |
| Structural Frame Durability (in HighVibration Apps)| Welded Frame with Minimal Reinforcement| Computermodeled stress analysis with internal ribbing & gussets| Data lapangan menunjukkan 40% longer service life before weld fatigue |
| Bentuk produk (Indeks Kubisiti) Menghancurkan sekunder| Varies Widely; Average CI of ~0.7| Consistent CI of 0.80.85 via optimized apron/rotor speed design| ~15% Lagi Produk Cubical |
| Throughput per Installed HP (for Limestone)| 100120 TPH per 100 Hp| 130150 TPH per 100 HP due to optimized chamber geometry & dinamik rotor| Hingga 25% Higher Efficiency |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Modelbergantung daripada 150 TPH berakhir 800 TPH in primary applications.
Keperluan kuasa: daripada 200 Hp (150 kw) ke 600 Hp (450 kw), configured for either electric motor or diesel drive.
Spesifikasi Rotor: Solid steel rotor with bolton discs; diameters from ~40” (1000mm) to ~60” (1500mm); widths matched to feed opening.
Spesifikasi Bahan: Main frame fabrications from ASTM A36/A572 steel; wear components available in AR400 steel plate or highchrome cast iron alloys.
Dimensi Fizikal (Model contoh): Feed Opening up to ~42” x ~48” (1065mm x1220mm); Machine weight approximately 25,000 – 55,000 lbs (1125 tan metrik).
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C; dust seals standard; optional Arctic packages or highdust environment kits available.

6. SENARIO APLIKASI

Pengeluaran Agregat Konkrit Kitar Semula

Cabaran: A recycling yard faced excessive wear costs from rebarcontaminated concrete and unpredictable downtime due to uncrushable material jams.
Penyelesaian: Implementation of a heavyduty fabricated impact crusher with hydraulic apron adjustment and a tramp iron relief system.
Keputusan: Reduced unplanned downtime by 60% due to quick jam clearing. Wear part life increased by an average of 35% through optimal alloy selection for the application.

Limestone Quarry Secondary Crushing

Cabaran: A quarry’s existing secondary circuit produced excessive fines (<5mm) while struggling with occasional claybound feed, causing throughput drops.
Solution Installation of an impact crusher configured with variable rotor speed control and a multistage apron configuration.
Results Achieved better product fraction control; reduced fines generation by approximately 20%. Throughput stabilized as the crusher handled occasional sticky material more effectively than the previous cone crusher setup.

7. PERTIMBANGAN KOMERSIL

Our fabricated impact crushers are offered in three primary tiers:
1. Peringkat Kewajipan Standard: Untuk konsisten, nonabrasive materials like clean limestone. Focuses on core reliability at an entry price point.
2. Peringkat Tugas Berat (Paling Biasa): Includes features like hydraulic adjustment, enhanced wear packages, and heavier rotors for mixed/recycled materials and general quarry use.
3. Peringkat Tumbuhan Modular/Mudah Alih: Crushers integrated into wheeled or skidmounted frames with preengineered feed/discharge systems for mobile contracting.

Ciri pilihan termasuk sistem pelinciran automatik,
advanced bearing temperature monitors,
and different drive configurations
(fluid coupling vs Vbelt).

Service packages range from basic commissioning
to comprehensive annual inspection contracts
with guaranteed parts availability SLAs

Financing options include equipment leasing,
program rentaltoown,
and projectbased financing solutions

8.Soalan Lazim

S1:What is your typical Minimum Order Quantity?
Our standard MOQ is one unit per order However we offer tiered pricing structures that provide discounts on orders for multiple units which is common for large contracting firms equipping several sites

Q2 Can your fabricated impact crusher replace our existing jaw cone setup?
In many secondary reduction applications yes Field data often shows an impact crusher can provide sufficient reduction at a lower capital cost than adding a secondary cone It requires analysis of your current feed size desired product specs

Q3 How do you ensure compatibility with our existing plant conveyor sizes discharge heights?
We require key interface dimensions during quotation Our engineering team designs discharge hoods support structures fit within your specified envelope ensuring smooth integration

Q4 What is the expected operational cost per ton for wear parts?
This varies significantly based on material abrasiveness We provide detailed estimates using industrystandard abrasion indices For example operating on clean limestone may yield $010$020/ton while recycled concrete could be $025$040/ton

S5 Adakah anda menawarkan jaminan prestasi?
Yes we provide guaranteed minimum throughput capacity based on agreedupon feed material specifications subject terms conditions outlined our commercial proposal

Q6 What is lead time from order placement delivery?
For standard heavyduty models lead time typically ranges between weeks depending current production schedule confirmed upon order placement Custom configurations require additional engineering time

Q7 What operator training provided?
We include comprehensive onsite operator maintenance training during commissioning covering safe operation routine checks basic troubleshooting procedures Documentation includes detailed parts manuals schematic diagrams