1. PEMBUKAAN PAINPOINT DRIVEN

Kos operasi yang semakin meningkat dan ketersediaan yang tidak dapat diramalkan menghakis keuntungan litar penghancur utama anda? Key challenges in gyratory crusher operation directly impact your bottom line:
Masa Henti Tidak Berjadual: Bearing failures or mainshaft issues can halt entire processing plants for days, menelan belanja ratusan ribu dalam pengeluaran yang hilang.
Kos Penyelenggaraan Tinggi: Kerap, laborintensive liner changes and component rebuilds consume both budget and critical manpower.
Inconsistent Throughput & Kualiti produk: Worn or poorly designed crushing chambers lead to fluctuating product gradation and reduced capacity, bottlenecking downstream processes.
Penggunaan Tenaga Berlebihan: Inefficient crushing action and highfriction components result in unsustainable power draw per ton of material processed.

Is your operation managing these recurring issues, or is it time for a crusher engineered to deliver reliability, kecekapan, and longterm cost control?

2. GAMBARAN KESELURUHAN PRODUK

The Premium Gyratory Crusher represents the pinnacle of primary crushing technology for hightonnage, perlombongan hardrock dan operasi agregat. Direka untuk berterusan, heavyduty service, it is the optimal solution for the initial reduction of runofmine ore or large quarry stone.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Large dump trucks or loaders deposit feed material directly into the crusher’s robust feed hopper.
2. Tindakan Menghancurkan: The hydraulically supported mainshaft assembly gyrates within a concave crushing chamber, applying compressive force to break material against the chamber walls.
3. Pelepasan produk: Crushed material exits through the discharge opening at the bottom of the chamber, with size controlled by the closedside setting (CSS).

Skop Permohonan & Batasan:
Skop: Ideal for primary crushing applications with feed sizes up to 1500mm, requiring capacities from 2,000 ke atas 10,000 t/h. Suited for abrasive ores (Tembaga, emas, besi) and hard rock aggregates.
Batasan: Not designed for recycled concrete/asphalt or highly plastic/claybound materials. Requires significant capital investment and a stable, asas konkrit bertetulang.

3. CIRI TERAS

Cekung yang dipatenkan & Mantle Profile | Asas Teknikal: Optimized nip angle and crushing chamber geometry | Faedah Operasi: Delivers consistent product gradation with fewer fines generation and reduced risk of bridging | Kesan ROI: Improved downstream mill throughput by 37% and lower liner wear cost per ton.

Sistem Kawalan Pintar Bersepadu | Asas Teknikal: Pemantauan masa nyata cabutan kuasa, tekanan, and CSS via IoT sensors | Faedah Operasi: Enables predictive maintenance alerts and automatic adjustment for optimal performance | Kesan ROI: Mengurangkan masa henti yang tidak dirancang sehingga 30% and optimizes energy consumption.

Reka bentuk tanpa labah-labah & TopService Concept | Asas Teknikal: Eliminates the traditional spider assembly; all service is performed from above | Faedah Operasi: Dramatically reduces liner changeout time from days to hours with smaller crews | Kesan ROI: Increases annual crusher availability by over 200 hours while lowering labor costs.

Forged Alloy Steel Mainshaft | Asas Teknikal: Singlepiece forging from highintegrity alloy steel with enhanced fatigue resistance | Faedah Operasi: Eliminates risk of catastrophic shaft failure under shock loads | Kesan ROI: Avoids multiweek shutdowns and replacement costs exceeding $500k.

Advanced Lube & Sistem hidraulik | Asas Teknikal: Dualcircuit system with automated temperature and contamination control | Faedah Operasi: Ensures positive pressure in bearings yearround, preventing dust ingress and overheating | Kesan ROI: Extends bearing service life by 40%, significantly cutting maintenance spend.

HeavyDuty Base & Pembinaan Rangka | Asas Teknikal: Analisis Unsur Terhingga (FEA)optimized design using highgrade steel plate | Faedah Operasi: Absorbs dynamic loads without stress fatigue, ensuring decades of structural integrity | Kesan ROI: Eliminates lifetime costs associated with base repairs or frame cracking.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Piawaian Industri | Premium Gyratory Crusher Solution | Kelebihan (% penambahbaikan) |
| : | : | : | : |
| Masa Tukar Pelapik (Set Penuh) | 72 96 jam | 96%| +24 mata peratusan |
| Penggunaan Tenaga Khusus (kWj/t) Berbeza mengikut bahan.| Garis dasar = 100%| Industry testing demonstrates a reduction to ~93%| ~7% improvement |
| Hayat Perkhidmatan Galas (L10) Under equivalent conditions.| ~50,000 hours| Field data shows extension to >70,000 jam| +40% penambahbaikan |

5. SPESIFIKASI TEKNIKAL

Julat Kapasiti: Boleh dikonfigurasikan daripada 2,500 ke 12,000 Ton metrik sejam.
Keperluan kuasa: Pandu rating motor dari 450 kW hingga lebih 1 MW; complete system includes dedicated lube and hydraulic power units.
Spesifikasi Bahan: Concaves/mantles available in premium manganese steel alloys; critical structural components fabricated from ASTM A36/A572 steel; mainshaft forged from SAE 4140/4340 aloi.
Dimensi Fizikal: Pembukaan suapan sehingga 1,500mm; total installed height varies by model (lebih kurang. 6m 9m); total operating weight from 250t 600t+.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 40°C hingga +50°C; dustsealed construction meets IP66 standards; suitable for highaltitude installations.

6. SENARIO APLIKASI

Pengembangan Lombong Tembaga Berskala Besar

Cabaran: A planned plant expansion required a primary crusher capable of sustaining >8,000 t/h on highly abrasive porphyry ore while fitting within tight space constraints of an existing pit layout.
Penyelesaian: Installation of a single Premium Gyratory Crusher with a compact "tanpa labah-labah" design profile.
Keputusan: Mencapai daya pengeluaran yang berterusan sebanyak 8,400 t/h with product P80 consistently below required spec. Liner life exceeded projections by 15%, contributing to a calculated payback period under three years versus alternative solutions.

HighProduction Granite Quarry

Cabaran: Frequent weekend liner changes were creating production bottlenecks. Unpredictable bearing temperatures led to two unscheduled stoppages in one year.
Penyelesaian: Implementation of a midrange Premium Gyratory Crusher featuring the TopService Concept and Intelligent Control System.
Keputusan:Liner change time reduced from three shifts to one shift (8 jam). The monitoring system provided early warning on lube system health, preventing a potential bearing failure. Annual availability increased to 96.8%.

7. PERTIMBANGAN KOMERSIL

Premium Gyratory Crushers are offered in three primary tiers based on size and duty:
1. Siri Tugas Berat: For megamines (>100k tpd), featuring maximum redundancy components. Pricing reflects custom engineering.
2. Siri Persembahan: For midtolarge scale mines and major quarries (20k100k tpd). Offers balanced capital/operating cost efficiency.
3. Configured Series: Preengineered models for specific aggregate duties (<15k tpd), offering shorter lead times.

Ciri Pilihan & Pakej:

Advanced Wear Monitoring System (radarbased)
Automated Setting Adjustment Package
Extended Warranty on drivetrain components (up to an additional two years)
Penyeliaan pentauliahan di tapak & program latihan pengendali

Service Agreements: Tailored plans are available covering scheduled inspections, preventive maintenance kits, diskaun bahagian (up to15%),and guaranteed emergency response times.

Pilihan Pembiayaan: Flexible commercial structures include capital lease agreements,turnkey project financing,and rentaltoown programs,directly supporting your CAPEX planning cycles.

8.Soalan Lazim

S1:What level of site preparation is required comparedto other primary crushers?
A:The foundation load specifications are comparableto other gyratory crushers of similar capacity.The TopService design often reduces overhead crane requirements,sometimes simplifying support structure design.

S2:What is the expected operational lifespanof the main structural components?
A:The base,bingkai,and mainshaft housing are engineeredfor a minimumdesign lifeof30years under normal operating conditions when maintained per our guidelines.This is validatedby FEAand historical datafrom earliergeneration units stillin operation after40+years.

Q3.How doesyour intelligent control system integratewith our existing plant DCS/SCADA?
A:The crusher's control system communicatesvia standard industrial protocols(OPC UA.Modbus TCP/IP).Our engineers will workwith your teamto define the data pointsfor integrationensuring key performance metricsare visibleon your central dashboards without requiring proprietary softwareon your end

Q4.What arethe typical lead timesfor major wear parts like concavesand mantles?
A:Leveraging global warehousingstrategieswe maintaintarget stock levelsfor critical wear partson our most common models.Aimto ship standard profile linerswithin46weeksfrom order confirmation.Emergency expedite optionsare available

Q5.Do you offerperformance guarantees?
A Yes we provideguaranteesfor rated capacitypower consumptionunder defined feed conditionsand mechanical availabilitysubjectto terms outlinedin our commercial agreement Theseare backedby decadesof field applicationdata