1. PEMBUKAAN PAINPOINT DRIVEN

Are unplanned breakdowns and inconsistent output crippling your aggregate production schedule? Untuk pengurus loji dan kontraktor kejuruteraan, the reliability of core crushing equipment directly dictates profitability. Common operational challenges with primary stone crushers include:

Masa Henti Berlebihan untuk Penyelenggaraan: Frequent liner changes and component wear lead to production halts, costing thousands per hour in lost output and labor.
Penggredan Produk Tidak Dapat Diramalkan: Inconsistent feed size or wearrelated performance drift results in offspec aggregate, forcing recrushing or product downgrades.
Kos Operasi yang Tinggi: Rising energy consumption per ton and the recurring expense of premium wear parts erode project margins.
Vulnerability to Tramp Metal & Uncrushables: Unplanned incidents with contaminant materials can cause catastrophic damage, resulting in lengthy, expensive repairs.

Is your current primary crusher a constant source of operational risk and cost overrun? The solution lies not just in a machine, but in an engineered system built for predictable performance and total cost of ownership.

2. GAMBARAN KESELURUHAN PRODUK

The Kursus rahang is a robust, heavyduty primary crushing machine designed for the first stage of size reduction in quarrying, perlombongan, and demolition recycling applications. Its core function is to compressively fracture large feed material (typically runofmine or runofquarry rock) into manageable sizes for secondary processing.

Aliran Kerja Operasi:
1. Pengambilan Suapan: Bahan mentah yang besar (hingga 8090% of crusher gape) is loaded into the vibrating grizzly feeder ahead of the crusher.
2. Penghancuran Mampatan: Material enters the fixed and movable jaw plates. The eccentric shaft drives the movable jaw in an elliptical motion, applying immense compressive force to the rock.
3. Pelepasan: Crushed material exits through the adjustable discharge opening at the bottom, with size determined by the closedside setting (CSS).

Skop Permohonan & Batasan:
Skop: Sesuai untuk keras, bahan kasar (granit, basalt, Sungai kerikil). Suited for stationary plants and mobile tracked setups. Handles a wide variety of feed sizes.
Batasan: Not optimal for soft, nonabrasive stone where other crusher types may be more efficient. Requires consistent feed control to prevent choking. Output tends to be more elongated compared to cone crushers.

3. CIRI TERAS

Ruang Penghancuran Dalam & Kinematik yang dioptimumkan | Asas Teknikal: Increased nip angle and longer crushing stroke | Faedah Operasi: Higher capacity per stroke and improved reduction ratio from feed to product | Kesan ROI: Greater throughput per operating hour reduces unit cost per ton.

HeavyDuty Fabricated Frame with StressRelieved Construction | Asas Teknikal: Analisis Unsur Terhingga (FEA) reka bentuk yang dioptimumkan dengan rawatan haba postweld | Faedah Operasi: Exceptional structural integrity withstands high cyclic loads, preventing frame fatigue cracks | Kesan ROI: Memanjangkan hayat perkhidmatan melebihi 20+ years under severe duty, melindungi pelaburan modal.

Hydraulic Toggle Adjustment & Clearing System | Asas Teknikal: Replaceable hydraulic cylinder for toggle plate tensioning and overload release | Faedah Operasi: Enables quick CSS adjustment for product control and automatic tramp iron release to protect from uncrushables | Kesan ROI: Minimizes downtime for settings changes; prevents costly damage from stall events.

HighPerformance Bearing Assembly with Labyrinth Seals | Asas Teknikal: Oversized spherical roller bearings on a forged eccentric shaft with multistage sealing | Faedah Operasi: Sustains high load capacities with minimal heat generation; effectively excludes dust and contaminants | Kesan ROI: Drastically extends bearing service intervals (>10,000 jam), reducing lubrication costs and failure risk.

BoltOn Wear Liners with Wedge Lock System | Asas Teknikal: Reversible manganese steel jaw dies secured by mechanical wedges | Faedah Operasi: Allows for rotation/ replacement of wear parts without backing material; reduces changeout time by up to 50% | Kesan ROI: Lowers maintenance labor costs and increases equipment availability.

Pangkalan Motor Bersepadu & Belt Drive Guarding | Asas Teknikal: Plat asas bersatu untuk penghancur, motor, and sheaves with full perimeter guarding | Faedah Operasi: Simplifies alignment during installation; ensures operator safety compliant with global standards (ISO/OSHA) | Kesan ROI: Reduces installation time/cost; mitigates site safety liability.

4. KELEBIHAN KOMPETITIF

| Metrik Prestasi | Penanda Aras Piawaian Industri | Our Jaw Crusher Solution | Kelebihan Berdokumen |
| : | : | : | : |
| Adanya (Masa aktif) | 9294% (Dijadualkan & Unscheduled) | >96% Ketersediaan Tahunan| +3% Penambahbaikan |
| Pakai Kehidupan (Jaw Dies Abrasive Rock) | 120,000 150,000 tan setiap set| 180,000 220,000 tan setiap set| +40% Penambahbaikan |
| Penggunaan tenaga (kWj/tan) Berbeza mengikut bahan| Garis dasar = 100%| Average reduction to ~90% of baseline| ~10% Improvement |
| Tramp Iron Recovery Time (Full Cycle)| Manual clearing can exceed 24 jam| Hydraulic clearing system completes cycle in <15 minit| ~90% Reduction |

5. SPESIFIKASI TEKNIKAL

Kapasiti Julat Model: daripada 150 TPH kepada 1,200 Tph (varies based on feed material & CSS).
Saiz Pembukaan Suapan: Ranging from 800mm x 550mm up to 1500mm x 1300mm.
Keperluan kuasa: Driven by electric motors from 75 kW sehingga 250 kw; voltage as per client specification (mis., 400V/50Hz atau 480V/60Hz).
Spesifikasi Bahan: Main frame – Highstrength steel plate (S355J2). Jaw dies – Premium Manganese Steel (1418%). Shaft – Forged Alloy Steel (42CrMo4).
Dimensi Fizikal & Berat: Approximate weights from 15 tan ke 70 tan; detailed layout drawings provided for foundation planning.
Julat Operasi Persekitaran: Direka untuk suhu ambien dari 20°C hingga +45°C. Dust seals effective in conditions up to IP65 equivalent protection.

6. SENARIO APLIKASI

Stesen Penghancuran Utama Kuari Granit

Cabaran: A large granite quarry faced frequent downtime due to premature jaw die wear (~100k tons/set) and struggled with maintaining consistent CSS manually as operators avoided timeconsuming adjustments.
Penyelesaian: Implementation of our heavyduty jaw crusher featuring extendedlife manganese jaws and a hydraulic toggle adjustment system.
Keputusan: Wear life extended to over 190k tons per set. CSS adjustments are now performed during scheduled breaks in <10 minit. Annual throughput increased by an estimated 8%, while liner costs decreased by 35%.

Pembinaan Bandar & Kitar Semula Sisa Perobohan

Cabaran: A C&D recycling plant needed a primary crusher resilient to occasional tramp metal (rebar, steel beams) that could handle variable concrete feed without constant fear of catastrophic failure.
Penyelesaian: Installation of our jaw crusher equipped with an automatic hydraulic overload protection system.
Keputusan: The system has successfully performed multiple automatic releases on uncrushable metal objects over two years without damage. This has eliminated related major repair events (~$25k average), ensuring continuous processing contracts are met.

7. PERTIMBANGAN KOMERSIL

Our jaw crushers are offered in three primary tiers:
1. Siri Tugas Standard: For consistent feed of moderately abrasive materials; competitive capital cost focus.
2. Siri Tugas Berat (Most Common): Includes all features listed above; optimized for maximum lifetime value in demanding quarry applications.
3. SuperDuty Series: Enhanced components for extreme abrasiveness or specific highcapacity requirements.

Optional features include automated lubrication systems integrated weighing sensors monitoring CSS wear metal detection systems on feed conveyor

Service packages range from basic commissioning supervision comprehensive multiyear planned maintenance agreements including parts kits regular inspections

Financing options available through partner institutions include straight equipment lease operating lease structures project financing tailored largescale greenfield developments

Soalan Lazim

Q1 What is required foundation preparation this jaw crusher?
A1 Detailed foundation drawings including all static dynamic loads are provided Our engineering team can review your civil plans ensure compatibility minimizing installation delays

Q2 How does this unit integrate existing secondary tertiary crushing screening circuit?
A2 We provide detailed interface data on recommended product conveyor specifications ensure optimal chokefed condition secondary cone crushers Our team can audit your flow sheet recommend adjustments maximize overall plant efficiency

Q3 What typical delivery lead time key spare parts?
A3 Critical wear parts jaw dies toggle plates shafts are held regional stock centers targeting shipment within 72 hours Nonstock items follow standard manufacturing schedule which our sales team provides transparency upon order

Q4 Are performance guarantees offered?
A4 Yes We offer guaranteed capacity based agreed upon material characteristics test reports Guarantees also cover mechanical components against defects specified period subject proper operation maintenance as outlined manual

Q5 Can older existing crushers retrofitted your improved components hydraulic toggle system?
A5 In many cases yes Retrofit kits available popular legacy models extend their life improve functionality feasibility study requires model serial number assessment