1. ABERTURA ACIONADA POR PAINPOINT

Os custos operacionais crescentes e o tempo de inatividade imprevisível estão corroendo suas margens de produção agregadas? Para gerentes de fábrica e empreiteiros de engenharia, the core of these challenges often originates at the primary crushing stage. Os pontos problemáticos comuns incluem:

Tempo de inatividade não programado: Frequent mechanical failures and lengthy component changes halt your entire processing line, custando milhares por hora em perda de produção e mão de obra.
Custos excessivos de desgaste: Abrasive feed material rapidly degrades crusher liners and wear parts, leading to high consumable expenses and frequent maintenance windows.
Saída inconsistente & Formato do produto: Variable feed size or hardness results in poor yield control and substandard product gradation, reducing the value of your final aggregate.
Alto consumo de energia: Inefficient crushing chambers and drives consume excessive power, making energy one of your largest, most volatile operational costs.
Segurança & 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. VISÃO GERAL DO PRODUTO: COMMERCIAL JAW CRUSHER

A commercial jaw crusher is a heavyduty, compressiontype primary crusher designed to reduce large, quarried rock (até 1,5 m de tamanho) into manageable feed for secondary processing. Its robust design is built for continuous, hightonnage operation in stationary plants or largescale mobile setups.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Large dump trucks deposit runofquarry rock into the vibratory grizzly feeder, que ignora o material subdimensionado e direciona o superdimensionado para o britador.
2. Esmagamento por compressão: 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. Ajuste de configuração de descarga: 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. Transporte de Produto: Crushed material is discharged onto a main conveyor belt for transport to the next stage of screening or secondary crushing.

Escopo de aplicação & Limitações:
Escopo: Ideal for primary reduction of hard abrasive materials (granito, basalto, quartzito), pedra semidura (calcário, arenito), e concreto/asfalto reciclado.
Limitações: Não é adequado para pegajoso, plasticclay materials that may cause chamber packing. Maximum reduction ratios are typically 6:1 para 8:1, making secondary crushing necessary for most fine aggregate specifications.

3. RECURSOS PRINCIPAIS

Câmara de britagem profunda & Ângulo de Nip Agressivo | Base Técnica: Kinematic geometry of swing jaw motion | Benefício Operacional: Enables higher throughput capacity per stroke and effective grip on slabby material | Impacto do ROI: Increases potential revenue output by 1015% within same machine footprint

HeavyDuty Fabricated Steel Frame with StressRelieving | Base Técnica: Análise de Elementos Finitos (FEA) design otimizado com tratamento térmico pós-soldagem | Benefício Operacional: Provides exceptional durability against shock loads and fatigue over a 20+ vida útil do ano | Impacto do ROI: Elimina o risco de falha catastrófica da estrutura; protects longterm capital asset value

Ajuste de alternância hidráulica & Sistema de compensação | Base Técnica: Cilindros hidráulicos de dupla ação substituem placas articuladas mecânicas tradicionais | Benefício Operacional: Allows remote adjustment of CSS for product control and automatic clearing of chamber blockages in minutes | Impacto do ROI: Reduces downtime for settings changes by over 80% versus manual systems

QuikChange Jaw Die Wedge System | Base Técnica: Mechanically locked wedge design for liner retention | Benefício Operacional: Permite segurança, fast replacement of manganese jaw dies without backing material or resin pouring | Impacto do ROI: Cuts liner changeout time by half, aumentando a disponibilidade da planta

Volantes de alta inércia & Eixo excêntrico robusto | Base Técnica: Balanced rotational mass energy storage | Benefício Operacional: Smoothes peak power demands, maintains momentum under load fluctuations for consistent crushing action | Impacto do ROI: Reduces cyclical stress on drive motor, reduzindo os custos de energia 57% and extending component life

Supressão de poeira integrada & Water Spray System | Base Técnica: Manifold with nozzles targeting feed entry and discharge points | Benefício Operacional: Effectively controls airborne particulate at source for compliance with site health regulations | Impacto do ROI: Mitigates risk of regulatory fines and reduces housekeeping labor

Sistema de lubrificação automatizado centralizado | Base Técnica: Programmable pump delivering precise grease volume to all key bearings | Benefício Operacional: Garante a lubrificação ideal do rolamento sem intervenção manual durante a operação | Impacto do ROI: Prevents premature bearing failure; dados de campo mostram um 40% extension in bearing service intervals.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Média) | Nossa solução para britador de mandíbula | Vantagem (% Melhoria) |
| : | : | : | : |
| Tempo de troca do revestimento (Morre a mandíbula) | 1224 horas (mechanical/welded) | 68 horas (QuikChange Wedge) | ~50% mais rápido |
| Disponibilidade (Tempo de atividade %) Sobre 12 Meses| ~8590% (including adjustments/stoppages)| >94% (média de campo documentada) |>45 pontos percentuais |
| Consumo Específico de Energia (kWh/tonelada)| Varia; linha de base = 100%| Redução média documentada para ~93%| ~7% mais eficiente |
| Use matrizes de vida útil da mandíbula (Granito Abrasivo)| Based on standard manganese grade| Upgraded Manganese Steel Alloy available| +1520% vida prolongada |

5. ESPECIFICAÇÕES TÉCNICAS

Designação do modelo: JC1500HD
Abertura de alimentação: 59” x 47” (1500mm x 1200mm)
Tamanho máximo de alimentação: Up to 47” (1200milímetros) comprimento da borda
Faixa de configuração do lado fechado: 6”-12” (150mm – 300 mm)
Faixa de capacidade (@ CSS): 550 – 950 STPH (500 – 860 MTPH), depende do tipo de material & gradação de alimentação.
Requisitos de energia da unidade: Final Nível IV / Stage V compliant dieselelectric or direct electric drive options available.
Crusher Drive Power: Até 400 HP /300 motor elétrico kW.
Peso total (Apenas triturador): Approximately ~125,000 lbs (~56,700 kg).
Principais especificações de materiais: Main frame fabricated highyield strength steel; Jaw dies premium manganese steel alloy; Eccentric shaft forged alloy steel; Rolamentos tipo rolo esférico.
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +45°C (4°F a +113°F). Enclosed lubrication system with heating/cooling options available.

6. CENÁRIOS DE APLICAÇÃO

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. CONSIDERAÇÕES COMERCIAIS

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

Níveis de preços:
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)

Pacotes de serviços:
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. Perguntas frequentes

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