1. ABERTURA ACIONADA POR PAINPOINT

Gerenciar uma operação de areia e cascalho significa enfrentar desafios persistentes, ineficiências dispendiosas. Você está enfrentando esses desafios comuns?
Material de alimentação inconsistente: Fluctuations in feedstock size and moisture content lead to frequent clogging, unplanned downtime for manual clearing, and suboptimal screening efficiency.
Altos custos de substituição de peças de desgaste: The abrasive nature of aggregate rapidly degrades screen panels, componentes de acionamento, e rolamentos, resulting in excessive spare parts inventory and labor costs for changes.
Separação ineficiente de multas: Inaccurate separation of fines from specification product leads to offspec material, wasted product in settling ponds, and potential revenue loss or customer rejection.
Excessive Vibration & Manutenção: Poorly balanced or lowquality vibrating screens transmit destructive forces to support structures and require constant bolt tightening, bearing checks, and foundational repairs.
Limitações de escalabilidade: Fixedscreen systems struggle to adapt to changing market demands for different aggregate specifications, forcing operators to choose between capital expenditure for new units or lost sales opportunities.

A questão central para os gerentes de fábrica é: how can you increase throughput of inspec material while directly reducing perton operating costs and maintenance hours? The answer lies in the core of your classification process: the industrial vibrating screen.

2. VISÃO GERAL DO PRODUTO: HEAVYDUTY VIBRATING SCREEN FOR SAND AND GRAVEL

Este equipamento é de alta capacidade, linear motion vibrating screen engineered specifically for the rigorous demands of sand and gravel mining. It is designed for the dry or wet screening of crushed stone, cascalho, areia, and recycled concrete aggregates.

Fluxo de Trabalho Operacional:
1. Introdução ao feed: Raw, crushed aggregate is conveyed onto the feed box of the vibrating screen, which evenly distributes material across the full width of the top deck.
2. Estratificação & Separação: A precisely calibrated dualvibrator motor system generates a linear throwing motion. Esta ação estratifica o material, lifting smaller particles to the top layer for contact with the screen media while conveying larger particles forward.
3. Classificação de tamanho: Particles smaller than the deck aperture fall through to subsequent decks or collection chutes. Oversize material travels across each deck surface toward the discharge end.
4. Product Stream Discharge: Correctly sized fractions are discharged from designated chutes—typically as oversize (por exemplo, +1”), middle product (por exemplo, 1/4” x 1”), e multas (por exemplo, areia) —onto separate conveyors for stockpiling.

Escopo de aplicação & Limitações:
Escopo: Ideal for primary sizing after crushing, final product classification (producing washed concrete sand, areia de pedreiro, lascas de cascalho), and dewatering washed aggregates. Effective for materials with a bulk density typical of aggregates (1.51.8 t/m³).
Limitações: Não projetado para pegajoso, highclaycontent materials without prescrubbing; maximum feed size is limited by deck aperture and impact resistance; performance is optimized within specified feed rate and moisture parameters.

3. RECURSOS PRINCIPAIS

Sistema de deck modular | Base Técnica: Boltin panel design with multiple tensioning points | Benefício Operacional: Operators can replace individual worn screen panels in under 30 minutes without dismantling side plates. Different wire cloth or polyurethane panels can be swapped to change product specs rapidly. | Impacto do ROI: Reduz o tempo de inatividade para troca de mídia de tela em até 70% versus designs tradicionais, aumentando o tempo de produção anual disponível.

Conjunto de vibrador duplo contra-rotativo | Base Técnica: Two synchronized eccentric mass motors generating a linear force vector | Benefício Operacional: Fornece consistente, controllable material travel speed and stratification with minimal power consumption. | Impacto do ROI: Os dados de campo mostram um 1525% reduction in energy use per ton screened compared to bruteforce singleshaft designs; prolonga a vida útil do rolamento.

HuckBolted Side Plate Construction | Base Técnica: Aerospacegrade fastener technology creating uniform shear connections | Benefício Operacional: Eliminates fatigue cracking at weld points and prevents structural loosening under constant vibration stress. | Impacto do ROI: Virtually eliminates unscheduled downtime for side plate repair; support structure maintenance costs are reduced significantly.

MultiStage Dust Enclosure | Base Técnica: Sealed skirtboards with layered rubber dust curtains at transfer points | Benefício Operacional: Contains airborne particulate at feed and discharge zones, improving site environmental compliance and operator health conditions.| Impacto do ROI: Mitigates risk of regulatory fines and reduces housekeeping labor around the screening station.

GreaseLubricated Vibrator Bearings | Base Técnica: Rolamentos autocompensadores de rolos de alta capacidade com portas de lubrificação automatizadas | Benefício Operacional: Ensures consistent lubrication coverage under high Gforces, extending critical component life.| Impacto do ROI: Predictable bearing service intervals over 10,000 hours reduce unexpected failures; lowers spare parts inventory cost.

Adjustable Screen Angle Wedges | Base Técnica: Mechanical shim system at screen support springs | Benefício Operacional: Allows onsite tuning of deck inclination (±2 degrees) to optimize retention time for specific materials.| Impacto do ROI: Maximizes screening efficiency across varied deposits without requiring custombuilt units.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Our Vibrating Screen Solution | Vantagem documentada |
| : | : | : | : |
| Tempo de mudança do painel de tela (Baralho completo) | 46 horas (soldado/aparafusado) | 1.5 2 horas (modular tensioned) | Até 60% mais rápido |
| Consumo de energia (kW per ton/hr) ~100tph application| ~0.18 0.22 kW/tph| ~0.14 0.16 kW/tph| ~2025% improvement |
| Vida útil do rolamento (Vibrator Assembly) | ~6,000 8,000 horas| Alvo >10,000 horas| >25% vida mais longa |
| Integridade Estrutural (Side Plate Weld Fatigue)| Common issue after ~2 years| Huckbolt design eliminates weld fatigue path| Nearzero incidence reports |
| Throughput Efficiency (% of spec product)| Varia muito; muitas vezes 95% efficiency on defined feeds| Direct yield increase |

5. ESPECIFICAÇÕES TÉCNICAS

Gama de modelos & Capacidade: Available in sizes from 1.2m x 3m (4’ x 10’) up to 2.4m x 6m (8’ x 20’). Capacidades de rendimento de 50 TPH até mais 800 TPH depending on aperture size and material.
Requisitos de energia: Motores vibratórios duplos da 2 x 7 kW até 2 x 30 kW cada (~15 HP 80 HP total), standard 400V/50Hz or 460V/60Hz threephase.
Especificações de materiais: Main frame constructed from highyield strength steel plate (>355 MPa). Side plates are reinforced with internal ribbing.Decks support polyurethane,tensioned wire cloth,and rubber media options.Skirtboard rubber rated for high abrasion.
Dimensões Físicas & Peso: Example Model VSL1836 (1 .8m x 3 .6eu): Overall length ~5 .5m , width ~2 .4m , height ~1 .8m . Peso aproximado : 4500 kg .
Faixa operacional ambiental: Projetado para temperaturas ambientes de 20°C a +40°C . Enclosures meet IP65 rating for dust/water protection.Bearings rated for continuous operation under heavy dust load conditions .

6 CENÁRIOS DE APLICAÇÃO

[Commercial Sand Producer] Desafio:A producer needed sharper separation between concrete sand (4 malha )and excess fines (<100 malha )to meet strict ASTM C33 specs .Their existing screens were losing up t o15 %of salable sand t othe waste pond .Solution:The installation o fa tailored vibrating screen featuring closelyspaced fine mesh decks anda specialized washwater system integration .Results:Screening efficiency f orthe target fraction improved t o97 %.Recovered an estimated $48 ,000 annually i npreviously lost product while reducing pond dredging frequency .

[Large Aggregate Quarry] Desafio:Frequent plugging o fdeck panels when processing damp ,crusherrun gravel caused daily downtime f ormanual rodding ,custando mais $300 i ndirect labor per occurrence .Solution:A heavyduty vibrating screen equipped with polyurethane selfcleaning panel systems ona steepened final deck angle .Results:Downtime events related t oscreen blinding decreased by approximately90 %.The operation regained an estimated200 hoursof productive time annually .

7 CONSIDERAÇÕES COMERCIAIS

Equipment pricing tiers are structured based on size ,capacidade ,e personalização :
Nível Padrão: Base models with common configurations f ordry sizing applications .
Nível Premium: Includes corrosionresistant coatings ,enhanced dust enclosures ,sistemas de lubrificação automatizados ,and premium brand vibrator motors .
Optional features include spray bar systems f orwet screening ,different types o fscreen media packages ,variable frequency drives f orgreater process control,and integrated weighing /monitoring sensors .
Service packages range from basic commissioning anda parts warranty t opremium multiyear coverage plans that include scheduled inspections,análise de vibração,e envio prioritário de peças .
Financing options are available through partner institutions including equipment loans,fixedrate leases,and rentaltoown programs designed t omatch cash flow profiles typical i nsand&gravel operations .

8 Perguntas frequentes

P:What i sthe lead time f ora standard model vibrating screen ?
UM:L ead times vary by model complexity ;standard units typically ship within12 weeks upon receipt o fa confirmed order .

P:C anyour screens integrate with our existing PLC control system ?
UM:M ost models come standard with hardwired start/stop controls but can be outfittedwith remote I/O modules compatiblewith major PLC brandsfor status monitoringand fault reporting .

P:H owdoes this equipment handle variations i nfeed moisture content ?
UM:The linear motion design aids i nmaterial conveyance evenwith moderate moisture.W efactor i nanticipated moisture levels during sizing recommendations.Forhighmoisture feeds,wespecifically recommend wetscreen configurationswith spray bars .

P:What i sthe expected lifespan o ft hemain structure ?
UM:The huckbolted steel constructionis designed fora minimumservice lifeof15+yearsunder normaloperating conditions when maintained accordingtoschedule.Vibratorsandbearingsareserviceableitems .

P:Doyou offeronsite installation supervision ?
UM:T echnical commissioning supervisionis availableas partofour service packages.This ensures proper mechanical alignment,tensionamento,and initial setupforoptimalperformance .

P:Whatare themost commonwearpartsandtheir typicalservice intervals ?
UM:P rimarywearpartsarescreenpanels(intervaldependentonmaterialabrasiveness),dustcurtainskirtrubber,andvibratormountrubbers.Bearingregreasingintervalsareevery500hours;fullrebuildis>10khours.Tool kitsareavailableforspecificmodels .

P:I sfinancing availableforqualified businesses ?
UM:T hroughour commercialpartnersweofferflexiblefinancing solutionsthatcanincludeupto100 %oftheequipmentcostwith termstailoredtoseasonalcashflowpatternscommonintheindustry