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, o estágio de britagem do núcleo é muitas vezes a fonte de gargalos críticos. Os desafios comuns incluem:
Tempo de inatividade não programado: Mudanças freqüentes de revestimento, component fatigue failures, and bearing seizures halt entire production lines, custando milhares por hora em perda de produção.
Altos custos de manutenção: Reactive repair cycles consume labor hours and spare parts budgets. The cumulative cost of unplanned maintenance often exceeds the equipment's capital expense over five years.
Saída inconsistente & Qualidade do Produto: Wearrelated performance drift leads to offspec product, increasing waste and causing downstream processing issues.
Consumo excessivo de energia: Inefficient crushing chambers and drive systems result in high power draw per ton of processed material, directly impacting operating costs.
Degradação rápida de peças de desgaste: Abrasive or hard feed materials can decimate standard manganese steel, leading to frequent replacement cycles and high consumables expenditure.

Is your primary crushing operation a cost center or a controlled, efficient profit driver? A solução não está apenas em uma máquina, but in an engineered system designed from the ground up for total cost of ownership.

2. VISÃO GERAL DO PRODUTO

O [Nome do fabricante] Primary Jaw Crusher is a heavyduty, stationary crushing machine engineered for the first reduction of hard rock, minério, e concreto de demolição. Its robust cast steel frame and kinematics are optimized for highvolume primary crushing applications where reliability is nonnegotiable.

Fluxo de Trabalho Operacional:
1. Ingestão de ração: Material de alimentação grande (até 80% do britador gape) é carregado no alimentador vibratório do urso pardo (opcional), which bypasses fines to increase capacity.
2. Esmagamento por compressão: Material enters the fixed deeppitched jaw chamber where the oscillating movable jaw exerts immense compressive force against the fixed jaw.
3. Descarga: Crushed material exits through the adjustable closedside setting (CSS) na parte inferior, determinar o tamanho do produto final.
4. Fluxo de Materiais: Product is conveyed to secondary screening or crushing stages.

Escopo de aplicação: Ideal para granito, basalto, minério de ferro, e concreto reciclado em pedreiras, mineração, and largescale construction waste recycling plants.
Limitações: Não é adequado para materiais pegajosos ou plásticos (por exemplo, clayrich ore without preprocessing). For higher reduction ratios in a single pass or softer materials, alternative crusher types may be recommended.

3. RECURSOS PRINCIPAIS

Câmara de britagem profunda & Ângulo de Nip Agressivo | Base Técnica: Optimized kinematics for increased feed acceptance and reduced bridging | Benefício Operacional: Higher capacity per stroke and fewer operator interventions to clear blockages | Impacto do ROI: Sustained throughput rates closer to nameplate capacity over a full shift.

Rolamentos autocompensadores de rolos para serviços pesados | Base Técnica: Larger bearing size with L10 life calculations exceeding industry norms | Benefício Operacional: Withstands peak shock loads from uncrushable material; extended service intervals | Impacto do ROI: Reduces risk of catastrophic bearing failure—a leading cause of extended downtime.

Sistema de ajuste CSS baseado em Wedge | Base Técnica: Mechanically locked wedge system with hydraulic assist option | Benefício Operacional: Quick, precise product size changes without shims; mantém a configuração sob carga | Impacto do ROI: Minimizes adjustment downtime from hours to minutes; garante gradação consistente do produto.

Revestimentos de desgaste BoltOn & Design de moldura modular | Base Técnica: Highstrength alloy steel frame with replaceable liner pockets | Benefício Operacional: Simplified liner replacement; localized wear repair without major frame welding | Impacto do ROI: Cuts liner change labor time by up to 40% versus projetos soldados; protege a integridade dos ativos principais.

PLCIntegrated Overload Protection (Opcional) | Base Técnica: Hydraulic toggle relief system with pressure sensors linked to plant control system | Benefício Operacional: Automatically clears tramp metal or uncrushables; resets without manual intervention | Benefício Operacional: Prevents damage to pitman, rolamentos, e moldura; avoids costly repairs from overload events.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Referência padrão da indústria | Nossa solução primária de britador de mandíbula | Vantagem documentada |
| : | : | : | : |
| Disponibilidade (Tempo de atividade) | 9294% (agendado & não programado) | 96%+ (based on field service logs) | +34% Tempo de atividade |
| Manganese Steel Liner Life (Granito Abrasivo) | ~450.000 MT de rendimento por conjunto | ~550,000 MT throughput per set (verificado) | +22% Vida útil do forro |
| Consumo de Energia por Tonelada Moída| Industry average baseline (100%)| Measured reduction via power monitoring systems| 812% kWh/tonelada |
| Tempo médio entre falhas (MTBF) Componentes Principais| ~7,500 operating hours| >10,000 horário de funcionamento (calculated)| +33% Confiabilidade |

5. ESPECIFICAÇÕES TÉCNICAS

Referência do modelo: JC120
Abertura de alimentação: 1200mm x 850 mm
Tamanho máximo de alimentação: 750mm comprimento da borda
Faixa de configuração do lado fechado: 100mm 250 mm
Faixa de capacidade (@ CSS): 300 650 MTPH (dependente do material)
Requisitos de energia da unidade: 132 Motor Elétrico kW
Peso total (Apenas triturador): ~38,000 kg
Construção da Estrutura Principal: Fabricated/welded steel plate with cast steel reinforcement at highstress points.
Haste & Especificação de rolamento: Forged eccentric shaft with SKF/FAG spherical roller bearings.
Faixa de temperatura operacional: 30°C a +45°C com sistema de lubrificação padrão.
Gerenciamento de poeira: Preparado para conexão do sistema de supressão de poeira seca.

6. CENÁRIOS DE APLICAÇÃO

Pedreiras de Hard Rock – Produção de Agregados de Granito

Desafio: A granite quarry faced severe liner wear on their existing primary crusher every 8 semanas (~320k tons), causing frequent production stoppages for liner changes exceeding 24 horas cada.
Solução: Installation of our JC120 Jaw Crusher with proprietary manganese steel chemistry and chamber profile optimization.
Resultados: Achieved an average liner life extension to 11 semanas (~440k tons). Combined with faster wedgelock changeouts (~16 hours), isso aumentou a disponibilidade anual do britador em aproximadamente 180 horas produtivas.

Construção em Grande Escala & Reciclagem de resíduos de demolição

Desafio: AC&D recycling plant experienced chronic blockages and premature wear when processing reinforced concrete slabs with intermittent rebar mats.
Solução: Deployment of our jaw crusher equipped with the hydraulic toggle overload protection system and heavyduty grizzly feeder to scalp fines.
Resultados: The automated overload system cleared uncrushable rebar tangles within seconds without stopping feed. This reduced unplanned stoppages by over 70% and protected downstream conveyors from metal damage.

7. CONSIDERAÇÕES COMERCIAIS

Our pricing structure is based on a modular approach:
Nível de equipamento básico: Includes core crusher assembly with standard motor drives and lubrication system.
Operational Readiness Tier: Base tier plus integrated motor starter panel(é), prefitted wear liners first set), basic installation toolkit.
Plant Integrated Tier: Includes optional features like hydraulic CSS adjustment system PLC interface kit automatic lubrication system

Optional features include customized wear liner profiles special alloy options for specific abrasion/corrosion environments extended warranty packages covering major components

We offer comprehensive service agreements covering scheduled maintenance inspections parts supply priority access to technical support Financing options including leasetoown capital equipment loans are available through our financial partners

8. Perguntas frequentes

1. What is the compatibility with our existing secondary crushing circuit?
Our engineering team can review your current plant flow sheet Secondary crushers typically require consistent wellsized feed which our jaw’s stable discharge setting provides We ensure discharge dimensions match your downstream equipment’s optimal feed requirements

2. How will this impact our overall plant energy consumption?
Field data shows an average reduction of kWh per ton processed due to efficient drive kinematics lower friction bearings This directly reduces your operating cost per ton

3 Quais são os prazos típicos de instalação?
For standard models lead time ranges from XY weeks upon order confirmation We provide detailed foundation drawings site preparation requirements prior to delivery

4 Você oferece garantias de desempenho?
Yes we provide guaranteed minimum capacity figures based on your specific feed material analysis subject to agreed upon operating conditions These are formalized in our commercial proposal

5 Que treinamento você oferece para nossa equipe de manutenção??
We include comprehensive onsite operational training during commissioning Additionally we offer detailed maintenance manuals video libraries access to technical webinars covering routine service procedures

6 Are spare parts readily available longterm?
We maintain a global network of certified parts depots Critical wear components like liners shafts bearings are stocked under longterm supply agreements ensuring availability throughout the machine’s lifecycle