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 circuito de britagem do núcleo é frequentemente a fonte de gargalos críticos. Os desafios comuns incluem:
Tempo de inatividade não programado: Frequent liner changes and unexpected mechanical failures halt your entire processing line, custando milhares por hora em perda de produção.
Alto consumo de peças de desgaste: Aggressive or abrasive feed material leads to premature wear on mantles, côncavo, e placas de mandíbula, creating volatile and recurring operational expenses.
Gradação inconsistente do produto: Fluctuations in feed size or hardness result in offspec product, leading to recrushing cycles, energia desperdiçada, e clientes insatisfeitos.
Rising Energy Costs: Inefficient crushing chambers and outdated drive systems draw excessive power without maximizing throughput per kilowatthour.
Limited Flexibility: Fixed configurations cannot adapt to changing feed materials or market demands for different aggregate sizes without significant manual adjustment and time.

Is your primary crushing station a cost center or a controlled, efficient asset? A solução não está apenas em uma máquina, mas em um sistema projetado para o custo total de propriedade.

2. VISÃO GERAL DO PRODUTO: HYDRAULIC CONE CRUSHER

The modern hydraulic cone crusher is a secondary/tertiary reduction machine engineered for highvolume production of consistent, agregado cúbico. Its operational workflow is centered on continuous compression crushing:
1. Introdução ao feed: Sized feed from a primary jaw crusher is directed into the top of the crushing chamber.
2. Compressive Reduction: The rotating mantle gyrates within a stationary concave liner, repeatedly compressing rock against rock until it fractures to size.
3. Dynamic Adjustment: A hydraulic system allows for realtime adjustment of the crusher’s closedside setting (CSS) during operation to maintain product spec.
4. Descarga & Limpeza: Crushed material falls by gravity to the discharge point. An automatic hydraulic clearing system rapidly releases the chamber to pass tramp metal or uncrushable material, minimizing stall risk.

Escopo de aplicação: Ideal para materiais duros e abrasivos (granito, basalto, quartzito) in stationary aggregate plants and large mining operations. Best suited for feed sizes typically under 250mm.
Limitação de chave: Not designed for primary crushing of runofquarry material or handling significant plastic/clay content without prescreening.

3. RECURSOS PRINCIPAIS

Sistema de controle hidroset | Base Técnica: Hydraulic pressure regulation of the main shaft position | Benefício Operacional: Allows operators to adjust crusher CSS remotely in under one minute for product gradation changes or wear compensation without stopping the crusher. | Impacto do ROI: Reduces nonproductive adjustment time by up to 80% em comparação com sistemas de calços manuais, aumentando a disponibilidade da planta.

Patented Crushing Chamber Design | Base Técnica: Computeroptimized geometry for interparticle rockonrock crushing | Benefício Operacional: Promotes a denser particle bed where rocks crush each other, not just the liners; produces superior cubicity while distributing wear more evenly. | Impacto do ROI: Can increase liner life by 1530% dependendo da abrasividade do material, reduzindo diretamente o custo para peças de desgaste.

Automated Overload Protection | Base Técnica: Pressure sensors monitoring main shaft hydraulic pressure | Benefício Operacional: Instantly detects an overload condition (por exemplo, metal vagabundo) and triggers the clearing cycle automatically, protecting the mechanical components from catastrophic damage. | Impacto do ROI: Prevents expensive repairs to head, shaft, and eccentric assembly; field data shows a reduction in major failure events by over 90%.

DualActing Hydraulic Cylinders | Base Técnica: Hydraulic cylinders that provide both upward force for setting adjustment and downward force for clearing | Benefício Operacional: Delivers faster, more powerful clearing strokes compared to springrelease systems, ensuring reliable recovery from cavity packing events. | Impacto do ROI: Minimizes downtime associated with digging out a stalled crusher—a process that can take hours.

Sistema de lubrificação centralizado | Base Técnica: Automated singlepoint lubricant delivery to key bearings and gears | Benefício Operacional: Ensures correct lubrication intervals and volumes without manual intervention at multiple grease points located in hazardous areas. | Impacto do ROI: Extends bearing service life by preventing under/overgreasing; reduces required maintenance labor hours per week.

4. VANTAGENS COMPETITIVAS

| Métrica de desempenho | Padrão da Indústria (Mechanical Spring Cone) | Hydraulic Cone Crusher Solution | Vantagem |
| : | : | : | : |
| Tempo de ajuste CSS (During Operation) | 24 Horas (Calço Manual) | 95% Mais rápido |
| Tramp Iron Clearing & Recovery Time| 3060 Minutos (Manual) / Variable Spring Return| 90% Mais rápido |
| Liner Life Consistency (Granito Abrasivo)| High Variability (±20%)| More Predictable Wear Profile (±5%)| Improved Planning & Inventory Control|
| Eficiência Energética (kWh/tonelada)| Linha de base| Até 10% Improvement via Optimized Chamber| Direct Power Cost Savings|
| Formato do produto (% Cúbico)| Varies with Wear & Alimentar| Consistente >85% Cubicity Maintained| Higher Product Value & Less Recirculation|

5. ESPECIFICAÇÕES TÉCNICAS

Capacidade da gama de modelos: 100 – 900 toneladas métricas por hora (dependent on chamber selection & CSS).
Requisito de potência do motor: 150 quilowatts – 600 kW (200 HP – 800 HP), supplied at 50/60 Hz as required.
Tamanho máximo de alimentação: Accepts feed up to 85% of inlet opening dimension; typical max feed ≤250mm.
Especificações de materiais: Highstrength cast steel main frame; manganese steel wearing liners; eixo principal de liga de aço forjado.
Dimensões Físicas (Typical MidRange Model): Aprox.. Comprimento: 4m x Largura: 3m x Altura: 3eu (excluindo motor & passarelas).
Faixa operacional ambiental: Designed for ambient temperatures from 20°C to +45°C with appropriate lubricants. Vedações contra poeira classificadas para condições padrão de pedreira.

6. CENÁRIOS DE APLICAÇÃO

Projeto de Expansão de Pedreira de Granito

Desafio: A large granite quarry needed to increase secondary crushing capacity by 40% but had limited physical footprint for expansion and needed stricter control over chip product gradation for asphalt mixes.
Solução: Implementation of two highcapacity hydraulic cone crushers with automated setting regulation replaced three older mechanical units.
Resultados: Conseguiu um 45% throughput increase within the existing footprint while reducing energy consumption per ton by 8%. Product gradation consistency improved such that recrushing of offspec material fell by over 70%.

Portable Contract Crushing Operation

Desafio: A contracting firm faced excessive mobilization time and high liner costs when moving between sites with varying rock hardness (limestone to hard gravel).
Solução: Deployment of a tracked plant featuring a hydraulic cone crusher with quickchange liner kits and remote CSS control.
Resultados: Sitetosite setup time reduced by one full working day due to rapid calibration. The ability to finetune CSS daily optimized liner life across different materials, extending average campaigns by an estimated 25%.

7. CONSIDERAÇÕES COMERCIAIS

Hydraulic cone crushers are offered across several investment tiers:
Nível de serviço padrão: Para consistente, materiais moderadamente abrasivos como calcário; focuses on core reliability with essential automation features.
Serviço Pesado / Nível Premium: For highly abrasive materials (armadilha de rocha, granito); includes enhanced wear packages, advanced monitoring sensors as standard.
Modular/SkidMounted Tier: Preassembled units with integrated lubrication and hydraulic systems reduce installation time and cost by up to onethird.

Optional features include advanced telemetry packages for remote performance monitoring automated wear compensation software based on amp draw trends

Service packages range from basic preventive maintenance plans up through comprehensive guaranteed uptime contracts which include planned parts replacement

Financing options are available including equipment leasing capital loans through partner institutions

Perguntas frequentes

1.Q What level of operator training is required versus our older mechanical spring cone crushers?
A Operators require specific training on the hydraulic control system interface which typically takes two days However overall operation is simplified as many critical functions like setting adjustment are automated reducing reliance on manual skill

2.Q Can this technology be integrated with our existing primary jaw crusher screening plant?
A Yes these units are engineered as modular components Standard discharge conveyor dimensions electrical interfaces allow integration into most existing circuits Plant layout review is recommended during quotation

3.Q How does automation impact longterm maintenance costs?
A While initial component complexity may be higher predictive diagnostics prevent catastrophic failures Scheduled maintenance becomes more predictable Industry data indicates total maintenance costs over years can be lower due avoided major breakdowns

4.Q What financing structures are commonly used?
A Common structures include capital equipment loans operating leases master rental agreements Purchase options often exist at lease end We can provide net present cost analysis comparing models

5.Q Are there application limits where this technology is not advised?
A This technology is not optimal as primary unit processing unscreened runofquarry material with high fines clay content which can cause packing It excels as secondary tertiary unit receiving presized feed