1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Растущие эксплуатационные расходы и непредсказуемая доступность снижают прибыльность вашего первичного контура дробления? Для руководителей заводов и инженерных подрядчиков, гирационная дробилка является критически важным активом, где отказы имеют экспоненциальные последствия. Общие проблемы включают в себя:
Внеплановые простои: Bearing failures or mainshaft issues can halt entire processing lines for days, costing hundreds of thousands in lost production.
Высокие затраты на техническое обслуживание: Частый, laborintensive liner changes and component wear directly impact maintenance budgets and manpower allocation.
Непостоянная пропускная способность: Poor feed distribution or worn crushing surfaces lead to product gradation fluctuations, downstream bottlenecks, and reduced overall plant efficiency.
Энергетическая неэффективность: Older or poorly optimized designs consume excessive power per ton of processed material, a fixed cost that directly affects operating margins.

How do you achieve higher throughput with greater reliability while controlling total cost of ownership? The answer lies in a purposeengineered gyratory crusher from a dedicated private label manufacturer focused on R&Ddriven performance.

2. ОБЗОР ПРОДУКТА

This product is a highcapacity primary gyratory crusher, engineered for private label partners who require robust, applicationspecific solutions for largescale mining and aggregate operations. Its design focuses on delivering maximum availability and optimal reduction ratios for hard, abrasive ores and rock.

Операционный рабочий процесс:
1. Приемка корма: Oversize material from haul trucks or loaders is directed into the steepsided feed hopper.
2. Сокрушительное действие: The hydraulically adjusted mainshaft assembly gyrates within the concave liners, applying compressive force to reduce material size.
3. Увольнять: Crushed product exits through the discharge opening at the bottom of the crushing chamber, with size controlled by the hydraulic setting adjustment system.
4. Погрузочно-разгрузочные работы: The product is conveyed to downstream secondary crushing or screening circuits.

Область применения & Ограничения:
Объем: Идеально подходит для крупнотоннажных перевозок (2,000+ ТПХ) primary crushing applications in metal ore mines (медь, железо, золото), large quarries producing aggregate, and major construction projects requiring onsite primary reduction.
Ограничения: Не подходит для малотоннажных операций. (<500 ТПХ), recycling applications with high tramp metal content without extensive protection systems, or portable/mobile plant installations due to size and weight.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Запатентованный вогнутый профиль | Техническая основа: Optimized crushing chamber geometry based on discrete element modeling (немецкая марка) | Операционная выгода: Delivers a consistent chokefed crushing action for uniform wear and stable product gradation | Воздействие на рентабельность инвестиций: Extends liner life by an average of 1520%, reducing liner cost per ton and changeout frequency

Integrated Smart Bearing System | Техническая основа: Multisensor monitoring of bearing temperature, вибрация, and lubrication pressure | Операционная выгода: Provides early warning diagnostics to prevent catastrophic bearing failure | Воздействие на рентабельность инвестиций: Eliminates unplanned downtime events related to bearing issues, protecting millions in potential production losses

Hydraulic Setting & Защита от перегрузки | Техническая основа: Dualfunction hydraulic cylinder for precise CSS adjustment and automatic relief under uncrushable material | Операционная выгода: Allows operators to adjust product size remotely and protects the crusher from mechanical damage | Воздействие на рентабельность инвестиций: Reduces setting time by 70% compared to manual systems and prevents costly repairs from tramp steel events

Философия дизайна TopService | Техническая основа: All routine service tasks (изменения вкладыша, spider arm refurbishment) accessible from above | Операционная выгода: Eliminates the need for personnel to work beneath suspended components or dismantle the crusher structure | Воздействие на рентабельность инвестиций: Сокращает время планового технического обслуживания до 50%, enhancing plant availability

Прямой привод & Torque Limiter System | Техническая основа: Lowspeed synchronous motor coupled via an air clutch with torque limiter | Операционная выгода: Provides smooth startup under load capability and protects drive train from shock loads | Воздействие на рентабельность инвестиций: Reduces electrical stress during startup by 60% versus VFDonly solutions, lowering peak demand charges

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Стандартный эталон отрасли | This Gyratory Crusher Solution | Документированное преимущество |
| : | : | : | : |
| Механическая доступность (Цель) | 92 94% | >96% (Contractual Target) | +24 процентные пункты |
| Лайнер Жизнь (Абразивная руда) | ~6 месяцев (Варьируется) | 78 Месяцы (Average Field Data)| +1520% Улучшение |
| Удельное энергопотребление (кВтч/т) ~0,8 1.2 kWh/t ~0.7 0.9 kWh/t ~1015% Improvement |
| Время настройки CSS <4 Часы 75% Быстрее |
| Общая стоимость владения (5Year Projection)| Baseline Model Averages +1218% Более низкая совокупная стоимость владения |

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Диапазон мощности: Настраивается из 2,000 слишком 10,000 метрические тонны в час (т/ч), depending on model size and feed material.
Мощность двигателя: Стандартные приводы от 450 кВт до 1 МВ+; engineered to client specifications.
Кормовое отверстие: Размеры зияния от 1,300 мм до 1,800 mm available.
Характеристики материала:
Основная рама & Head Center: Highstrength cast steel alloy.
Вогнутый & Mantle Liners: Марганцевые стальные сплавы; optional premium alloys for specific abrasion/impact conditions available.
Главный вал: Forged alloy steel with precision machining.
Физические размеры & Масса: Significant footprint; exact dimensions provided per model. Approximate installed weights range from 350 тонн до более 800 тонны.
Экологический рабочий диапазон: Рассчитан на температуру окружающей среды от 40°C до +50°C с соответствующими системами смазки.; стандарт пылезащиты.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

Расширение медного рудника

Challenge A Tier1 copper operation needed to increase primary circuit throughput by 25% without expanding their truck fleet or dump pocket footprint. Their existing crusher was a bottleneck with frequent linerrelated downtime.

Solution Implementation of our largestcapacity gyratory crusher model featuring the patented concave profile for higher reduction ratio in a single pass.

Результаты. Пропускная способность увеличилась на 28%. Liner life improved from an average of approximately five months to sixandahalf months under identical ore conditions. Annual production targets were met three weeks ahead of schedule following commissioning.

Granite Quarry Primary Circuit Upgrade

Challenge A major aggregate producer faced volatile energy costs and high maintenance expenses on their aging primary crusher. Product consistency was also an issue affecting their premium product lines.

Solution A midrange gyratory crusher was selected with a focus on energy efficiency via direct drive optimization and superior chamber geometry.

Results Specific energy consumption decreased by an average of approximately twelve percent yearoveryear despite increased operating hours.The consistent gradation reduced recirculating load in secondary circuits by nearly eighteen percent.The quarry reported meeting tighter specification bands more reliably for key customer contracts.

7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Our private label manufacturing model provides flexible commercial pathways tailored for OEMs and largescale endusers:

Ценовые уровни: Structured around core model size (Загрузочное отверстие), drive power rating,and level of standard automation.Control system integration is offered as either basic local control or full PLC/SCADA interface packages.

Дополнительные функции & Обновления: Key options include advanced predictive maintenance sensor suites,dust suppression ring kits,material level monitoring systems,and proprietary wearresistant alloy packages for liners.

Пакеты услуг: Available service agreements range from basic technical documentation support through comprehensive multiyear performance contracts covering planned maintenance,инспекции,and guaranteed parts availability with defined response times.

Варианты финансирования: We work with established financial partners ableto structure leasing arrangements,tailored payment plans aligned with project milestones,and other financing solutions upon request.This facilitates capital budget planningfor our clients' projects.

8.Часто задаваемые вопросы

вопрос:What levelof engineering supportis provided duringthe integrationof thisgyratorycrusherintoan existingplantlayout?
A OurR&Dandapplicationengineeringteamsworkdirectlywithyourprojectengineersto reviewfoundationdesignsfeedanddischargearrangementsandinterfacingwithexistingconveyorsystemsWe providecomprehensivelayoutdrawingsforcesandloaddatato ensureproperintegration

вопрос:Canyourcrushersbeconfiguredtooperatewithautomationsystemssuppliedbyothervendors?
A YesThecorecrushercontrolsystemisdesignedwithstandardindustrialcommunicationprotocols(egOPCUAProfibusEthernet/IP)allowingforseamlessdataintegrationintoplantwideprocesscontrolandmonitoringsystems

вопрос:Whatisthetypicalleadtimefromordertocommissioningforastandardmodel?
A Leadtimesvarybymodelsizeandcustomizationbutgenerallyrangefrom12to18monthsforcompletecrushersupplyincludingengineeringmanufacturingfactorytestinganddeliverySchedulesareconfirmeduponprojectkickoff

вопрос:Aretheredocumentedcasesofretrofittingyourcrushingchambertechnologyintoexistinggyratorycrushersfromothermanufacturers?
A WhileourprimaryfocusisnewunitswehaveexecutedseveralsuccessfulmodernizationprojectsforcompatiblelegacycrushersTheseinvolvereplacingkeywearcomponentsandsometimeshydraulicsystemstodeliverperformanceimprovementsAcasestudyreviewcanbe provideduponrequest

вопрос:Whatdefinesthe"Общая стоимость владения"advantageinyourcomparisons?
A OurTCOanalysisovera5yearperiodaccountsforinitialcapitalcostenergyconsumptionprojectedwearpartslifeandreplacementcostsscheduledmaintenancelaborhoursandexpectedavailabilitylossesFielddatafromsimilarenvironmentsformsthebasisfortheseprojections

вопрос:Doyouoffertestcrushingofcustomermaterialsamplespriorto purchase?
A YesWeoperateapilotscalecrushingfacilityandcanperformcomprehensivematerialtestworkincludingabrasivenessandcompressionstrengthanalysisto validatecapacitymodelingandliner liferecommendationsThisdataisincludedinourtechnicalproposal

вопрос:Whatarethestandardwarrantytermsforthemainmechanicalcomponents?
A Themainstructuralcomponents(mainframeheadcenter)mainshaftassemblyandbearingscarryastandardwarrantyof24monthsfromcommissioningor26monthsfromshipmentwhicheveroccurfirstsubjecttocorrectinstallationoperationasperourmanuals