Борьба с неэффективностью первичного дробления: The High Cost of Compromise

Are your aggregate production or mining operations constrained by the primary crushing stage? Inefficient jaw crusher performance directly impacts your entire downstream process, manifesting as:

Чрезмерное время простоя для технического обслуживания: Frequent liner changes and unplanned stops for blockages can consume 1520% of available operating hours, потеря пропускной способности обходится десятками тысяч.
Непредсказуемая градация продукта: Inconsistent feed opening dynamics and wear lead to poor size distribution, overworking secondary crushers and reducing final product yield.
Растущие эксплуатационные расходы: Premature component wear, высокий расход энергии на тонну, and high labor intensity for routine servicing erode profit margins.
Ограниченная гибкость подачи: Inability to handle a varied mix of feed materials (например, abrasive basalt, recycled concrete with rebar, highclay ores) forces production to slow down or stop.

Is your primary crusher a reliable asset driving profitability, or a recurring source of bottleneck and expense? The solution lies in specifying equipment engineered not just to crush, но для оптимизации совокупной стоимости владения.

Обзор продукта: JC5000 HeavyDuty Jaw Crusher

The JC5000 is a robust, singletoggle jaw crusher engineered for highcapacity primary crushing in demanding quarrying, добыча полезных ископаемых, и приложения для переработки сноса. Its design focuses on delivering consistent throughput with minimized operational intervention.

Операционный рабочий процесс:
1. Потребление корма: Большой (500mm x 250mm) feed opening accepts runofmine or runofquarry material directly from haul trucks.
2. Компрессионное дробление: A steep nip angle and aggressive crushing motion applies intense compressive force to fracture material against the fixed jaw plate.
3. Увольнять & Распродажа: The hydraulically assisted toggle system provides quick reversal of the moving jaw to clear blockages and assist in tramp metal release without stopping the crusher.
4. Транспортировка продукта: Crushed material exits at a consistent CSS (Закрытая боковая установка), typically between 75mm 150mm, готов к вторичной переработке.

Область применения & Ограничения:
Идеально подходит для: Карьеры твердых пород (гранит, базальт), mediumscale mining operations, largescale construction waste recycling plants.
Ограничения: Not designed for ultrafine grinding or as a standalone solution for finished aggregate. Максимальный рекомендуемый размер корма 80% размера загрузочного отверстия. Requires a stable foundation and appropriate upstream feeding equipment.

Основные функции: Инженерное обеспечение для оперативного превосходства

Гидравлическая система регулировки рычага | Техническая основа: Integrated hydraulic cylinder replaces mechanical shims | Операционная выгода: CSS adjustment takes minutes versus hours, performed safely from ground level | Воздействие на рентабельность инвестиций: Сокращает время простоя при смене продукта до 90%, increasing annual utilization.

Эксцентриковый вал карьерного класса | Техническая основа: Forged from highintegrity alloy steel, поддерживается увеличенными сферическими роликоподшипниками | Операционная выгода: Sustains peak load under shock conditions; bearings run cooler with extended L10 life | Воздействие на рентабельность инвестиций: Eliminates premature shaft failure; field data shows bearing service intervals extended by 40%.

Оптимизированная геометрия камеры | Техническая основа: Computermodeled kinematics create an aggressive nip angle and deep crushing chamber | Операционная выгода: Enhances throughput capacity and promotes slabby material breakage over flaking | Воздействие на рентабельность инвестиций: Доставляет до 10% more tons per hour at equivalent power draw compared to previous generation designs.

Прочная рамная конструкция | Техническая основа: Fabricated from stressrelieved steel plate with reinforced ribbing at all highstress points | Операционная выгода: Provides longterm alignment stability under cyclical loading, защита внутренних компонентов | Воздействие на рентабельность инвестиций: Mitigates risk of frame fatigue cracking, обеспечение структурной целостности в течение 15+ срок службы год.

Повышенная безопасность & Удобство обслуживания | Техническая основа: Centralized grease points; accessible cheek plate bolts; guarding integrated into structure | Операционная выгода| Routine maintenance tasks are faster and safer for technicians| Воздействие на рентабельность инвестиций| Lowers scheduled maintenance labor hours by an estimated 25%, improving site safety compliance.

Конкурентные преимущества: Измеримый прирост производительности

The JC5000 Jaw Crusher is designed to outperform conventional solutions across critical metrics.

| Метрика производительности | Отраслевой стандарт (Сопоставимый класс) | Документированная производительность решения JC5000 | Преимущество (% Улучшение) |
| : | : | : | : |
| Доступность (Время работы) | ~85% (факторинговая корректировка & blockage downtime)| >92% (with hydraulic toggle & очистка) | +8% |
| Лайнер Жизнь (Абразивный камень) | ~120 000 тонн за комплект (Мн14%)| ~150 000 тонн за комплект (Mn18% optional) | +25% |
| Энергоэффективность (кВтч/тонна)| Варьируется в широких пределах; baseline = 1.0x factor| Field data shows consistent reduction averaging ~0.9x factor |10% |
| Время настройки CSS| 24 часы с экипажем| <30 minutes with single operator |87% |

Технические характеристики

Кормовое отверстие: 500mm x 250mm
Максимальный размер подачи: 400мм
Диапазон настройки закрытой стороны: 75mm 150mm
Диапазон мощности: 180 350 тонн в час (зависит от исходного материала и CSS)
Требования к мощности привода: 75kW /100HP electric motor (стандартный)
Вес дробилки (исключая двигатель): Примерно 16 метрические тонны
Основные характеристики материалов:
Frame Fabrication Grade Steel
Jaw Plates Premium manganese steel (Mn14% standard; Мн18%, Mn22% optional)
Eccentric Shaft Forged EN24/34CrNiMo6 equivalent
Bearings Spherical roller bearings; Timken/SKF/FAG grade
Диапазон рабочих температур: 20от °C до +40 °C со стандартными смазочными материалами.
Размеры (Д х Ш х В): ~3.5m x 2.8m x 2.9m

Сценарии применения

Granite Quarry Expansion Project Challenge:

A quarry needed to increase primary circuit throughput by 30% without expanding its footprint or major civil works. Their existing crusher created bottlenecks due to slow adjustment times and frequent liner wear checks.

Решение:

Implementation of one JC5000 Jaw Crusher as the new primary unit. Key features utilized were the hydraulic toggle for rapid product sizing changes between road base and rail ballast production runs.

Результаты:

Throughput goals were met within the first quarter. The site manager reported a 22% reduction in weekly labor hours dedicated to crusher maintenance and adjustments, reallocating personnel to other areas.

С&D Recycling Plant Upgrade Challenge:

A recycling plant processing mixed demolition waste faced excessive downtime from uncrushable materials jamming the primary jaw, requiring full shutdowns and manual clearing several times weekly.

Решение:

Replacement with a JC5000 Jaw Crusher equipped with an automatic hydraulic tramp release system integrated into the toggle mechanism.

Результаты:

Blockage events requiring full shutdown were virtually eliminated. The plant recorded a 17% increase in monthly processed volume due to reduced stoppages while protecting downstream conveyors from metal damage.

Коммерческие соображения

Equipment pricing is structured around core configuration:

1. Base Machine Tier Includes crusher frame assembly drive sheave flywheels standard manganese liners guards lubrication system

2 Дополнительные пакеты функций
Hydraulic Toggle Adjustment Kit Automatic Tramp Release System HeavyDuty Skid Base Frame Belt Drive Guard Package HigherGrade Manganese Liners Mn18Mn22

3 Service Support Packages Proactive maintenance plans are available including scheduled inspections parts kits priority technical support Extended warranty options can be negotiated based on application review

4 Financing Options Flexible commercial terms are offered through partnered financial institutions including equipment leasing capital loan structures or rentaltopurchase agreements tailored to project cash flow

Часто задаваемые вопросы

What power supply is required for the JC5000 A standard 75kW 400V50Hz3phase electric motor is supplied Can it be configured for diesel drive Yes skidmounted diesel drive packages are available as an option

How does the hydraulic toggle system affect reliability The system simplifies mechanics replacing dozens of manual shims It uses proven industrial hydraulic components designed specifically for highshock environments reliability data indicates no reduction in overall system uptime

What is the lead time on replacement wear parts Commonly used parts like jaw plates cheek plates are typically held in regional stock centers with availability within 48 weeks Nonstock items have a manufacturing lead time communicated upon order

Can the JC5000 handle wet sticky clayladen material While capable performance will be reduced compared to dry rock We recommend site evaluation For severe clay applications pre screening or grizzly feeding should be considered

What commercial terms are available Minimum order quantity is one 1 unit We offer comprehensive commercial support including FOB CIF DAP delivery terms based on customer location Full payment letters of credit are standard structured payment plans can be discussed