1. ОТКРЫТИЕ С УПРАВЛЕНИЕМ PAINPOINT

Managing a sand and gravel operation means contending with persistent, дорогостоящая неэффективность. Сталкиваетесь ли вы с этими общими проблемами?
Большое время простоя из-за износа: Constant abrasion from silica sand and aggregate leads to premature failure of pumps, вкладыши, и экраны, resulting in unplanned stoppages for replacement.
Непоследовательная градация продукта: Inefficient screening or classification yields offspec material, reducing the percentage of premium, indemand products and increasing waste stockpiles.
Избыток воды & Потребляемая мощность: Inefficient washing, обезвоживание, and material handling systems inflate utility costs—a primary operational expense that directly erodes profit margins.
High Labor & Затраты на техническое обслуживание: Equipment requiring frequent manual adjustment, constant monitoring for blockages, or complex maintenance routines increases your operational overhead and safety exposure.
Lost Revenue from Fines: Poorly designed recovery systems fail to capture marketable fine sand fractions, washing valuable product into settling ponds.

Центральный вопрос для руководителей предприятий заключается в следующем.: how can you specify equipment that directly targets these pain points to improve availability, control grading, and reduce cost per ton?

2. ОБЗОР ПРОДУКТА: HIGHCAPACITY AGGREGATE SCREENS

This product category covers heavyduty vibrating screens engineered for the primary sizing, скальпирование, and fine separation of sand and gravel. Designed for continuous duty in harsh environments, they are a critical node in determining plant throughput and product quality.

Операционный рабочий процесс:
1. Кормить & Распределение: Runofmine or crushed feed is evenly distributed across the full width of the screen box via a dedicated feeder or spreader conveyor.
2. Стратификация & Разделение: Highfrequency vibration stratifies material, forcing smaller particles down to the screen media while larger particles convey across the deck surface.
3. Размеры & Увольнять: Sized fractions pass through designated screen decks (например, top deck: +1», middle deck: 1/4” to 1”, bottom deck: 1/4») and are discharged into separate chutes or onto product stockpiling conveyors.

Область применения: Ideal for hightonnage quarry applications processing natural sand & gravel or crushed stone. Suitable for dry screening or as part of a wet washing circuit.
Ограничения: Не предназначен для липких, highclay material without prescreening or washing attachments. Maximum feed size is limited by box design and deck punch plate specifications.

3. ОСНОВНЫЕ ХАРАКТЕРИСТИКИ

Модульная система палуб | Техническая основа: Boltin panel design with multiple media options (wire cloth, полиуретан, резина) | Операционная выгода: Operators can change panel types or sizes in sections to adapt to deposit changes or product specs without full deck replacement. | Воздействие на рентабельность инвестиций: Reduces media change downtime by up to 40% and allows precise media selection to optimize wear life vs. open area.

DualVibration Mechanism | Техническая основа: Two synchronized counterrotating eccentric shafts generating a linear stroke | Операционная выгода: Provides positive material conveyance with minimal plugging or blinding, maintaining rated capacity even with damp feed material. | Воздействие на рентабельность инвестиций: Ensures consistent throughput (тонн/час), protecting downstream process stability and overall plant yield.

Sealed Bearing Cartridge Assembly | Техническая основа: Prelubricated, labyrinthsealed bearing units mounted external to the screen body | Операционная выгода: Isolates critical drive components from dust and water ingress; enables bearing changeout without dismantling the vibrator assembly. | Воздействие на рентабельность инвестиций: Extends bearing service life by 23x versus standard designs and reduces mean time to repair (среднее время восстановления) более чем 60%.

SubResonant Drive Tuning | Техническая основа: Drive system operates below the natural frequency of the springsupported screen frame | Операционная выгода: Dramatically reduces dynamic loads transferred to the support structure during startup and shutdown cycles. | Воздействие на рентабельность инвестиций: Eliminates the need for massive reinforced concrete foundations; allows installation on steel support structures, reducing civil costs by approximately 25%.

QuickRelease Tensioning System | Техническая основа: Hydraulic or mechanical wedgebased system for screen cloth tensioning | Операционная выгода: Enables singleoperator tensioning or replacement of screen media in under 30 minutes per panel. | Воздействие на рентабельность инвестиций: Directly addresses labor cost containment and increases plant availability during routine maintenance windows.

4. КОНКУРЕНТНЫЕ ПРЕИМУЩЕСТВА

| Метрика производительности | Отраслевой стандарт | HighCapacity Aggregate Screen Solution | Преимущество (% улучшение) |
| : | : | : | : |
| Время смены носителя на экране (Полная колода) | 812 часы (crew of 3) | 46 часы (crew of 2) | ~ на 50 % быстрее |
| Bearing Mean Time Between Failure (среднее время безотказной работы) | 8,000 10,000 часы | 18,000 22,000 часы | ~120% longer life |
| Потребляемая мощность на тонну переработки| Базовый уровень (100%)| Оптимизированный ход & mass dynamics reduces draw by ~15%| 15% более эффективный |
| NearSize Material Accuracy (0.5 aperture)| ~85% efficiency| Patented ball tray/deck cleaning maintains >92% эффективность| ~8% more premium product |
| Structural Load Transmitted to Base| Базовый уровень (100%)| Subresonant tuning reduces dynamic load by ~70%| 70% less force |

_(Field data based on comparative analysis of similar duty cycles.)_

5. ТЕХНИЧЕСКИЕ ХАРАКТЕРИСТИКИ

Номинальная мощность: зависит от модели; ranges from 500 TPH превышает 2,500 TPH of sand & gravel feed.
Требования к питанию: Dualdrive motors from 30 HP в 100 HP total (480V/60Hz/3Ph standard). Частотно-регулируемый привод (ЧРП) optional for stroke/timing adjustment.
Характеристики материала: Side plates constructed from hightensile AR400 steel; Deck frames from reinforced carbon steel; Optional corrosionresistant coatings for saline or highhumidity environments.
Физические размеры (Типичный): Singledeck units from \(10' x \(5'\) up to tripledeck units at \(20' x \(8'\). Weight ranges from ~12k lbs to over 45k lbs.
Экологический рабочий диапазон: Designed for ambient temperatures from 20°C (4°Ф) to +50°C (122°Ф). Dusttight enclosures available; washdown systems standard on wet screening models.

6. СЦЕНАРИИ ПРИМЕНЕНИЯ

[Commercial Sand Producer – Midwest USA] Испытание: A major producer needed higher throughput on their 30140 specialty sands but faced chronic blinding on fine mesh screens during humid periods.Решение: Implementation of our highcapacity aggregate screens equipped with polyurethane modular decks featuring integrated ball trays.Результаты: Screen blinding was eliminated entirely through continuous selfcleaning action. Production of inspec fine sands increased by an average of 18%, while unscheduled downtime events related to screening fell by over 90%.

[Large Aggregate Quarry – Southeast Asia] Испытание: The existing screening plant created significant structural vibration issues on its elevated steel platform foundation.Решение: Replacement with our subresonant tuned aggregate screens designed specifically for steel structure mounting.Результаты: Measured vibration at the support beams was reduced by over twothirds (22 mm/s). This allowed safe expansion of processing lines on existing infrastructure without costly reinforcement.

[Integrated C&D Recycling Operation – Europe] Испытание: Processing recycled concrete aggregate caused extreme wear on traditional wire cloth screens.Решение: Installation using our modular deck system fitted with specialized abrasionresistant rubber panels.Результаты: Screen panel service life increased from an average of three weeks up to fourteen weeks per set—a fourfold improvement—drastically cutting consumable costs.

7. КОММЕРЧЕСКИЕ СООБРАЖЕНИЯ

Our specification process is structured around your required capacity:

Уровень I (Стандартная обязанность, <800 ТПХ): Base models ideal for steadystate operations processing consistent material profiles.
Дополнительные функции: Basic spray bars
Пакет услуг: Parts warranty + recommended spare parts kit

Уровень II (Сверхмощный, <1600 ТПХ): Enhanced models featuring upgraded bearings
Дополнительные функции: VFD controls
Пакет услуг: Extended warranty

Уровень III (Экстремальный долг, <2500+ ТПХ): Fully configured systems including subresonant tuning
Дополнительные функции: Full automation interface packages
Пакет услуг: Onsite commissioning supervision

Financing options include capital lease agreements tailored around seasonal cash flow cycles common in aggregate production.

Часто задаваемые вопросы

What is your typical lead time?

Lead times vary based on model complexity but typically range between [XY] weeks upon receipt of order.

Can this equipment be integrated into my existing plant layout?

Да; our engineering team provides detailed installation drawings based on your site plan.

What is your warranty policy?

We offer a standard [Х]year warranty covering all structural components against manufacturing defects

Предоставляете ли вы гарантии выполнения?

Да; we guarantee rated throughput capacity when processing feed material within agreedupon specifications

Какое обучение вы предоставляете?

We include comprehensive operator training during commissioning