Bespoke Jc5000 جبڑے کولہو بروشر
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع وقت ختم ڪري رهيا آهن توهان جي مجموعي يا کان کني جي منافعي جي مارجن کي? پرائمري ڪرشنگ آپريشن ۾ اهم چئلينج اڪثر شامل آهن:
سار سنڀال لاءِ اضافي وقت: بار بار لائنر تبديلين ۽ ميخانياتي ترتيبن کي توهان جي پوري پروسيسنگ لائن کي روڪيو, گم ٿيل پيداوار ۾ هزارين في ڪلاڪ خرچ.
ٽريمپ ميٽل کان اڻ رٿيل اسٽاپ: Unseen contaminants cause significant damage to crusher internals, leading to catastrophic failure and costly repairs.
متضاد پيداوار جي درجه بندي: Fluctuations in feed material or wear patterns result in offspec product, forcing recrushing and reducing plant throughput efficiency.
اعلي آپريشنل خرچ: Rising energy consumption per ton and the frequent replacement of highwear components directly impact your bottom line.
فيڊ جي تبديلين لاء سختي: Fixed geometry crushers struggle with changing feed sizes or material hardness, رڪاوٽون پيدا ڪرڻ.
Is your primary crusher a reliable asset or a constant source of concern? The solution requires engineering focused on durability, پهچ, and process stability.
2. پيداوار جو جائزو
The Bespoke JC5000 is a highcapacity, singletoggle jaw crusher کان کني ۾ سڀ کان وڌيڪ گهربل پرائمري ڪرشنگ ايپليڪيشنن لاءِ انجنيئر, کوٽڻ, and heavyduty recycling. Its robust design prioritizes continuous operation with minimal intervention.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: وڏو رن آف مائن يا ڪوارريرن مواد (1300mm تائين) اونهي ۾ هدايت ڪئي وئي آهي, غير ڇڪڻ واري ڪرشنگ چيمبر.
2. Compressive Crushing: The aggressive elliptical motion of the singletoggle jaw applies intense compressive force against the fixed jaw, effectively breaking even the hardest abrasive rock.
3. خارج ٿيڻ & صفائي: ڪٽيل مواد خارج ٿيڻ جي افتتاح ذريعي نڪرندو آهي, with a hydraulic toggle tensioning and release system providing automatic protection against uncrushables.
ايپليڪيشن جو دائرو: سخت پٿر کان کني لاء مثالي (لوهه, gold bearing ore), گرينائيٽ / بيسالٽ کوٽائي, ۽ سليگ پروسيسنگ. Designed as a stationary primary unit for plants targeting sustained throughputs between 750 1500 mtph depending on material and closed side setting.
حدون: ultrafine پيداوار جي sizing لاء ٺهيل نه آهي (secondary/tertiary roles) or processing of wet, sticky materials without prior scalping. Requires a solid foundation and appropriate feed system integration.
3. بنيادي خاصيتون
HeavyDuty فريم & Welded دٻاء رليف | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) optimized steel fabrication with postweld heat treatment | آپريشنل فائدا: cyclical بوجھ جي تحت فريم ٿڪ ڀڃڻ کي ختم ڪري ٿو; ensures longterm structural integrity in 24/7 آپريشن | ROI اثر: ڏهاڪن تائين خدمت جي زندگي کي وڌايو; prevents catastrophic frame failure requiring total unit replacement.
هائيڊولڪ ٽوگل & ترتيب ڏيڻ وارو نظام | ٽيڪنيڪل بنياد: Integrated hydraulic ram for toggle tensioning and automatic clearing | آپريشنل فائدا: Allows quick adjustment of CSS under load and automatically releases tramp metal, resetting itself without manual intervention | ROI اثر: Reduces unplanned downtime from tramp events by up to 80%; enables precise product control without stopping.
Quarry+ Jaw Die Design | ٽيڪنيڪل بنياد: Optimized tooth profile and thicker manganese sections based on cavity dynamics simulation | آپريشنل فائدا: Increases wear life by promoting interparticle crushing; reduces frequency of die rotation/replacement cycles | ROI اثر: لباس جي حصن جي قيمت گھٽائي ٿي; extends campaign life between maintenance stops by an average of 35%.
سڌو ڊرائيو VBelts ذريعي & TEFC Motor | ٽيڪنيڪل بنياد: Hightorque motor connected via multiple Vbelts to flywheel shaft | آپريشنل فائدا: Provides smooth power transmission, absorbs load shocks better than directcoupled drives; standard TEFC motor suits harsh environments | ROI اثر: Reduces stress on drive components; lowers maintenance complexity; improves overall electrical efficiency.
Integrated PreFabricated Installation System | ٽيڪنيڪل بنياد: Unit supplied with preengineered base frame, موٽر subframe, and alignment aids | آپريشنل فائدا: Dramatically reduces field installation time and ensures perfect alignment for optimal vibrationfree operation | ROI اثر: Cuts commissioning time by up to 50%, وقت جي پيداوار کي تيز ڪرڻ.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (تقابلي جبڑے کولڻ وارا) | Bespoke JC5000 حل | فائدو (% سڌارو) |
| : | : | : | : |
| زندگيءَ جو لباس (جيو مري)| Based on standard manganese profiles | Quarry+ design with thickened sections & آپٽمائزڊ ڪينيميٽيڪس| +3040% وڌايل زندگي |
| ٽرام ڌاتو جي بحالي جو وقت| Manual clearing requiring disassembly (~ 48 ڪلاڪ) | Hydraulic toggle autoreset cycle (<10 منٽ) |95% بند وقت |
| سالياني دستيابي| 8590% (فيڪٽرنگ لائنر تبديليون & ترميمون)| فيلڊ ڊيٽا کي سپورٽ ڪري ٿو >94% دستيابي| +45% مطلق واڌارو |
| توانائي في ٽين ڪڪڙ| Varies significantly with setting & مواد| آپٽمائزڊ ڪينيميٽيڪس & chamber design reduce wasteful motion| 510% سڌارو |
| Installation/Commissioning Period| 57 days with foundation work & ترتيب ڏيڻ| Prefabricated system reduces mechanical assembly time |40% installation labor |
_Availability based on comparable duty in hard rock applications._
5. ٽيڪنيڪل وضاحتون
فيڊ کولڻ: 1300mm x 1600mm (51" x 63")
وڌ ۾ وڌ فيڊ سائيز: Up to 1100mm (43")
بند ٿيل پاسي جي سيٽنگ جي حد: 150mm 300mm (6" 12")
گنجائش جي حد: 750 1500 ميٽرڪ ٽين في ڪلاڪ (varies with material density, خوراڪ جي درجه بندي, ۽ CSS)
ڊرائيو پاور جي گهرج: 200 ڪلواٽ / 250 HP برقي موٽر (TEFC)
ڪل وزن (صرف کولہو): لڳ ڀڳ 86,000 ڪلو
اهم مواد جي وضاحت:
فريم: ٺهيل اسٽيل پليٽ (SAE 1020), دٻاءُ گهٽ.
Swing Jaw/Fixed Jaw: Highstrength cast steel.
جيو مري: پريميئم مينگنيز اسٽيل (14%18%).
سنسڪرت شافٽ: جعلساز اسٽيل EN24/34CrNiMo6+.
آپريٽنگ جي درجه حرارت جي حد: 20°C کان +45°C (4°F کان +113°F)
Foundational Requirements: Detailed civil drawings provided; requires substantial mass concrete foundation.
6. درخواست جا منظر
Hard Rock Gold Mine – Primary Ore Reduction
چيلنج: A West African gold mine faced excessive downtime from weekly jaw die rotations and monthly maintenance stops on their aging primary crusher. Unpredictable wear was causing throughput fluctuations.
حل: Installation of a Bespoke JC5000 jaw crusher with Quarry+ dies and hydraulic toggle system.
نتيجا: Achieved a consistent campaign life of 6 weeks between die rotations. The hydraulic system cleared two major tramp metal events without stoppage. Annual availability increased from 86% جي طرف 93%, contributing to an estimated 18,000 additional tons processed annually.
Granite Quarry – Aggregate Base Production
چيلنج: A large quarry supplying road base material needed more consistent product gradation to meet strict DOT specifications without secondary recrush. Their existing crusher produced excessive flaky material.
حل: Implementation of the JC5000 with its optimized crushing chamber geometry and easyadjust hydraulic CSS control.
نتيجا:
CSS adjustments under load allowed operators to finetune output in minutes versus hours. The improved nip angle produced a more cubical product at the primary stage,
reducing load on secondary cone crushers by 15%. Overall plant yield of inspec material increased by 8%.
7. تجارتي خيالات
The Bespoke JC5000 is offered as a capital investment designed for longterm operational payback.
Base Equipment Price Tier: Includes crusher assembly,
هائيڊولڪ ٽوگل ايڊجسٽمينٽ سسٽم,
معياري جبو مري,
drive sheaves,
and documentation pack.
اختياري خاصيتون & واڌارو
– Automated Greasing System
– Wear Monitoring Kit (laser profile)
– Special Alloy Jaw Dies for highly abrasive feeds
– Custom SkidMounting for semimobile applications
سروس پيڪيجز:
1. ڪميشننگ سپورٽ پيڪيج
2.رٿيل سار سنڀال جو معاهدو
3.مڪمل خدمت جو معاهدو
فنانسنگ جا اختيار:
Available through our partners including equipment leasing,
operational leasetoown structures,
and project financing tailored for major capital expenditure
8.FAQ
Q1.Is the JC5000 compatible with my existing plant feed system( apron feeder/vibrating grizzly)?
A1.The JC5000 requires proper feed regulation but is designed to interface with standard industrial feeding equipment.Critical dimensions are provided early in the specification process
Q2.What is the expected operational costperton for wear parts?
A2.Costperton varies based on material abrasiveness.In comparable granite applications,the Quarry+ die design has demonstrated costs 2030% lower than previous generation jaws.Field data is available upon request
Q3.How does the hydraulic toggle system affect routine maintenance?
A3.It simplifies it.The system eliminates mechanical springs/shims reducing inspection points.Lubrication requirements are centralized.Routine tasks focus primarily on die condition monitoring
Q4.What training is provided for our maintenance crew?
A4.A comprehensive twoday onsite training program covers safe operation daily inspections routine maintenance procedures basic troubleshooting specific to this machine's systems
Q5.Are there financing options that align payback periods with projected efficiency gains?
A5 Yes.We offer structured finance solutions where repayment schedules can be modeled against typical efficiency gains(energy savings extended wear life increased throughput)
Q6.Can you provide sitespecific foundation drawings?
A6.Upon order confirmation we provide detailed certified foundation drawings including all loading data anchor bolt locations necessary for your civil engineering team
