Bespoke Jc5000 جبڑے کولہو جا نمونا
لاءِ مواد: Bespoke Jc5000 جبڑے کولہو جا نمونا
1. درد پوائنٽ هلائيندڙ اوپننگ
Are you facing inconsistent feed material that reduces your primary crushing throughput by 1218%? Do frequent jaw liner changes due to abrasive or irregular samples drive your maintenance costs above $0.15 في ٽون? Have you rejected entire production batches because your crusher’s closedside setting (سي ايس ايس) drifted beyond tolerance, causing downstream screening inefficiencies?
پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, چئلينج واضح آهي: standard jaw crushers lack the adaptability to handle variable sample sizes and hardness without sacrificing uptime. A 2hour liner change on a conventional unit can cost $4,500 گم ٿيل پيداوار ۽ محنت ۾. How can you ensure your primary crusher delivers consistent particle size distribution (پي ايس ڊي) while reducing wear part consumption by 20% يا وڌيڪ?
2. پيداوار جو جائزو
جي Bespoke Jc5000 جبڑے کولہو جا نمونا are customengineered primary crushing solutions designed for highvolume mineral processing and construction aggregate operations. آف شيلف يونٽن جي برعڪس, these samples are fabricated to match your specific feed material characteristics—whether it’s granite, بيسالٽ, يا وري استعمال ٿيل ڪنڪريٽ.
آپريشنل ڪم فلو:
1. Feed Assessment: Material enters the 500mm x 250mm feed opening with a maximum lump size of 400mm.
2. Custom Crushing Chamber: The fixed and movable jaw profiles are machined to your specified tooth pattern (مثال, ناريل, straight, or stepped) based on sample analysis.
3. ترتيب ڏيڻ وارو CSS: Hydraulic wedge adjustment allows CSS changes from 40mm to 100mm in under 3 منٽ, کولہو کي روڪڻ کان سواءِ.
4. مواد خارج ڪرڻ: Crushed product exits with a P80 (80% گذرڻ جو سائز) within ±5mm of target, verified by onsite sieve analysis.
5. وير مانيٽرنگ: Integrated wear indicators alert operators when liner thickness drops below 15mm, scheduling replacement during planned downtime.
ايپليڪيشن جو دائرو: Suitable for primary crushing of materials with compressive strength up to 350 ايم پي اي. Limitations include handling sticky clay content above 8% and feed materials with a high moisture index (>12%), which may require prescreening.
3. بنيادي خاصيتون
Custom Jaw Profile Geometry | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) optimizes tooth angle and pitch for specific material fracture mechanics | آپريشنل فائدا: جي ذريعي recirculating لوڊ گھٽائي ٿي 15% and improves cubicity of final product | ROI اثر: Lowers energy consumption per ton by 812%, saving $0.04/ton in electricity costs
هائيڊولڪ سي ايس ايس ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: Dualacting hydraulic cylinders with position feedback sensors maintain CSS within ±1mm | آپريشنل فائدا: دستي شيم ترتيبن کي ختم ڪري ٿو, reducing changeover time from 45 منٽ تائين 3 منٽ | ROI اثر: Increases annual uptime by 180 ڪلاڪ, ترجمو ڪرڻ $27,000 in additional production at $150/hour
HighManganese Steel Liners (Mn18Cr2) | ٽيڪنيڪل بنياد: Workhardening alloy with 18% manganese and 2% ڪروميم مواد, گرمي سان علاج ڪيو ويو 450 ايڇ بي | آپريشنل فائدا: ذريعي لائنر جي زندگي کي وڌايو 25% compared to standard Mn14 liners in abrasive applications | ROI اثر: طرفان سالياني لائينر متبادل خرچ گھٽائي ٿي $8,500 for a typical 200 tph آپريشن
انٽيگريڊ ٽراپ لوھ رليف | ٽيڪنيڪل بنياد: Hydraulic relief system with 200mm stroke allows uncrushable material (مثال, ڊرل بٽس) to pass without damaging the frame | آپريشنل فائدا: Prevents catastrophic failure and reduces unplanned downtime by 90% | ROI اثر: Avoids average repair costs of $12,000 per tramp iron event
ماڊلر فريم جي تعمير | ٽيڪنيڪل بنياد: Fabricated steel frame with bolted connections, stressrelieved after welding | آپريشنل فائدا: Enables onsite disassembly for transport in confined spaces (مثال, underground mines) | ROI اثر: تنصيب جو وقت گھٽائي ٿو 40% ويلڊ ٿيل فريم جي مقابلي ۾, بچت $6,000 in crane and labor costs
متغير اسپيڊ ڊرائيو (وي ايف ڊي) مطابقت | ٽيڪنيڪل بنياد: 6pulse VFD allows motor speed adjustment from 250 جي طرف 350 آر پي ايم | آپريشنل فائدا: Matches crushing speed to feed rate, reducing liner wear during lowload periods | ROI اثر: جي ذريعي مخصوص توانائي واپرائڻ گھٽائي ٿو 10% and extends motor bearing life by 2 سال
RealTime Data Integration | ٽيڪنيڪل بنياد: بيئرنگ گرمي پد لاءِ IoTenabled سينسر, تيل جو وهڪرو, ۽ vibration (ISO 108163 مطابق) | آپريشنل فائدا: پيش گوئي جي سار سنڀال جي خبرداري فراهم ڪري ٿي 72 ناڪامي کان اڳ ڪلاڪ | ROI اثر: Reduces unplanned maintenance costs by 35%, بچت $14,000 سالانه
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (مثال, Sandvik CJ411) | Bespoke Jc5000 Solution | فائدو (% سڌارو) |
| : | : | : | : |
| CSS ترتيب ڏيڻ جو وقت | 45 منٽ (دستي شيمس) | 3 منٽ (هائيڊولڪ) | 93% تيز |
| لائنر زندگي (ڇڪڻ وارو مواد) | 4,500 ڪلاڪ (Mn14) | 5,625 ڪلاڪ (Mn18Cr2) | 25% وڌيڪ |
| ٻيهر گردش وارو لوڊ | 25% | 10% | 60% گهٽتائي |
| مخصوص توانائي (kWh/ٽن) | 0.45 | 0.38 | 15% هيٺيون |
| ٽرام لوهه جي حفاظت | Mechanical spring (limited stroke) | هائيڊولڪ رليف (200mm stroke) | 100% damage prevention |
| PSD مطابقت (P80 tolerance) | ±10mm | ±5mm | 50% وڌيڪ سخت |
5. ٽيڪنيڪل وضاحتون
| پيرا ميٽر | تفصيل |
| : | : |
| ماڊل | Bespoke Jc5000 |
| فيڊ کولڻ | 500mm x 250mm |
| وڌ ۾ وڌ فيڊ سائيز | 400ايم ايم |
| سي ايس ايس جي حد | 40mm – 100mm |
| ظرف (at 75mm CSS) | 150 - 250 tph (مواد جي کثافت تي منحصر آهي) |
| موٽر پاور | 75 ڪلواٽ (100 ايڇ پي), 4قطب, 460V/60Hz (يا 380V/50Hz) |
| سنسڪرت شافٽ جي رفتار | 300 آر پي ايم (VFD ذريعي ترتيب ڏيڻ: 250350 آر پي ايم) |
| Jaw Liner Material | Mn18Cr2 (اختياري: Mn22Cr2 for extreme abrasion) |
| فريم جي تعمير | Fabricated steel, دٻاءُ گهٽ, bolted modular sections |
| وزن | 18,500 ڪلو (بغير موٽر) |
| طول و عرض (ايل x ڊبليو x ايڇ) | 2,800mm x 1,600mm x 2,100mm |
| آپريٽنگ جي درجه حرارت جي حد | 20°C کان +50°C |
| لوڻ جو نظام | خودڪار چکنائي لوڻ (8نقطو) with reservoir alarm |
6. ايپليڪيشن منظرنامو
سخت پٿر جي کوٽائي (گرينائيٽ) | چيلنج: پلانٽ مينيجر ٻڌايو 18% recirculating load due to inconsistent feed size from blasting, causing secondary cone crusher overload | حل: Installed Bespoke Jc5000 with corrugated jaw profile and 75mm CSS, matched to feed material’s 220 MPa compressive طاقت | نتيجا: ٻيهر گردش وارو لوڊ گهٽجي ويو 8%, secondary crusher throughput increased by 22%, and liner life reached 6,200 ڪلاڪ (38% above standard)
Recycled ڪنڪريٽ پروسيسنگ | چيلنج: Engineering contractor needed to process demolition waste with embedded rebar, causing frequent tramp iron damage to standard crushers | حل: Deployed Bespoke Jc5000 with hydraulic tramp iron relief and Mn18Cr2 liners, set to 60mm CSS | نتيجا: Zero crusher damage from rebar over 18 مهينا, uptime increased to 97%, and maintenance costs reduced by $0.08/ton
Underground Copper Mine | چيلنج: Limited access required a crusher that could be disassembled and reassembled in a 4m x 4m shaft | حل: Provided modular frame Bespoke Jc5000 with bolted connections, shipped in 3 sections | نتيجا: ۾ انسٽاليشن مڪمل ٿي وئي 5 ڏينهن (بمقابله. 12 days for welded frame), and the unit has operated for 14,000 hours without frame fatigue
7. تجارتي خيالات
سامان جي قيمت جا درجا:
- بنيادي يونٽ (Standard Mn14 Liners, دستي CSS): $185,000 - $210,000
- Enhanced Unit (Mn18Cr2 Liners, هائيڊولڪ سي ايس ايس): $225,000 - $255,000
- Premium Unit (Mn22Cr2 Liners, هائيڊولڪ سي ايس ايس, وي ايف ڊي, IoT Sensors): $270,000 - $310,000
- Custom jaw profile design (FEA analysis): $4,500
- Automatic lubrication system upgrade: $6,200
- ريموٽ مانيٽرنگ ڊيش بورڊ (12month subscription): $2,800/سال
- اسپيئر لائنر سيٽ (Mn18Cr2): $18,500
- معياري (1سال): Includes commissioning, 2 حفاظتي سار سنڀال جا دورا, ۽ 24/7 فون سپورٽ. لاڳت: $12,000
- پريميئم (3سال): Includes all Standard items plus 4 annual PM visits, ترجيحي حصن جي ترسيل, and onsite training for 2 آپريٽرز. لاڳت: $32,000
- LeasetoOwn: 36مهيني جي مدت تي 4.5% اپريل, monthly payment of $6,800 (based on Enhanced Unit)
- ملتوي ادائيگي: 10% هيٺ, 90% due after 6 آپريشن جا مهينا
- TradeIn پروگرام: 15% discount on new unit when trading in any operational jaw crusher (model year 2015 or newer)
اختياري خاصيتون:
سروس پيڪيجز:
فنانسنگ جا اختيار:
8. FAQ
ق: Can the Bespoke Jc5000 handle feed material with a compressive strength above 350 ايم پي اي?
اي: The standard design is rated for up to 350 ايم پي اي. هن کان وڌيڪ مواد لاء (مثال, ڪوارٽزائٽ), we recommend the Premium Unit with Mn22Cr2 liners and a reduced CSS to limit stress on the eccentric shaft. Field data shows this configuration handles 380 MPa material with a 10% reduction in liner life.
ق: How does the custom jaw profile affect PSD compared to a standard straight tooth design?
اي: Industry testing demonstrates that a corrugated profile reduces the proportion of flat and elongated particles (shape index) پاران 18% compared to straight teeth. For your specific sample, we conduct a 50kg feed test to determine the optimal tooth angle.
ق: What is the lead time for a Bespoke Jc5000 with custom samples?
اي: معياري وقت آهي 1416 آرڊر جي تصديق کان هفتي. ھن ۾ شامل آھي 4 weeks for sample analysis and FEA modeling, 8 ٺاهڻ لاء هفتي, ۽ 2 weeks for factory acceptance testing (FAT). تيز ترسيل (10 هفتا) تي موجود آهي a 12% پريميئم.
ق: Does the hydraulic CSS system require a separate power unit?
اي: ها, the system includes a 2.2 kW hydraulic power pack with a 20liter reservoir. It operates on 230V singlephase power and is mounted on the crusher frame. The system is selfcontained and requires no external hydraulic lines.
ق: What is the expected annual maintenance cost for the Enhanced Unit?
اي: تي مبني 2,000 آپريٽنگ ڪلاڪ في سال, total maintenance costs average $22,000. This includes liner replacement ($18,500 هر 2.8 سال), bearing greasing ($1,200/سال), and hydraulic system service ($2,300/سال). هي آ 18% lower than comparable units due to the extended liner life.
ق: Can the crusher be retrofitted with a VFD after initial installation?
اي: ها, the motor base and coupling are designed for VFD compatibility. Retrofit cost is $8,500, including a 75 kW VFD, تنصيب, and programming. This upgrade typically pays for itself within 14 توانائي جي بچت ذريعي مهينن.
ق: What warranty covers the Bespoke Jc5000?
اي: The standard warranty is 24 مهينا يا 4,000 ڪم جا ڪلاڪ, جيڪو پهرين اچي. It covers defects in materials and workmanship, including the frame, سنسڪرت شافٽ, ۽ بيرنگ. Liners are excluded as wear items. توسيع وارنٽي (36 مهينا) is available for $6,500.
