بلڪ Jc5000 جبڑے کولہو پهچائڻ
1. PAINPOINT driven اوپننگ
آپريشنل خرچن کي وڌائي رهيا آهن ۽ غير متوقع وقت ختم ڪري رهيا آهن توهان جي بنيادي ڪرشنگ سرڪٽ جي منافعي کي? پلانٽ مينيجرز ۽ انجنيئرنگ ٺيڪيدارن لاءِ, پرائمري ڪرشنگ اسٽيج هڪ نازڪ رڪاوٽ آهي جتي غير موثريت پوري پروسيسنگ لائن ذريعي ڇڪي ٿي. عام چئلينج شامل آهن:
سار سنڀال لاءِ اضافي وقت: بار بار لائنر تبديلين ۽ غير متوقع ميڪيڪل ناڪامي پيداوار کي روڪيو, ھزارين في ڪلاڪ جي خرچ ۾ گم ٿي وڃڻ.
اعلي لباس حصو واپرائڻ: Aggressive or abrasive feed material leads to premature jaw plate wear, توهان جي قيمت کي وڌائڻ ۽ انوینٽري مئنيجمينٽ سر درد پيدا ڪرڻ.
متضاد پيداوار جي درجه بندي: Fluctuations in feed size or hardness result in an uneven discharge product, placing stress on downstream screening and secondary crushers.
سخت سيٽ اپ جون حدون: Fixed jaw crushers cannot adapt to changing project demands or feed characteristics, locking you into a single operational profile.
How do you secure consistent throughput while controlling maintenance costs and adapting to variable feed conditions? The solution requires a robust design focused on durability, serviceability, and sustained performance.
2. پيداوار جو جائزو
The Bulk JC5000 is a highcapacity, singletoggle jaw crusher engineered for primary crushing in demanding mining, کوٽڻ, ۽ وڏي پيماني تي تعميراتي ايپليڪيشنون. It processes runofmine rock, ڌماڪي سان ڀريل پٿر, and demolition concrete into a consistent, ٿلهو مجموعو.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: وڏي پيماني تي مواد (1300mm تائين) is directed into the deep crushing chamber by vibrating grizzly feeders.
2. کمپريشن کرشنگ: The elliptical motion of the single toggle forces the movable jaw against the fixed jaw, جبل کي ڀڃڻ لاءِ دٻاءُ واري قوت لاڳو ڪرڻ.
3. خارج ٿيڻ & صفائي: ڪٽيل مواد هيٺان خارج ٿيڻ واري اوپننگ ذريعي نڪرندو آهي (سي ايس ايس), with the aggressive stroke ensuring efficient clearing even under high load.
ايپليڪيشن جو دائرو: سخت پٿر لاء مثالي (گرينائيٽ, بيسالٽ), ٻرندڙ معدنيات, and recycled concrete with strengths up to 400 ايم پي اي. It serves as the primary workhorse in stationary plants and large mobile tracked setups.
حدون: گندي لاء ٺهيل ناهي, sticky materials that may cause chamber packing without proper feed conditioning. For ultrafine output (<50ايم ايم), secondary or tertiary crushing stages are required.
3. بنيادي خاصيتون
ڊيپ چيمبر ڊيزائن | ٽيڪنيڪل بنياد: Optimized nip angle and long linear crushing path | آپريشنل فائدا: Enables higher volume intake per cycle and reduces bridging risks | ROI اثر: Increases potential throughput by up to 15% versus shallower chambers of similar inlet size
هائيڊولڪ ٽوگل ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: Replaceable hydraulic cylinder for tensioning & overload release | آپريشنل فائدا: Allows remote CSS adjustment under load and protects against tramp metal damage | ROI اثر: غير منصوبابندي واري وقت کي گھٽائي ٿو سراسري طور تي 30 hours annually related to tramp iron incidents
HeavyDuty رولر بيئرنگ اسيمبلي | ٽيڪنيڪل بنياد: مکيه شافٽ تي گول خود ترتيب ڏيڻ وارو رولر بيئرنگ | آپريشنل فائدا: Supports higher radial loads and operates at lower temperatures than bronze bushings | ROI اثر: Extends bearing service life by approximately 40%, lowering part replacement frequency
BoltOn Wear Liners | ٽيڪنيڪل بنياد: Modular manganese steel liners on frame sides | آپريشنل فائدا: Protects crusher frame from abrasion; replaced independently of jaw dies | ROI اثر: Preserves structural integrity of main frame for decades, avoiding capital replacement costs
مرڪزي گريسنگ پوائنٽس | ٽيڪنيڪل بنياد: Automated or manual greasing lines routed to all major bearings | آپريشنل فائدا: محفوظ ڪري ٿو, routine lubrication without direct operator access to moving parts | ROI اثر: Standardizes preventive maintenance, reducing lubricationrelated failures by over 80%
Reinforced Swing Jaw Design | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) optimized cast steel structure with thick ribs | آپريشنل فائدا: Provides maximum fatigue resistance under cyclic loading stresses | ROI اثر: Minimizes risk of catastrophic jaw failure, ensuring multiyear structural service life
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (تقابلي ڪلاس) | Bulk JC5000 Solution | فائدو (% سڌارو) |
| : | : | : | : |
| Average Jaw Plate Life (ابراھيندڙ گرينائيٽ) | ~ 180,000 MTONs في سيٽ (Standard Mn18) | ~250,000 MTONs في سيٽ (Premium Mn22) +38% |
| CSS ترتيب ڏيڻ جو وقت / Liner Turnover| 46 ڪلاڪ (دستي شيم جي ترتيب) 900 TPH in field trials| >6% Higher Output |
5. ٽيڪنيڪل وضاحتون
فيڊ کولڻ: 1300mm x 1000mm (51" x 40")
وڌ ۾ وڌ فيڊ سائيز: 1100mm تائين ڪنڊ ڊگھائي
بند طرف سيٽنگ (سي ايس ايس) حد: 150mm 300mm
گنجائش جي حد: تائين 950 ٽين في ڪلاڪ (کاڌ خوراڪ جي مواد تي دارومدار & سي ايس ايس)
ڊرائيو پاور جي گهرج: 132 kW اليڪٽرڪ موٽر
ڪل وزن (صرف کولہو): لڳ ڀڳ 62 ٽين
اهم مواد جي وضاحت:
مکيه فريم: Fabricated heavyduty steel plate
ٻرندڙ جبل & Fixed Jaw Dies: پريميئم مينگنيز اسٽيل
سنسڪرت شافٽ: جڙيل مصري اسٽيل
آپريٽنگ جي درجه حرارت جي حد: 30°C to +45°C with appropriate lubricants
طول و عرض (ايل x ڊبليو x ايڇ): ~4m x 3m x 3m
6. درخواست جا منظر
Hard Rock Quarry Expansion Challenge:
A granite quarry needed to increase primary circuit output by 25% without expanding its plant footprint or secondary crushing line.
حل:
Two older jaw crushers were replaced with a single Bulk JC5000 unit configured with a wider CSS to produce optimal feed for existing cone crushers.
نتيجا:
جي ذريعي وڌي ويو 28%. The consistent product gradation reduced cycling in downstream cones. Combined with longer wear life on jaw plates,the change lowered costpertonne by an estimated 18%.
LargeScale Mineral Processing Plant Challenge:
An iron ore operation faced excessive unplanned downtime due to tramp steel damaging its primary crusher,losing an average of $15k per incident.
حل:
Implementation of the Bulk JC5000 with its hydraulic toggle system for automatic overload protection.
نتيجا:
Field data shows three overload events were safely cleared without shutdown in one quarter.Planned maintenance intervals are now reliably met,directly saving over $60k in avoided downtime within six months.
7. تجارتي خيالات
The Bulk JC5000 is positioned as a capital investment for operations focused on longterm total cost of ownership reduction.
بنيادي سامان جي قيمت جو درجو: ڪرشر شامل آهي,موٽر mounts,and drive sheaves.Competitively structured against equivalent OEM offerings.
اختياري خاصيتون & پيڪيجز:
ڪارڪردگي پيڪيج: Includes automated grease system,موٽر اسٽارٽر,and wear part monitoring sensors.
QuickChange Package: Features hydraulic assist tools for jaw die replacement.
Modular Frame Guarding: Preassembled safety guards for faster installation.
سروس معاهدو:
1Year OnSite Warranty with factory commissioning support.
3Year /5Year Extended Protection Plans covering major components.
Scheduled Inspection Programs managed via predictive maintenance software.
Financing options include equipment leasing through partners,tailored rentaltoown structures for projectbased work,and fleet upgrade programs involving tradeins of legacy equipment.
8.FAQ
Q1:What is the compatibility of the Bulk JC5000 with my existing vibrating grizzly feeder and discharge conveyor?
A1:The JC5000 is designed to standard industry mounting footprints.Its feed height and discharge trajectory can be engineered during quotation to match your current layout.Engineering support is provided for integration reviews.
Q2:What is the expected operational impact during liner changeouts?
A2:The design prioritizes service access.Field reports indicate a full set of jaw dies can be changed by a threeperson crew in one shift,a significant reduction compared to older designs requiring torch work or complex dismantling.
Q3:What commercial terms are available beyond upfront purchase?
A3.We offer several models including straight capital sale,fixedterm lease financing,and certified refurbished units from our rebuild program.Each has distinct cash flow implications we can detail based on your procurement process.
Q4:What power supply infrastructure is required?
A4.The unit requires a dedicated supply compatible with its 132 kW motor.Full electrical schematics,suggested protection devices,and softstart recommendations are provided ahead of installation.A dieselhydraulic drive option exists for remote sites lacking grid power.
Q5:What training is provided for our maintenance team?
A5.Comprehensive training modules are included,covershing safe operation,معمولي سار سنڀال جا طريقا,and basic troubleshooting.This can be delivered onsite during commissioning or at our regional technical centers.Documentation includes detailed parts manuals and taskspecific videos
