Impact Crushers Manufacturing Quote
1. PAINPOINT driven اوپننگ
Are you managing unpredictable product gradation and excessive fines generation that compromise your final product yield? Is unscheduled downtime for wear part replacement eroding your operational budget and halting production lines? Are you facing escalating costs from high energy consumption per ton of processed material or from premature failure of components not designed for your specific feed material?
اهي معمولي غير موثر نه آهن; they are direct threats to your plant’s profitability. Unplanned maintenance on a primary or secondary crushing stage can cost tens of thousands in lost production per day, while inconsistent output requires costly reprocessing. سوال بڻجي ٿو: how do you achieve precise size reduction with greater reliability and lower total operating cost? The answer lies in selecting an impact crusher engineered to turn these operational challenges into measurable gains.
2. پيداوار جو جائزو
هڪ جديد افقي شافٽ اثر (ايڇ ايس آءِ) کولہو پرائمري لاءِ سامان جو هڪ بنيادي ٽڪرو آهي, ثانوي, and tertiary reduction of medium to low abrasiveness materials like limestone, ٻيهر استعمال ٿيل ڪنڪريٽ, اسفالٽ, ۽ تباهي جو ملبو. Its operational workflow is defined by a highvelocity impact principle:
1. فيڊ داخلا: مواد کي فيڊ چيٽ ذريعي ڪرشنگ چيمبر ۾ متعارف ڪرايو ويو آهي.
2. Rotor Acceleration: A highspeed rotor equipped with durable hammers or blow bars propels the feed material outward.
3. Impact Breakage: The hurled material impacts onto adjustable breaker aprons or anvils, shattering along natural cleavage planes.
4. ماپ ڪنٽرول: The gap between the rotor and the aprons, along with apron positioning, حتمي پيداوار جي ماپ جو تعين ڪري ٿو. Material continues to be impacted until it passes through the adjustable setting.
5. خارج ٿيڻ: Sized material exits the chamber onto a conveyor system for further processing or stockpiling.
Application scope is optimal for nonabrasive to moderately abrasive materials where a cubical product shape is desired. Limitations include reduced efficiency and higher wear costs when processing highly abrasive feeds (مثال, ڪجهه آتشي پٿر), where compressive crushers may offer better longterm economics.
3. بنيادي خاصيتون
هائيڊولڪ ايڊجسٽمينٽ سسٽم | ٽيڪنيڪل بنياد: انٽيگريڊ هائيڊولڪ سلنڈرز ڪنٽرولنگ ايپرون پوزيشن | آپريشنل فائدا: Allows operators to adjust product gradation or clear blockages in minutes from a central location, دستي مداخلت کان سواء | ROI اثر: تائين جي ترتيب جي گھٽتائي کي گھٽائي ٿو 80%, increasing plant availability and enabling rapid response to specification changes
Solid Rotor Design with WeldOn Discs | ٽيڪنيڪل بنياد: Monobloc steel rotor with welded discs for maximum inertia | آپريشنل فائدا: Delivers higher crushing force per revolution, improving reduction ratios and throughput on tougher feed materials | ROI اثر: جي ذريعي امڪاني throughput وڌائي ٿو 1525% compared to lighter rotor designs, قيمت گھٽائڻ
MultiFunctional Breaker Aprons | ٽيڪنيڪل بنياد: Threeposition aprons that function as both impact surfaces and grinding paths | آپريشنل فائدا: Provides optimal control over particle size distribution (پي ايس ڊي), allowing tuning for fewer fines or enhanced shaping | ROI اثر: Improves product yield within spec by an average of 8%, reducing waste and maximizing saleable material
QuickChange Wear Part Locking System | ٽيڪنيڪل بنياد: Mechanical wedge or hydraulic locking bolts for blow bars and apron liners | آپريشنل فائدا: Enires safe, toolfree wear part changes in under one hour for a single operator | ROI اثر: Cuts scheduled maintenance time by over 60%, سڌو سنئون سالياني آپريٽنگ ڪلاڪ وڌائڻ
سڌو ڊرائيو ملائڻ | ٽيڪنيڪل بنياد: Fluid coupling or Vbelt drive connecting motor directly to rotor | آپريشنل فائدا: لوڊ هيٺ هموار شروعاتي مهيا ڪري ٿي, protects motor from shock loads, and transmits power more efficiently than gearboxes | ROI اثر: ذريعي توانائي جي ڪارڪردگي کي بهتر بڻائي ٿو 57% versus indirect drives and eliminates gearbox maintenance costs
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار | اسان جي HSI کولہو حل | فائدو (% سڌارو) |
| : | : | : | : |
| لباس جو حصو تبديل ڪرڻ وقت (ميجر) | 68 ڪلاڪ (crew of 23) | 0.7 عام| برقرار رکي ٿو >0.85 across settings| More consistent shape |
5. ٽيڪنيڪل وضاحتون
گنجائش جي حد: ماڊل تي منحصر, کان 150 TPH کان مٿي 800 TPH in secondary applications.
روٽر قطر & ويڪر: Ø1000mm x 1000mm کان Ø1500mm x 2000mm تائين.
ڊرائيو پاور گهرجن: کان اليڪٽرڪ موٽر 200 kW کان 600 ڪلواٽ, معياري صنعتي بجلي جي فراهمي سان هم آهنگ.
فيڊ اوپننگ سائيز: Up to 1000mm x 1200mm for primary models; smaller for tertiary configurations.
اهم مواد جي وضاحت: روٽر هاء tensile اسٽيل مان ٺهيل; گھڻن مصرعن ۾ موجود بلو بار (Martensitic اسٽيل, سيرامڪ جامع); abrasionresistant steel liners throughout chamber.
جسماني طول و عرض (عام وڏي ماڊل): لڳ ڀڳ. ڊگھائي: ~ 4 م, ويڪر: ~ 3 م, اوچائي: ~ 3 م (فيڊ هاپر کان سواء).
ماحولياتي آپريٽنگ رينج: 20 ° C کان + 45 ° C تائين محيطي درجه حرارت لاء ٺهيل; dustsealed بيرنگ معياري.
6. درخواست جا منظر
مجموعي پيداوار & چونا پٿر جي کوٽائي | چيلنج: A Midwest quarry needed consistent 8 stone specification with lower fines yield for asphalt production while contending with variable moisture content in feed.| حل: Installation of a tertiary HSI crusher with multifunction aprons and hydraulic adjustment.| نتيجا: Achieved a sustained cubicity index of >0.88 and reduced minus8 material by 12%, increasing premium product yield. Adjustment time for gradation shifts was cut from half a day to under thirty minutes.
اڏاوت & ڊيموليشن ويسٽ ري سائيڪلنگ| چيلنج: اي سي&D recycling facility faced excessive wear costs and unacceptably high contamination levels in final aggregate due to uncrushable materials jamming their crusher.| حل:: Implementation of a primary HSI crusher equipped with a massive solid rotor design and automatic hydraulic apron release system.| نتيجا:: Throughput increased by an estimated18% due to fewer jams.The automatic release system prevented major damage events,two incidents in the first year alone that were previously costing over $25k each in repairs and downtime.
7.تجارتي خيالات
Equipment pricing is tiered based on rotor size,motor power,and feature set,ranging from capital investment suitablefor midsized contractors up tomajor quarrying operations.Options include:
Automated Control Systems Integration
Specialized Wear Part Alloysfor specific abrasion/corrosion profiles
Skidmounted or modular designsfor semiportable applications
Service packages are structured around predictable total cost of ownership.Typical offerings include scheduled inspection plans,wear part kits at fixed annual rates,and remote monitoring diagnostics.Financing options encompassing straight capital purchase,fleet leasing structures,and throughputbased agreements are availableto match your cash flow requirements.
8.FAQ
ق:What typesof feed material are notsuitable fora horizontal shaft impact crusher?
اي:HIS crushers are generally not recommendedfor highly abrasive materials like granite,trap rockor quartzite wherewear costs would be prohibitive.For these applications,a compressionbased jawor cone crusher typically offers better longterm economics.
ق:Canyour impactcrushersbe integrated into our existing PLCcontrolled plant automation?
A Yes.All models come standardwith provisionsfor remote monitoringof key parameters( برداشت جي درجه حرارت,وائبريشن )and can receive control signalsfor start/stopand apron positioning,making full integrationinto existing SCADA systems straightforward.
Q How does the total operating cost comparetoa cone crusherin similar duties?
A For suitable materials( lowto moderate abrasiveness ),an HSI typically offers lower initial capital cost,significantly lower maintenance complexity,and comparable energy cost.Its advantagein producinga cubical product often resultsinhigher downstream value.The economic crossover pointis heavily dependenton local wear partcostsandthe requiredproduct shape specification.
Q Whatisthe expected service lifeof critical componentslike the main rotor?
A With proper operationand avoidanceof uncrushable contaminants,the solidrotor bodyis designedforthe lifetimeofthe machine(20+سال).Individual wear components(blowbars.apron liners)have lifespans measuredin weeksormonths basedon throughputand material abrasiveness.Detailed life estimatesare provided during application review.
Q Are training resources providedfor our maintenance crew?
A Comprehensive onsite commissioningand trainingis includedwith purchase.This covers safe operation,معمولي سار سنڀال جا طريقا,andthe specific wear part changeout sequencefor your model.Digital manualsand parts catalogsare also provided
