Jc5000 جبڑے کولہو ڪارخانو بروشر
مواد: Jc5000 جبڑے کولہو ڪارخانو بروشر
1. درد پوائنٽ هلائيندڙ اوپننگ
Your primary crushing circuit is the bottleneck. Every hour of unplanned downtime on a 500+ TPH jaw crusher costs your operation between $15,000 ۽ $50,000 in lost production and demurrage fees. Are you still managing premature wear on toggle plates that fail at 800 ڪلاڪ? Are your maintenance crews spending 12+ hours on a simple jaw die change due to poor access? Do you face inconsistent product gradation that forces your secondary cone crusher to operate at 70% ڪارڪردگي? These are not theoretical risks. Industry data from the past five years shows that 60% of primary crusher failures stem from inadequate frame strength and substandard bearing housing design. The Jc5000 Jaw Crusher is engineered to eliminate these specific cost centers.
2. پيداوار جو جائزو
Jc5000 هڪ ڳري ڊيوٽي آهي, singletoggle overhead eccentric jaw crusher designed for continuous primary reduction of hard rock and recycled materials. It operates on a direct drive hydraulic assist system, delivering a 500 TPH nominal capacity at a closed side setting (سي ايس ايس) of 150mm.
آپريشنل ڪم فلو:
1. کاڌو: مواد (up to 900mm feed opening) enters the crushing chamber via a vibrating feeder or direct truck dump.
2. ڪِرڻ: سنسڪرت شافٽ گھمندو آهي, moving the swing jaw in an elliptical path against the fixed jaw, compressing material until it fractures.
3. خارج ٿيڻ: ڀريل مواد (typically 150mm minus) exits through the adjustable CSS at the base of the Vshaped chamber.
4. تحفظ: Hydraulic relief cylinders automatically open the setting to pass uncrushable tramp iron, resetting in under 30 سيڪنڊ.
ايپليڪيشن جو دائرو: Primary crushing for granite, بيسالٽ, درياهه جي پٿر, and limestone in quarrying and mining operations. حدون: Not recommended for wet, sticky clay materials exceeding 15% moisture content without a grizzly feeder bypass.
3. بنيادي خاصيتون
هائيڊولڪ ويج سي ايس ايس ايڊجسٽمينٽ | ٽيڪنيڪل بنياد: Doubleacting hydraulic cylinders replace mechanical shims | آپريشنل فائدا: Your operators can adjust the CSS from 75mm to 200mm in under 5 minutes via a remote pendant, eliminating 2hour manual shim changes | ROI اثر: Reduces downtime for product specification changes by 90%, هڪ اندازي جي بچت $4,000 per adjustment event.
محدود عنصرن جو تجزيو (ايف اي اي) اصلاح ٿيل فريم | ٽيڪنيڪل بنياد: دٻاءُ کان نجات حاصل ڪئي, heavyduty steel plate construction with reinforced ribbing at the pitman bearing housing | آپريشنل فائدا: The frame withstands peak crushing forces of 800 tons without cracking, خدمت جي زندگي کي وڌايو 40,000 ڪم جا ڪلاڪ | ROI اثر: Eliminates one major frame rebuild cycle over a 10year period, بچت $120,000 in capital repair costs.
ٽوگل پليٽ & Seat Protection System | ٽيڪنيڪل بنياد: Ductile iron toggle plate with a shear pin design and replaceable bronze seat inserts | آپريشنل فائدا: The toggle plate acts as a sacrificial fuse; if a noncrushable object enters, the plate fractures before damaging the pitman or frame | ROI اثر: Reduces catastrophic failure repair costs from $50,000 (pitman replacement) جي طرف $2,500 (toggle plate replacement).
Spherical Roller Bearings with Labyrinth Seals | ٽيڪنيڪل بنياد: Fourrow spherical roller bearings in the pitman, sealed with a multistage labyrinth and grease purge system | آپريشنل فائدا: Prevents dust ingress in highparticulate environments, برداشت واري زندگي کي وڌائڻ 25,000 عام لوڊ هيٺ ڪلاڪ | ROI اثر: بيئرنگ جي بدلي جي تعدد کي گھٽائي ٿو 40% compared to standard lip seals, بچت $8,000 في بدلي واقعي.
موٽڻ لائق & Interchangeable Jaw Dies | ٽيڪنيڪل بنياد: 18% مينگنيز اسٽيل (Mn18Cr2) dies with a symmetrical tooth profile | آپريشنل فائدا: Your crew can flip the stationary and movable dies to expose a fresh wear face, extending die life by 35% متبادل کان اڳ | ROI اثر: Reduces annual wear part consumption by $15,000 لاءِ 500 TPH آپريشن.
هائيڊولڪ چيمبر صاف ڪرڻ وارو نظام | ٽيڪنيڪل بنياد: Hydraulic cylinders on the toggle beam retract the swing jaw | آپريشنل فائدا: If the chamber stalls, the operator can clear a jammed rock in 10 minutes without torches or manual labor | ROI اثر: ختم ڪري ٿو 4 hours of downtime per jam event, بچت $60,000 annually in lost production for a typical quarry.
Modular SubFrame & Skid Mount | ٽيڪنيڪل بنياد: Preassembled subframe with vibration isolation mounts | آپريشنل فائدا: Installation time is reduced to 3 days on a prepared concrete pad, بمقابله 7 days for fieldwelded frames | ROI اثر: Reduces site installation labor costs by $18,000.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | انڊسٽري معيار (500 TPH ڪلاس) | Jc5000 حل | فائدو (% سڌارو) |
| : | : | : | : |
| CSS ترتيب ڏيڻ جو وقت | 120 منٽ (دستي شيمس) | 5 منٽ (هائيڊولڪ ويج) | 96% تيز |
| Frame Service Life | 25,000 ڪلاڪ (معياري اسٽيل) | 40,000+ ڪلاڪ (FEA optimized) | 60% وڌيڪ |
| بيئرنگ مٽائڻ وارو وقفو | 15,000 ڪلاڪ | 25,000 ڪلاڪ | 40% وڌيڪ |
| ٽرام لوهه جي حفاظت | Mechanical springs (slow reset) | هائيڊولڪ رليف (30 sec reset) | 90% تيز بحالي |
| Jaw Die Utilization | 65% (single use) | 100% (reversible جوڙجڪ) | 54% more wear metal used |
| انسٽاليشن وقت | 7 ڏينهن | 3 ڏينهن | 57% تيز سيٽ اپ |
5. ٽيڪنيڪل وضاحتون
| پيرا ميٽر | تفصيل |
| : | : |
| ماڊل | Jc5000 |
| فيڊ کولڻ (ڊبليو ايڪس ڊي) | 1,200 ايم ايم x 900 ايم ايم |
| نامياتي صلاحيت | 350 500 ٽي پي ايڇ (CSS ۽ مادي کثافت تي منحصر آهي) |
| بند طرف سيٽنگ (سي ايس ايس) حد | 75 ايم ايم 200 ايم ايم |
| تجويز ڪيل وڌ ۾ وڌ فيڊ سائيز | 750 ايم ايم (90% گذرڻ) |
| سنسڪرت شافٽ جي رفتار | 220 آر پي ايم |
| موٽر پاور | 160 ڪلواٽ (220 ايڇ پي) 200 ڪلواٽ (270 ايڇ پي) |
| مکيه فريم مواد | ASTM A36 / S355JR steel plate, دٻاءُ گهٽ |
| جبل مرڻ جو مواد | Mn18Cr2 (18% منگني) |
| ڪل وزن (لڳ ڀڳ) | 48,000 ڪلو (106,000 lbs) |
| آپريٽنگ جي درجه حرارت جي حد | 20°C کان +45°C (4°F کان 113°F) |
| لوڻ جو نظام | گريس (automatic system optional) |
6. ايپليڪيشن منظرنامو
سخت پٿر جي کوٽائي (گرينائيٽ) | چيلنج: A quarry in Norway was experiencing 800hour toggle plate failures due to high silica content (65% SiO2). Downtime for replacement was 6 ڪلاڪ في واقعي. | حل: Installed the Jc5000 with the ductile iron toggle plate and hydraulic relief system. | نتيجا: Toggle plate life increased to 2,400 ڪلاڪ. Hydraulic relief cleared three tramp iron events in the first year without any mechanical damage. سالياني سار سنڀال جي خرچن ۾ گهٽتائي $34,000.
ريسائيڪلنگ (ڪنڪريٽ & اسفالٽ) | چيلنج: A recycling contractor in Germany needed a crusher that could handle rebarladen concrete without frequent jams. Standard jaw crushers required manual torch cutting every 20 ڪلاڪ. | حل: Deployed the Jc5000 with the hydraulic chamber clearing system. | نتيجا: Jam clearing time reduced from 3 ڪلاڪ تائين 10 منٽ. جي ذريعي وڌي ويو 15% گھٽتائي وقت جي ڪري. The operator achieved a 12month payback on the crusher premium.
زير زمين کان کني (ٽامي جي مٽي) | چيلنج: A mine in Chile required a lowprofile primary crusher for a decline access drift. گنجائش محدود هئي, and vibration transmission to the surrounding rock was a concern. | حل: Used the Jc5000 modular subframe with vibration isolation mounts. | نتيجا: Installation was completed in 2.5 ڏينهن. Vibration levels at the rock interface were reduced by 70% compared to the previous fixed installation. The crusher has operated for 18 months without a structural failure.
7. تجارتي خيالات
سامان جي قيمت جا درجا:
- بنيادي يونٽ (Jc5000B): $285,000 ڪرشر شامل آهي, موٽر, ويبلٽس, and standard grease lubrication.
- ترقي يافته پيڪيج (Jc5000A): $345,000 Adds hydraulic wedge CSS adjustment, hydraulic chamber clearing, and automatic grease system.
- پريميئم پيڪيج (Jc5000P): $395,000 Includes all advanced features plus a remote monitoring system (وائبريشن, گرمي پد, پاور ڊرا), spare toggle plate kit, and a full set of jaw dies.
- Ceramic Insert Jaw Dies: +$12,000 (extends life by 50% abrasive اپليڪيشن ۾).
- Crusher Duty Motor (200 ڪلواٽ): +$8,500.
- Feed Chute Liner Package: +$4,200.
- معياري وارنٽي: 12 مهينا يا 3,000 ڪم جا ڪلاڪ.
- توسيع وارنٽي (Plus): 36 مهينا يا 10,000 ڪلاڪ (سالياني چڪاس شامل آهي). لاڳت: 8% يونٽ جي قيمت.
- ڪارڪردگي جي ضمانت: ضمانت 500 TPH at 150mm CSS for specific material types. لاڳت: 5% يونٽ جي قيمت (rebate if not met).
- آپريٽنگ ليز: 3660 مهيني جا شرط, starting at $6,200/month for the Advanced Package.
- Capital Lease with $1 Buyout: 48مهيني جي مدت, 6.5% اپريل (ڪريڊٽ جي منظوري جي تابع).
- ملتوي ادائيگي جو منصوبو: 10% هيٺ, first payment due in 90 ڏينهن.
اختياري خاصيتون:
سروس پيڪيجز:
فنانسنگ جا اختيار:
8. FAQ
ق: Can the Jc5000 handle material with high moisture content?
اي: The Jc5000 is designed for dry to moderately moist material (تائين 10% نمي). For material exceeding 15% نمي, we recommend a grizzly feeder to bypass fines. The crushing chamber geometry is optimized to minimize packing, but sticky clay can still cause bridging.
ق: What is the expected lifespan of the jaw dies in a typical granite application?
اي: Field data from our customers shows an average of 1,200 جي طرف 1,800 operating hours for the Mn18Cr2 dies in granite with 60% SiO2. Using the reversible feature, you can achieve up to 2,400 hours total life before replacement.
ق: How does the hydraulic tramp iron system differ from spring relief?
اي: Spring systems require manual resetting and often fail to open fully under high pressure. The Jc5000 hydraulic system uses a nitrogen accumulator to provide a controlled opening force. It resets automatically in under 30 سيڪنڊ, restoring the CSS to its original setting without operator intervention.
ق: What are the foundation requirements for the Jc5000?
اي: A reinforced concrete pad of at least 6m x 4m x 1.5m thick is required, with anchor bolts embedded per our provided template. The modular subframe reduces the need for precise leveling, but the pad must support a static load of 60 tons plus dynamic loading.
ق: Is the Jc5000 compatible with existing plant control systems?
اي: ها. The Advanced and Premium packages include a PLC with Modbus RTU and Ethernet/IP communication protocols. It can integrate with your existing SCADA system to provide realtime data on power draw, برداشت جي درجه حرارت, and CSS position.
ق: What is the lead time for a Jc5000 order?
اي: معياري وقت آهي 1416 آرڊر جي تصديق کان هفتي. The Premium package may require 1820 weeks due to the remote monitoring system integration. جلدي حڪم (810 هفتا) a سان موجود آهن 10% پريميئم.
ق: بين الاقوامي خريد ڪندڙن لاءِ ڪهڙا مالياتي اختيار موجود آهن?
اي: We offer export credit agency (اي سي اي) backed financing for qualified buyers in select regions. For standard international sales, we accept letters of credit (ايل/سي) نظر ۾ يا 30% سان گڏ جمع 70% شپنگ دستاويزن جي خلاف. Operating leases are available for North American and European customers.
