Luxury Jc5000 Jaw Crusher Manufacturers
ھدف پلانٽ مينيجرز, خريداري جي ڊائريڪٽرن, ۽ انجنيئرنگ ٺيڪيدار: هڪ ٽيڪنيڪل & Commercial Evaluation of the JC5000 Jaw Crusher
1. PAINPOINT driven اوپننگ
Managing primary crushing operations involves persistent challenges that directly impact your bottom line. If you are evaluating a new primary jaw crusher, you are likely seeking solutions to these specific issues:
اڻ شيڊول بند وقت: Bearing failures or frame fatigue cracks can halt your entire processing line. جي حقيقي قيمت ڇا آهي 48+ hours of lost production while awaiting repairs and components?
اعلي آپريشنل خرچ: Are you constantly managing high energy consumption per ton of material processed and facing escalating costs for wear part replacement in highly abrasive environments?
غير مطابقت رکندڙ ذريعي & پيداوار جي درجه بندي: Fluctuations in feed material hardness or size can cause chokefeeding or poor cavity utilization, leading to suboptimal yield and downstream process inefficiencies.
سار سنڀال جي پيچيدگي: Does routine maintenance require excessive manpower and time? Are critical components difficult and unsafe to access, increasing labor costs and exposure risk?
ڪيپيٽل لاڪ اپ: Is your capital equipment failing to deliver the projected lifespan or total cost of ownership, requiring earlierthananticipated reinvestment?
The selection of a primary crusher is a longterm strategic decision. The following analysis provides a detailed examination of the JC5000 Jaw Crusher to determine if its engineering addresses these operational and financial challenges.
2. پيداوار جو جائزو
JC5000 هڪ ڳري ڊيوٽي آهي, سنگل ٽوگل جبڑے کولہو انجنيئر ٿيل اعلي ظرفيت لاءِ مائننگ ۾ پرائمري ڪرشنگ, وڏي پيماني تي کوٽائي, and major construction aggregate production. Its design focuses on maximizing mechanical reliability and throughput in continuous, severeduty cycles.
آپريشنل ڪم فلو:
1. کاڌ خوراڪ: Oversized feed material (1500mm تائين) اونهي ۾ هدايت ڪئي وئي آهي, هڪ vibrating grizzly فيڊر ذريعي nonchoking ڪرشنگ چيمبر (اختياري).
2. ڇڪڻ وارو عمل: هڪ مضبوط سنسڪرت شافٽ متحرڪ طور تي متوازن حرڪت واري جبڑے جي پليٽ کي بيضوي حرڪت ۾ هلائي ٿو, applying compressive force to reduce material against a fixed jaw plate.
3. ڊسچارج سيٽنگ: بند سيٽنگ (سي ايس ايس) is hydraulically adjustable from the control panel while under load or during operation, allowing rapid product size changes without downtime.
4. مواد خارج ڪرڻ: ڪٽيل مواد هيٺان خارج ٿيڻ واري اوپننگ ذريعي نڪرندو آهي, with product size consistency maintained by the steep nip angle and aggressive kinematics.
ايپليڪيشن جو دائرو & حدون:
دائرو: سخت پٿر لاء مثالي (گرينائيٽ, بيسالٽ), لوهه, and abrasive conglomerates in stationary plant configurations. Suited for operations requiring consistent throughput between 750 1,400 mtph depending on material characteristics and CSS.
حدون: Not designed for recycling or mixed demolition waste without prescreening. Requires a stable reinforced concrete foundation and significant plant footprint. Maximum feed size and capacity are contingent on specific material density and abrasiveness.
3. بنيادي خاصيتون
HeavyDuty فريم ڊيزائن | ٽيڪنيڪل بنياد: محدود عنصرن جو تجزيو (ايف اي اي) بهتر دٻاء جي ورڇ | آپريشنل فائدا: Eliminates stress concentration points that lead to frame cracking under cyclical loading | ROI اثر: Extended structural life reduces risk of catastrophic failure and premature asset replacement.
Hydrostatic ڊرائيو سسٽم | ٽيڪنيڪل بنياد: Direct hydraulic motor drive with variable displacement pumps | آپريشنل فائدا: مڪمل لوڊ هيٺ هموار شروعات فراهم ڪري ٿي, رڪاوٽون صاف ڪرڻ لاء واپسي وارو آپريشن, and infinite variable speed control | ROI اثر: Lower mechanical stress on drive components extends belt & زندگي گذارڻ; energy efficiency improves at partial loads.
Integrated Toggle Plate Protection | ٽيڪنيڪل بنياد: Mechanically actuated shear bolt system behind the toggle plate | آپريشنل فائدا: Protects crusher from uncrushable material (مثال, ڌاتو ڌاتو) by initiating a safe mechanical failure point | ROI اثر: Prevents damage to major castings (پيٽ وارو, فريم), avoiding repairs that cost 1020x more than replacing a shear bolt.
QuickChange WedgeLocked Jaw Plates | ٽيڪنيڪل بنياد: Interlocking wedge & bolt retention system without traditional backing resin | آپريشنل فائدا: Enables full jaw plate changeout in under 8 hours with standard plant tools | ROI اثر: Minimizes downtime for wear part replacement, increasing annual operating hours and revenuegenerating capacity.
مرڪزي گريسنگ & PLC خودڪار | ٽيڪنيڪل بنياد: Automated lubrication cycles managed by Programmable Logic Controller (پي ايل سي) with feedback sensors | آپريشنل فائدا: Ensures consistent bearing lubrication without operator intervention; provides realtime alerts for flow faults | ROI اثر: Eliminates bearing failures due to manual greasing errors, directly reducing a top cause of unscheduled stoppages.
4. مقابلي جا فائدا
| ڪارڪردگي ميٽرڪ | Industry Standard for 1250x1000mm Class Crusher | JC5000 جبڑے کولہو حل | فائدو (% سڌارو) |
| : | : | : | : |
| دستيابي (اپٽائم)| 9294% (مقرر & اڻ شيڊول) | Field data indicates 96%+ sustained availability| +24% سڌارو |
| زندگيءَ جو لباس (Mn18/22 Jaw Plates)| ~550,000 MT granite (@ CSS 180mm)| >700,000 MT demonstrated in field trials| +27% واڌارو |
| توانائي جو واھپو| ~0.85 kWh/ton processed average| ~0.72 kWh/ton documented in thirdparty audits| ~ 15٪ گهٽتائي |
| سار سنڀال بند وقت (سالياني)| 180220 hours for routine/service| جو ھدف 22% گهٽتائي |
| Hydraulic Adjustment Cycle Time| دستي شيم جي ترتيب (~ 48 ڪلاڪ)| Remote hydraulic adjustment (<10 منٽ)| ~98% faster |
5. ٽيڪنيڪل وضاحتون
فيڊ کولڻ: 1250mm x 1000mm
وڌ ۾ وڌ فيڊ سائيز: Up to 1500mm lump (dependent on feed geometry)
گنجائش جي حد: 750 - 1,400 ميٽرڪ ٽين في ڪلاڪ (varies with material density, سختي, ۽ CSS)
ڊرائيو پاور: Electric motor options from 200kW to 250kW; Hydrostatic drive system standard.
ڪل وزن: لڳ ڀڳ 85,000 ڪلو (صرف کولہو)
اهم مواد جي وضاحت:
فريم: FEAoptimized ربنگ سان ٺهيل اسٽيل پليٽ.
Swing Jaw/Pitman: Highstrength cast steel.
Main Eccentric Shaft: سڌائي واري مشين سان جڙيل مصري اسٽيل.
بيئرنگ: Spherical roller bearings rated for extreme loads.
جسماني طول و عرض (ايل x ڊبليو x ايڇ): ~4.2m x 3.8m x 3.5m
ماحولياتي آپريٽنگ رينج: Designed for ambient temperatures from 20°C to +50°C with appropriate lubricants. Dust seals rated for typical quarry/mine conditions.
6. درخواست جا منظر
گرينائيٽ ڪواري توسيع پروجيڪٽ
Challenge A major aggregate producer needed to increase primary circuit throughput by 25% without expanding their plant footprint or foundation work.
Solution Replacement of two older jaw crushers with a single JC5000 Jaw Crusher equipped with an intelligent feed control system.
Results Throughput increased by an average of 28%. Plant availability rose from 91% ختم ڪرڻ 96% within the first year due to reduced mechanical issues. Energy consumption per ton dropped by an estimated $1 million USD over five years.
لوھ لوھ پروسيسنگ پلانٽ اپ گريڊ
Challenge Frequent tramp metal events from upstream mining were causing catastrophic damage to the existing primary crusher's toggle seat and pitman casting.
Solution Installation of the JC5000 Jaw Crusher featuring its integrated shear bolt protection system alongside an upgraded metal detection system.
ٻن سالن جي آپريشن ۾ نتيجا, three tramp metal events successfully triggered the shear bolt system. Each event resulted in less than $5k USD in parts/labor versus an estimated $80k+ USD repair plus one week's downtime previously experienced.
7 تجارتي خيالات
The JC5000 Jaw Crusher is positioned as a premium capital asset with total costofownership justification over a minimum expected service life of fifteen years under normal conditions.
Pricing is structured around core configuration:
Tier A – Base Unit includes crusher motor drives basic hydraulic power pack PLC controls
Tier B – Premium Package adds automated grease system wear monitoring sensors spare wear parts kit
Tier C – Turnkey Skid includes crusher premounted on heavyduty skid with integrated walkways ladders prepiped lubrication
Optional Features Highperformance jaw plate alloys extended warranty packages remote telemetry connectivity
Service Packages Annual inspection contracts fixedprice lifecycle maintenance agreements guaranteed parts availability programs
Financing Options Available through partners include capital lease operating lease project financing terms typically range from three seven years
A detailed quotation will itemize these options allowing for precise capital expenditure planning
FAQ
What type of feeder is recommended for optimal performance with the JC5000?
A vibrating grizzly feeder VGF matched to the crushers intake width is strongly recommended It ensures even distribution across the full chamber length maximizes capacity prevents bridging
Can existing plant electrical infrastructure support this crushers power requirements?
The JC5000 requires connection based on its specific motor configuration typically starting at kW A site audit by our engineers can verify compatibility including softstart requirements
How does hydraulic adjustment compare mechanically to traditional shim adjustment?
The hydraulic system uses cylinders positioned behind the toggle seat It adjusts both jaws simultaneously maintaining chamber geometry This method provides greater precision under load eliminating unplanned downtime associated with manual shimming
What is included in your standard warranty coverage?
We provide months coverage on all major components frame pitman shaft bearings against defects in materials workmanship Wear parts jaw plates cheek plates are covered separately under specific terms based on application
ڇا توهان ڪارڪردگي جي ضمانت پيش ڪندا آهيو
Yes we provide guaranteed minimum capacity figures based on certified feed material samples These are contractually agreed prior to purchase ensuring mutual alignment on operational expectations
