Jc5000 Polic nofulla Kompanitë e Inspektimit
1. HAPJE NGA PIKA E DIKIMIT
Are your primary crushing operations constrained by inconsistent throughput, punishing maintenance costs, dhe joproduktive të paplanifikuara? Për menaxherët e impianteve dhe kontraktorët inxhinierikë, the primary crusher is the cornerstone of mineral processing and aggregate production. When it underperforms, the entire operation feels the impact. Merrni parasysh këto sfida të zakonshme:
Kohë joproduktive të paplanifikuara: Bearing failures or component wear can halt your entire processing line, kushton mijëra në orë në prodhim të humbur.
Konsumi i lartë i pjesëve të konsumit: Aggressive feed materials rapidly degrade jaw dies, leading to frequent changeouts, high parts inventories, and labor costs that erode profit margins.
Gradim i paqëndrueshëm i produktit: An unstable or inefficient crushing chamber fails to produce a consistent, wellshaped product, creating bottlenecks for downstream screening and secondary crushing stages.
Tërheqja e tepërt e energjisë: Inefficient crushing motion and outdated drive systems result in higherthannecessary power consumption, a direct and growing operational expense.
Ngurtësia & Çështjet e fondacionit: A crusher frame lacking structural integrity can lead to premature fatigue, alignment problems, and require costly, reinforced foundations.
Is your current solution equipped to deliver the reliability and costpertonne metrics required in today’s competitive market? The specification of your primary jaw crusher is a critical capital decision with decadelong implications for operational efficiency.
2. PËRMBLEDHJE E PRODUKTIT
Thërrmuesi i nofullës JC5000 është me kapacitet të lartë, singletoggle primary crusher engineered for the most demanding mining and quarrying applications. Its design focuses on maximizing throughput of hard, abrasive materials while minimizing lifetime operating costs.
Rrjedha e punës operative:
1. Marrja e ushqimit: Large runofmine feed (madhësia e gungës deri në 1.5 m) drejtohet në thellësi, dhomë dërrmuese pa mbytje.
2. Veprimi dërrmues: A robust eccentric shaft drives a dynamically balanced moving jaw in an aggressive elliptical motion, applying high inertia force to reduce feed material.
3. Shkarkimi & Pastrimi: The steep nip angle and optimized toggle plate kinematics facilitate faster material discharge, preventing chokepoints and promoting continuous flow.
4. Përcjellja e produktit: Crushed material exits at the bottom discharge point onto a primary conveyor for transport to the next stage of processing.
Fusha e Aplikimit: Ideal for stationary primary crushing plants in hard rock mining (mineral hekuri, ari, bakri), granite/quarry operations, dhe prodhimi agregat në shkallë të gjerë.
Kufizimet: Not designed for recycling or construction demolition debris where tramp metal contamination is extreme. Requires a stable electrical supply commensurate with its highpower drive motor.
3. TIPARET THEMELORE
Dizajni i kornizës HeavyDuty | Baza Teknike: Analiza e elementeve të fundme (FEA) shpërndarje e optimizuar e stresit | Përfitimi Operacional: Eliminates frame fatigue cracking under maximum load conditions; allows installation on standard concrete foundations | Ndikimi i ROI: Zvogëlon rrezikun e dështimit katastrofik strukturor; lowers initial civil works cost by up to 15%.
Hydrostatic Wedge Adjustment System | Baza Teknike: Hydraulically actuated wedges replace manual shims | Përfitimi Operacional: Aktivizon rregullimin në distancë të CSS në minuta kundrejt orëve; improves operator safety by eliminating manual handling | Ndikimi i ROI: Cuts downtime for product size changes by over 80%, rritjen e fleksibilitetit të bimëve.
Dhoma e thellë dërrmuese simetrike | Baza Teknike: Optimized geometry with steep nip angle (26°) | Përfitimi Operacional: Enhances feed acceptance capability and promotes accelerated material flow; redukton urën; increases jaw die life via even wear distribution | Ndikimi i ROI: Boosts average throughput by 1015%; zgjat intervalet e pjesëve të konsumimit.
Mbajtëse rul sferike & Forged Eccentric Shaft Assembly | Baza Teknike: Oversized bearings with L10 life calculation exceeding 50,000 orë; integral forging eliminates stress points | Përfitimi Operacional: Provides unmatched reliability under shock loads; ensures consistent alignment for peak efficiency | Ndikimi i ROI: Virtually eliminates bearingrelated unscheduled stoppages over the crusher’s service life.
PLCIntegrated Toggle Plate Protection | Baza Teknike: Hydraulic ram replaces conventional shear pins/pull rods with system pressure monitoring | Përfitimi Operacional: Automatically releases tramp metal/uncrushable material; resets automatically without entering crusher cavity | Ndikimi i ROI: Prevents damage to shaft/bearings; reduces downtime from tramp events from hours to minutes.
Ngasja direkte nëpërmjet VBelts & TEFC Motor | Baza Teknike: Hightorque motor coupled via multiple Vbelts for energy transmission with inherent slippage protection | Përfitimi Operacional: Smoothens load peaks on the drive train; offers simpler maintenance compared to fluid couplings or direct drives | Ndikimi i ROI: Lowers peak current draw on electrical infrastructure; reduces spare parts complexity.
4. PËRPARËSITË KONKURRETARE
| Metrikë e performancës | Standardi i Industrisë (Klasa e krahasueshme) | JC5000 Zgjidhje polic nofulla | Avantazhi (% Përmirësimi) |
| : | : | : | : |
| MTBF (Koha mesatare ndërmjet dështimeve)| ~1,500 operating hours on critical bearings| Të dhënat në terren tregojnë >4,000 hours under equivalent duty| >165% përmirësim |
| Vishni Jetën (Manganese Jaw Dies)| 120,000 - 150,000 tonnes processed| Consistent reports of 180,000 - 220,000 tonnes achieved| 2045% jetë më të gjatë |
| Koha e rregullimit të CSS| Rregullimi manual i shiritit: 48 orë| Hydrostatic wedge system: <45 minuta| ~ 90% ulje |
| Konsumi i energjisë për ton| Baseline reference of 100%| Measured reduction due to efficient kinematics & makinë direkte| 58% më të ulëta |
| Kapaciteti i xhiros (Granit i fortë)| Rated at ~750 tph at specified CSS| Sustained output regularly achieves 800830 tph under same conditions| ~710% higher output |
5. SPECIFIKIMET TEKNIKE
Hapja e furnizimit: 1500mm x 2000 mm (59" x 79")
Madhësia maksimale e furnizimit: Deri në 1250 mm (49")
Cilësimet anësore të mbyllura (CSS) Gama: 180mm 300 mm (7" 12")
Gama e Kapacitetit: Deri në 1500 ton në orë (në varësi të materialit ushqimor dhe CSS)
Kërkesa e fuqisë së makinës: Twin 200kW (260HP) TEFC motors or equivalent singledrive option.
Pesha totale (Vetëm polic): Përafërsisht 125 ton metrikë
Specifikimet kryesore të materialit:
Fabrikimi i kornizës: Highstrength steel plate with internal ribbing.
Moving Jaw/Fixed Jaw Dies: Çeliku i manganit premium (14%,18%,22% në dispozicion).
Bosht ekscentrik: Çeliku i aliazhuar i farkëtuar EN24/34CrNiMo6+.
Kushinetat: Spherical roller type with automated lubrication ports.
Gama e funksionimit të mjedisit: Projektuar për temperaturat e ambientit nga 20°C deri në +50°C (4°F deri +122 °F). Dust seals rated for standard quarry/mine dust conditions.
6. Skenarët e APLIKIMIT
Miniera e Bakrit Hard Rock - Stacioni Primar Thërrmues
Sfida: A South American operation faced excessive downtime from jaw die changes every six weeks and required a threeday shutdown for CSS adjustments on their legacy primary crusher.
Zgjidhje: Implementation of two JC5000 Jaw Crushers configured with the hydrostatic wedge system and deepchamber jaw profiles.
Rezultatet: Wear part life extended to nineweek intervals. CSS adjustments completed during scheduled weekly maintenance windows (<1 orë). Combined effect increased annual available crushing time by an estimated ~400 hours.
LargeScale Granite Quarry – HighAbrasion Duty
Sfida: Achieving consistent product gradation for railway ballast while managing extreme abrasion wear that led to high operating costs per tonne.
Zgjidhje: A JC5000 replaced an older doubletoggle design. Its deep symmetrical chamber promoted better particleonparticle breakage and even wear across jaw dies.
Rezultatet: Product shape improved (+12% përmbajtje kub), meeting stringent ballast specs more consistently. Despite higher upfront cost,the costpertonne of wear parts decreased by approximately18% in the first year of operation.
7. KONSIDERATA TREGTARE
The JC5000 Jaw Crusher is offered as a capital asset solution focused on total cost of ownership.
Niveli i çmimeve të pajisjeve bazë: Includes crusher assembly,motorët,Vbelts drives,and standard lubrication system.Factory testing is included prior to shipment.
Paketat opsionale të veçorive:
Paketa e Automatizimit: Includes PLC controls with touchscreen interface,crusher condition monitoring sensors,and automated lubrication unit.
Wear Part Alloy Upgrade: Selection of premium manganese steel alloys tailored for specific material abrasiveness/impact.
Modular Installation Kit: Prefabricated walkways,shkallët,and service platforms designed for faster,safe site erection.
Paketat e Shërbimit:
1.Plani i Mirëmbajtjes Parandaluese:Inspektimet e planifikuara,analiza lubrifikuese,and annual health checks.
2.Wear Part Supply Agreement:Gauranteed inventory holding,predictable pricing,and scheduled delivery aligned with your maintenance planning.
3.Mbështetje teknike në vend:Dedicated field service engineers available for major overhauls or troubleshooting.
Financing Options are available through partner institutions including equipment leasing structures,tailored loan agreements,and rentaltoown programs designedto align payment scheduleswith project cash flow timelines
FAQ
Q1:What are the foundation requirementsfor installingthe JC5000?
A:The FEAoptimized frame design significantly reduces dynamic loads comparedto older designsof similar capacity.Generally,a standard reinforced concrete foundation meeting specified loadbearing criteriais sufficient.Detailed civil drawingsare providedwith purchase
Q2 How does this crusher handle wet sticky feed material?
A While designed primarilyfor hard rock,the deep chamberand aggressive dischargeaidsin clearingmaterial However extremely sticky clayscan pose challenges like anyjawcrusher We recommend evaluatingfeed characteristicsand may suggest specific chamberdesign modificationsif necessary
Q3 What isthe expected lead timefrom orderto commissioning?
A Lead timesvary basedon global manufacturing schedules Typically deliveryis within months followinga firm order Commissioning supportis providedas partof our technical service offering
Q4 Arewear parts interchangeablewith othercrushersin this class?
A No TheJC uses proprietaryjawdie profilesand bearingassemblies engineeredfor its specific kinematics This ensuresoptimal performanceand longevity Third party partswill voidthe factory warranty
Q5 Can we integrate existingdust suppressionor automation systems?
A Yes Thecrushers controlpanel includesstandardizedinterface pointsfor external systems suchas dust suppression activationor plantwide SCADA communication Our engineeringteam can provideprotocol documentationfor integration
Q6 Whatdoes themanufacturers warrantycoverspecifically?
A Thestandard warrantyprovides months coverageon allpartsand laboragainst defectsin materialsor workmanship It excludeswear itemslike jawdies whichhave their own performanceguarantee basedon processedtonnage Extendedwarrantyoptionsare available
Q7 Do you offerperformance testingprior topurchase?
A We offercomprehensive testreportsfrom our facilityand can arrangevisitsfor qualifiedbuyers totestwith samplematerial where feasible Performanceguaranteesbasedon agreedfeed specificationsare includedin commercialcontracts
