1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Quản lý liên tục, Lưu lượng lớn nguyên liệu thô và clinker là điểm nghẽn dai dẳng trong sản xuất xi măng. Inefficient or unreliable material transport directly impacts your plant’s throughput, tiêu thụ năng lượng, and maintenance overhead. Are you facing these specific challenges with your current system?

Thời gian ngừng hoạt động quá mức để bảo trì: Frequent chain failures, sự đổ tràn, or misalignment in conveying systems can halt an entire production line, gây thiệt hại hàng ngàn mỗi giờ cho sản lượng bị mất.
Tiêu thụ năng lượng cao: Inefficient drives and outdated conveying technology contribute significantly to your plant’s power bill, làm xói mòn tỷ suất lợi nhuận.
Material Degradation & Đổ tràn: Improper handling during transport leads to product loss through dust generation and spillage, creating cleanup costs and potential environmental compliance issues.
Tính linh hoạt hạn chế & Khả năng mở rộng: Inflexible systems struggle to adapt to changes in feedstock or required throughput, hindering process optimization and expansion plans.
Hoạt động tăng trưởng & Rủi ro an toàn: Reliance on manual intervention for loading/unloading or dealing with constant jams increases exposure to safety incidents and repetitive strain injuries.

If these operational costs sound familiar, the specification of your bulk material handling equipment requires a critical review.

2. TỔNG QUAN SẢN PHẨM: HeavyDuty Apron Feeders

Một máy cấp liệu tạp dề hạng nặng là một thiết bị mạnh mẽ, continuousduty machine designed for controlled volumetric feeding of abrasive, nặng, and largesized materials—such as limestone, đá phiến sét, clinker, and slag—in primary crushing and raw mill feed applications. Its operation is based on a series of overlapping pans mounted on crawler chains that form a continuous moving bed.

Quy trình hoạt động:
1. Đang tải: Material is directly dumped onto the feeder pans from a dump hopper or under a stockpile.
2. Chuyên chở: The interconnected pans are pulled by heavyduty chains driven by a gearboxconnected motor. The material rides on the solid pan surface.
3. Phóng điện: Material is carried horizontally or on an incline to a controlled discharge point, typically onto a conveyor belt or directly into a crusher.

Phạm vi ứng dụng: Ideal for primary feeding of ROM (RunofMine) nguyên vật liệu, handling hot clinker (up to specified temperature limits), and severeduty applications with high impact loads. It is the preferred solution where belt feeders would be cut or punctured.

Hạn chế: Not suitable for fine powders alone; higher initial capital cost compared to some belt feeders; requires more substantial foundational support due to weight.

3. TÍNH NĂNG CỐT LÕI

Forged Alloy Chain System | Cơ sở kỹ thuật: Hightensile strength alloy steel with precision heat treatment | Lợi ích hoạt động: Provides exceptional resistance to shock loading and abrasion from heavy materials like limestone boulders | Tác động ROI: Dữ liệu trường hiển thị lên đến 40% longer service life compared to standard chains, reducing replacement frequency and associated downtime costs.

Segmented Overlapping Pans | Cơ sở kỹ thuật: Cast manganese steel pans with boltedon liners | Lợi ích hoạt động: Contains material completely, minimizing spillage and dust; worn liners can be replaced individually without removing entire pan sections | Tác động ROI: Lowers material loss and reduces liner replacement labor time by an average of 35%.

Ổ tần số thay đổi (VFD) Điều khiển | Cơ sở kỹ thuật: Điều khiển động cơ AC cho phép điều chỉnh chính xác tốc độ và mô-men xoắn động cơ | Lợi ích hoạt động: Enables exact feed rate control from 10% ĐẾN 100% capacity to match downstream process demand; provides softstart capability | Tác động ROI: Optimizes crusher or mill feed for maximum efficiency; reduces inrush current during startup, lowering energy costs.

Bịt kín & Lubricated Roller Bearings | Cơ sở kỹ thuật: Labyrinth seals with automatic grease purge systems at each head shaft bearing | Lợi ích hoạt động: Excludes abrasive dust from critical bearing surfaces under high load conditions | Tác động ROI: Kéo dài tuổi thọ vòng bi hơn 50%, preventing unplanned stoppages due to bearing seizure.

Modular Pan & Thiết kế khung | Cơ sở kỹ thuật: Bolttogether frame sections and standardized pan modules | Lợi ích hoạt động: Đơn giản hóa việc vận chuyển, installation onsite within confined spaces like existing feed floors; facilitates future length extensions | Tác động ROI: Giảm thời gian lắp đặt khoảng 25% versus welded monolithic frames.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Bộ nạp tạp dề tiêu chuẩn công nghiệp | Giải pháp nạp tạp dề HeavyDuty của chúng tôi | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Thời gian trung bình giữa các lần thất bại (MTBF) Hệ thống dây chuyền| ~8.000 giờ hoạt động| >12,000 giờ hoạt động| +50% |
| Energy Efficiency at Rated Load| Đường cơ sở (100%)| Hệ thống truyền động được tối ưu hóa & Kiểm soát VFD| Lên đến 15% reduction in kW/ton |
| Pan Liner Replacement Time (per segment)| ~4 giờ (mối hàn/bu lông đầy đủ)| ~2.5 hours (modular bolton)| 37% |
| Maximum Handling Capacity (tph)| Varies by width/design| Engineered head shaft & drive for 20% overload capacity| +20% surge capability |

5. THÔNG SỐ KỸ THUẬT

Phạm vi công suất: Từ 500 TPH đến hơn 3,000 TPH standard models; custom engineering available.
Yêu cầu về nguồn điện: Được dẫn động bởi động cơ từ 75 kW để 400 kW+, supplied with IP66 protection rating for harsh environments. Compatible with plant voltages up to 6.6kV.
Thông số vật liệu: Chảo: ASTM A128 Grade BHN Manganese Steel liners on structural steel bases. Dây chuyền: Thép hợp kim rèn, heattreated for hardness core with tough exterior.
Kích thước vật lý: Chiều rộng tiêu chuẩn từ 1,5m đến 3m; lengths customized from 4m to over 30m. Incline capability up to 25 độ.
Phạm vi hoạt động môi trường: Phạm vi nhiệt độ môi trường xung quanh: 20°C đến +45°C. Capable of handling material temperatures up to 120°C continuously (special designs available for hotter clinker).

6. KỊCH BẢN ỨNG DỤNG

Cement Plant Primary Crushing Feed | Thử thách: A plant experienced chronic downtime due to belt feeder ripping under impact from large (>1tôi) limestone boulders from the quarry ROM pad. Spillage was severe.| Giải pháp: Installation of a widewidth heavyduty apron feeder between the dump hopper and jaw crusher.| Kết quả: Eliminated feederrelated stoppages entirely for over two years since installation; spillage reduced by an estimated 95%; crusher feed rate stabilized for optimal operation.

Xử lý xả máy làm mát Clinker | Thử thách: Clinker nóng (khoảng. 80°C) was causing excessive wear on standard conveyor belts at the cooler outlet, leading to quarterly belt replacements.| Giải pháp: Implementation of an inclined apron feeder designed for elevated temperatures as the first stage transporter.| Kết quả: Conveyor belt life extended threefold; total system availability increased due to predictable wear patterns on replaceable apron pan liners.

7. CÂN NHẮC THƯƠNG MẠI

Bậc giá: Configured based on width/length/capacity specifications:
Cấp I (2500 TPH): Customengineered superheavy duty design.

Tính năng tùy chọn: Integrated weighing systems (belt scale), automatic lubrication systems tailored for specific intervals/conditions wear monitoring sensors integrated into chain pins full guarding packages per local regulations.

Gói dịch vụ có sẵn:

Hỗ trợ vận hành
Annual Inspection Program
Critical Spare Parts Kits
OnSite Training

Financing options include capital lease operating lease structures tailored project financing through our industrial finance partners terms typically range from months years depending upon agreement structure

8.Câu hỏi thường gặp

Q1.Is this equipment compatible with our existing PLCbased control system?
Yes all variable frequency drives come equipped standard communication protocols such as Modbus TCP/IP Profibus DP allowing integration into most modern plant distributed control systems

Q2.What is typical lead time delivery?
For standard capacity models within our Tier II range lead time averages weeks Custom engineered highcapacity units require detailed engineering plan accordingly

Q3.Does installation require extensive foundation work?
The modular frame design simplifies foundation requirements however due significant weight dynamic loads proper reinforced concrete foundations are essential Detailed civil drawings are provided part our technical package

Q4.How does this address operator safety concerns?
The fully enclosed pan design contains material reducing dust exposure risk The inclusion zerospeed switches ensures machinery cannot start unexpectedly during inspection All rotating parts are guarded per ISO standards

Q5.What warranty coverage provided?
We offer months comprehensive warranty covering defects materials workmanship Extended warranty options are available purchase covering major components such as chains sprockets gearboxes

Q6.Can you supply matching spare parts years down line?
Yes we maintain digital manufacturing records all major components ensuring that replacement parts will match original specifications exactly even decades after initial purchase

Q7.Are performance guarantees offered?
Yes we provide guaranteed minimum throughput capacity based on specified material characteristics along with guaranteed power consumption envelope under defined operating conditions