1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Are escalating operational costs and unpredictable downtime eroding your aggregate or mineral processing margins? Primary crushing stages present persistent challenges: excessive wear part consumption driving high costperton, unplanned stoppages for tramp metal damage, and inconsistent feed size reduction causing bottlenecks downstream. Consider the impact of just one extra hour of unscheduled maintenance per week on your annual production targets. How much revenue is lost to vibrationrelated foundation stress and premature bearing failures? What is the true cost of a crusher that cannot adapt to varying feed material hardness without manual intervention? These are not merely equipment issues; they are direct threats to plant throughput and profitability. A primary jaw crusher must be a pillar of reliability, not a source of variability.

2. TỔNG QUAN SẢN PHẨM

JC5000 có công suất cao, singletoggle jaw crusher engineered for the most demanding primary crushing applications in mining, khai thác đá, và tái chế xây dựng quy mô lớn. Its design focuses on delivering maximum availability and the lowest possible operating cost in its class.

Quy trình hoạt động:
1. Lượng thức ăn ăn vào: Vật liệu mỏ hoặc mỏ khai thác lớn (lên tới 1500mm) được hướng vào vực sâu, buồng nghiền không nghẹt thở.
2. Giảm kích thước: A robust eccentric shaft drives a dynamically balanced moving jaw in an elliptical motion, applying compressive force to fracture material against the fixed jaw.
3. Phóng điện: Crushed product exits at the bottom of the chamber, with a discharge setting adjustable via hydraulic wedge or shim systems to ensure precise output gradation.

Phạm vi ứng dụng: Lý tưởng cho đá cứng (đá granit, đá bazan), quặng mài mòn, và phá dỡ bê tông. It is designed as a stationary primary unit for hightonnage fixedplant operations.

Hạn chế: Not suitable for sticky, plastic clays or as a mobile unit without significant structural support. Requires a prepared foundation and substantial primary feed conveyance infrastructure.

3. TÍNH NĂNG CỐT LÕI

Chuyển đổi thủy lực & Hệ thống điều chỉnh | Cơ sở kỹ thuật: Xi lanh thủy lực tác động kép thay thế tấm chuyển đổi cơ khí | Lợi ích hoạt động: Cho phép an toàn, remote clearing of blockages and adjustment of the closedside setting (CSS) in minutes versus hours | Tác động ROI: Giảm thời gian ngừng hoạt động để điều chỉnh thường xuyên lên tới 80% and minimizes personnel exposure to hazardous manual tasks.

HeavyDuty Spherical Roller Bearing Cartridge | Cơ sở kỹ thuật: Forged steel cartridge with oversized bearings designed for high radial and axial loads | Lợi ích hoạt động: Eliminates stress concentrations on bearing seats, extends lubrication intervals, and ensures precise shaft alignment under shock loading | Tác động ROI: Dữ liệu hiện trường cho thấy một 40% increase in average bearing service life compared to traditional pillow block designs.

Boltless Fixed Jaw Die Retention | Cơ sở kỹ thuật: Wedgelock system secures jaw dies without traditional head bolts | Lợi ích hoạt động: Allows faster, safer die changes; eliminates bolt stretch failures and thread seizure issues common in highvibration environments | Tác động ROI: Giảm thời gian thay lớp lót khoảng 30%, increasing crusher availability.

Phân tích phần tử hữu hạn (FEA) Optimized Frame | Cơ sở kỹ thuật: Computermodeled stress distribution used to reinforce highload zones with additional steel while optimizing weight elsewhere | Lợi ích hoạt động: Provides exceptional rigidity to withstand peak crushing forces with minimal frame flex, protecting internal components | Tác động ROI: Mitigates risk of catastrophic frame fatigue failure, protecting longterm asset value.

Tùy chọn sàng lọc trước Grizzly tích hợp | Cơ sở kỹ thuật: Vibrating grizzly section mounted directly onto crusher feed hopper | Lợi ích hoạt động: Bypasses subcrushsize fines directly to discharge belt, reducing unnecessary wear in the crushing chamber and boosting effective capacity | Tác động ROI: Can increase processed tonnage by 1525% on material with high fines content by eliminating chamber choke points.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Lớp có thể so sánh) | JC5000 Solution Documented Result | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Mặc một phần cuộc sống (Mn18/22 Jaw Dies) | 120,000 150,000 MTon (Đá granite mài mòn) | 180,000 220,000 MTon (Đá granite mài mòn) | +50% Cuộc sống kéo dài |
| Annual Planned Maintenance Hours| ~250 hours (bao gồm. thay đổi lót & điều chỉnh) | ~160 hours (bao gồm. thay đổi lót & điều chỉnh) |36% Maintenance Time |
| Tiêu thụ điện năng trên mỗi tấn nghiền| Đường cơ sở (100%) at CSS of 200mm on Basalt| Measured at CSS of 200mm on Basalt |8% Sử dụng năng lượng |
| Noise Emission at 10 Mét| ~105 dBA during operation| ~98 dBA during operation |7 dBA Reduction |

_Based on internal testing reports vs. previous generation designs; actual results may vary based on feed material and operating conditions._

5. THÔNG SỐ KỸ THUẬT

Mở nguồn cấp dữ liệu: 1500mm x 2000mm (59" x 79")
Kích thước nguồn cấp dữ liệu tối đa: Up to 1300mm (51")
Phạm vi cài đặt bên đóng: 175 300 mm (7" 12")
Phạm vi công suất: Lên đến 1,750 MTPH depending on material type & CSS
Yêu cầu năng lượng ổ đĩa: 200 kW / Up to VSD compatible
Tổng trọng lượng (Chỉ máy nghiền): Khoảng 86 tấn mét
Thông số kỹ thuật vật liệu chính: Khung thép chế tạo cường độ cao; Forged quenched & tempered eccentric shaft; Manganese steel jaw dies standard.
Phạm vi hoạt động môi trường: Được thiết kế cho nhiệt độ môi trường xung quanh từ 20°C đến +50°C (4°F đến +122°F). Dust sealing kits available for extreme conditions.

6. KỊCH BẢN ỨNG DỤNG

Khai thác đá cứng - Sản xuất cốt liệu đá granite

Thử thách: A large granite quarry faced unsustainable costs due to frequent jaw die changes every 90k tons and excessive downtime from tramp steel incidents damaging pitman bearings.
Giải pháp: Implementation of two JC5000 units featuring the hydraulic toggle system for quick clearing and boltless die retention.
Kết quả: Achieved an average die life extension to 165k tons per set. The hydraulic system cleared three major tramp metal events in under 30 minutes each—incidents that previously caused 8+ hours of downtime per event—resulting in an estimated 450 additional production hours annually.

Iron Ore Primary Crushing Station

Thử thách: An iron ore processing plant required higher primary throughput but was limited by an older crusher's inability to handle variable feed hardness without constant manual CSS adjustment.
Giải pháp: Installation of a JC5000 equipped with automated wear compensation software linked to its hydraulic adjustment system.
Kết quả: The system automatically maintained consistent product top size despite fluctuating ore hardness bands (±15% UCS). This stabilized feed to the secondary circuit, increasing overall plant throughput by an average of 9%. Power monitoring showed a 7% reduction in specific energy consumption versus the retired unit.

7. CÂN NHẮC THƯƠNG MẠI

The JC5000 is positioned as a capital investment focused on total cost of ownership reduction over a standard duty cycle exceeding 10 năm.

Base Equipment Pricing Tier: Reflects its heavyduty construction class; structured around core configuration options such as motor type (fixed speed vs VSD), drive arrangement (sheave & vbelts vs direct coupling), and standard vs heavyduty skid base.
Tính năng tùy chọn & Gói:
Integrated Grizzly Feeder Module
Automated Wear Compensation System
HighAmbient Temperature Lubrication Package
Dust Sealing Kit Level I or II
Remote Monitoring Telematics Package
Gói dịch vụ: Available from multiyear preventive maintenance agreements with guaranteed parts availability SLAs upto fullscope performancebased contracts where service provider guarantees uptime percentage.
Tùy chọn tài chính: Available through partners including equipment leasing structures tailored for municipal entities or capital expenditure loans designed for private mining contractors seeking predictable monthly payments aligned with project cash flow.

8. Câu hỏi thường gặp

1. Is the JC5000 compatible with our existing primary feed conveyor and discharge infrastructure?
Detailed interface drawings are provided during presales engineering review. The crusher requires specific feed heights and discharge clearances which can often be adapted with existing structures; our engineering team conducts compatibility assessments as standard practice.

2. Tác động vận hành dự kiến ​​trong quá trình cài đặt là gì?
As a major stationary unit requiring a reinforced concrete foundation installation typically involves scheduled plant shutdown period ranging from two four weeks depending on site readiness including foundation cure time component assembly commissioning

3. How does warranty coverage work what does it include?
Standard warranty covers defects materials workmanship critical components like main frame pitman eccentric shaft bearings period months operation whichever comes first Wear parts jaw dies subject separate wear life guarantee based negotiated applicationspecific tonnage targets

4. Are spare parts readily available what are lead times?
Critical spare parts rotating assemblies bearing cartridges hydraulic cylinders held regional distribution centers Noncritical fabricated components typically available within weeks from manufacturing Global logistics network supports expedited shipping where required

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