1. KHAI THÁC ĐIỀU KHIỂN PAINPOINT

Chi phí vận hành đang leo thang và thời gian ngừng hoạt động không thể đoán trước đang làm xói mòn lợi nhuận dự án của bạn? Dành cho người quản lý nhà máy và chuyên gia mua sắm, the core crushing stage is often the primary bottleneck. Common challenges with suboptimal stone crusher machines include:

Mặc quá mức & Component Failure: Premature wear on liners, hàm, or cones leads to frequent, unplanned stoppages for replacement, costing thousands in parts and lost production daily.
Đầu ra không nhất quán & Ô nhiễm sản phẩm: Poor crushing chamber design or unstable operation results in offspec product gradation, increasing recirculation load and reducing saleable material yield.
Tiêu thụ năng lượng cao: Inefficient drive systems and poor power utilization directly inflate your kWhperton cost, a significant variable in highvolume operations.
Difficult Maintenance & Rủi ro an toàn: Tổ hợp, timeconsuming maintenance procedures require extended downtime and expose technicians to unnecessary hazards during liner changes or clearing blockages.
Infrastructure Rigidity: Máy nghiền cố định thiếu tính di động cho các dự án nhiều địa điểm, while poorly designed mobile units compromise on stability and throughput.

Is your current equipment delivering predictable tonnage at a controlled cost per ton? The solution requires a machine engineered not just to crush rock, but to crush operational inefficiency.

2. TỔNG QUAN SẢN PHẨM

The FabriCore HD Series Jaw Crusher is a heavyduty, primary crushing station engineered for highabrasion quarrying, khai thác mỏ, và các ứng dụng tái chế phá hủy. Nó được thiết kế mạnh mẽ, stationary solution for operations prioritizing maximum uptime and lowest costperton over mobility.

Quy trình hoạt động:
1. Lượng thức ăn ăn vào: Oversized raw feed (rom) is delivered via dump truck or loader into the vibratory grizzly feeder.
2. Giảm sơ cấp: Material enters the deep crushing chamber where a powerful elliptical jaw motion applies compressive force against a fixed jaw plate.
3. Kiểm soát cấp độ: Vật liệu nghiền thoát ra qua lỗ xả có thể điều chỉnh được (CSS), determining the maximum product size.
4. Phóng điện & vận chuyển: Sized material is discharged onto the integral product conveyor for transport to secondary processing or stockpiling.

Phạm vi ứng dụng: Lý tưởng cho đá cứng (đá granit, đá bazan), abrasive ore, và các mảnh vụn phá hủy bê tông cốt thép. Suited for fixedplant installations with expected annual production exceeding 500,000 tấn.

Hạn chế chính: Not designed as a mobile trackmounted unit. Requires stable concrete foundation and appropriate feed system engineering. Maximum recommended feed size is 85% of the feed opening dimension.

3. TÍNH NĂNG CỐT LÕI

Monoblock Fabricated Frame | Cơ sở kỹ thuật: Highstrength, welded steel construction with finite element analysis (FEA) tối ưu hóa | Lợi ích hoạt động: Eliminates stress points and frame fatigue cracking common in bolted designs; ensures longterm alignment of crushing components | Tác động ROI: Giảm chi phí sửa chữa kết cấu theo ước tính 60% over the crusher's lifespan; extends service life beyond industry average.

Hệ thống truyền động thủy tĩnh | Cơ sở kỹ thuật: Direct hydraulic drive with variable displacement motors | Lợi ích hoạt động: Provides smooth startup under full load, reversible operation for clearing blockages, and infinite CSS adjustment under load | Tác động ROI: Lowers peak electrical demand; reduces mechanical transmission wear; increases operational availability by enabling quick clearing of stalls.

Toggle System with Pressure Relief | Cơ sở kỹ thuật: Hydraulic toggle cylinder with integrated nitrogen accumulator overload protection | Lợi ích hoạt động: Automatically releases tramp metal or uncrushables without shearing pins or requiring manual intervention | Tác động ROI: Prevents catastrophic damage to other components; field data shows a reduction in tramp ironrelated downtime by over 90%.

Liner Lifetime Optimization | Cơ sở kỹ thuật: Computeraided chamber profile design and reversible/interchangeable manganese steel liners | Lợi ích hoạt động: Promotes interparticle crushing for better shape; allows use of both liner ends before replacement; simplifies inventory | Tác động ROI: Increases liner life by 1530%; reduces consumable costs per ton crushed.

Điểm bôi trơn tập trung | Cơ sở kỹ thuật: Singlepoint connection to a network of lubrication lines for all major bearings | Lợi ích hoạt động: Cho phép an toàn, rapid greasing during scheduled stops without dismantling guards; ensures consistent bearing protection | Tác động ROI: Cuts routine lubrication service time by half; extends critical bearing service intervals.

Gắn động cơ tích hợp & Bảo vệ vành đai | Cơ sở kỹ thuật: Factoryaligned motor base and fully enclosed,

bolton belt guard assembly | Lợi ích hoạt động: Eliminates field alignment issues; provides superior operator safety and contains dust around the drive | Tác động ROI: Reduces installation/commissioning time; minimizes risk of injuryrelated stoppages.

4. LỢI THẾ CẠNH TRANH

| Chỉ số hiệu suất | Tiêu chuẩn ngành (Competitive Jaw Crusher) | FabriCore HD Series Solution | Lợi thế (% Sự cải tiến) |
| : | : | : | : |
| Thời gian thay đổi lớp lót| 1824 giờ (thời gian ngừng hoạt động) | < 12 giờ (thời gian ngừng hoạt động) | ~45% faster |
| Tiêu thụ điện năng| Fixed speed motor / Vbelt drive| Hydrostatic direct drive with loadsensing control| Lên đến 12% kWh/tấn thấp hơn |
| Thời gian phục hồi sắt lang thang| Manual pin removal / cutting torch (24 giờ)| Hydraulic toggle reversal from operator station (<10 phút)| ~95% faster |
| Frame Structural Warranty| 13 years standard warranty on frame/weldments| Lifetime warranty against defects in materials/workmanship| Definitive longterm assurance |
| sẵn có (Thời gian hoạt động)| Industry target ~8590% (ước lượng)| Fieldreported >94% in comparable applications| ~5% absolute increase |

5. THÔNG SỐ KỸ THUẬT

Model Featured: FabriCore HD4862
Mở nguồn cấp dữ liệu: 48" x 62" (1200mmx1500mm)
Kích thước nguồn cấp dữ liệu tối đa: 41" (1050mm)
Cài đặt bên đóng (CSS) Phạm vi: 6" 14" (150mm 350mm)
Phạm vi công suất (@ CSS được xác định): 450 1,200 STPH (phụ thuộc vào nguyên liệu thức ăn & sự phân cấp)
Yêu cầu năng lượng ổ đĩa: Chung kết cấp IV / Stage V compliant diesel engine OR electric motor option:
Electric Motor Option: 300 HP (225 kW), 460V/60Hz/3Ph
Tổng trọng lượng (máy nghiền + trung chuyển + Conveyor): Xấp xỉ. 185,000 pound (84,000 kg)
Thông số kỹ thuật vật liệu chính:
Frame Steel: ASTM A572 Grade 50
Jaw Liners: Thép Mangan Austenit (14%18%)
Main Shaft Forging: Highalloy steel, siêu âm thử nghiệm
Vỏ ổ trục: Cast ductile iron
Phạm vi hoạt động môi trường: 20°C đến +50°C (4°F đến +122°F). Dust suppression kit recommended for arid environments.

6. KỊCH BẢN ỨNG DỤNG

Trạm nghiền sơ cấp mỏ đá granite

Thử thách:
A southeastern US granite quarry faced recurring frame weld failures on their primary jaw crusher after just four years of service. Unplanned downtime for repairs exceeded two weeks annually alongside high energy costs from an inefficient drive system.
Giải pháp:
Replacement with a FabriCore HD4862 Jaw Crusher featuring the monoblock fabricated frame and hydrostatic drive system.
Kết quả:
Zero structural issues reported after five years of operation. Energy monitoring showed an average reduction of $18 per operating hour in power costs at peak rates. Annual availability increased from approximately $86\%$ ĐẾN $95\%$.

Urban Demolition Recycling Hub

Thử thách:
A contractor processing reinforced concrete from urban demolition struggled with frequent stallouts due to uncrushable rebar mats embedded in slabs. Each event required a full shutdown and dangerous manual torchcutting work inside the chamber.
Giải pháp:
Installation of a FabriCore HD3650 Jaw Crusher equipped with the hydraulic toggle pressure relief system.
Kết quả:
The system automatically detects overloads and reverses to eject uncrushables within one minute via remote control from the operator cabin. This eliminated an average of three manual interventions per week—reducing safety risk—and increased daily throughput by preventing extended stoppages.

7. CÂN NHẮC THƯƠNG MẠI

Our pricing structure is based on transparent configuration:

Cấp trang bị cơ bản ($XXXk $XXXk): Includes core FabriCore HD crusher with standard manganese liners,
electric motor drive option,
và điều khiển cơ bản.

Optional Feature Packages:
Gói tự động hóa ($XXk): Includes CSS adjustment via PLC,
cảm biến giám sát hao mòn,
remote diagnostics port.
Gói mài mòn hạng nặng ($XXk): Upgraded liner alloys,
additional wear plates at critical impact points,
ceramiclined feed chute sections.

Service Agreements:
1.Planned Maintenance Plan ($Xk/year): Kiểm tra theo lịch trình,
lubrication kits,
priority technical support.
2.Comprehensive Uptime Plan ($XXk/year): Includes all planned maintenance plus discounted parts pricing up to $40\%$ off list price,
guaranteed emergency parts dispatch within $24$ giờ.

Financing Options are available through our industrial partners including operating leases ($36$60 điều khoản tháng),
cho vay thiết bị,
and leasetopurchase agreements designed to preserve capital expenditure budgets.

(Ghi chú: Specific pricing figures are omitted here as they vary based on final specification,
currency region,
và điều kiện thị trường.)

8\. FAQ\\\\\\\\\\\\\\\\n\n\Q1\. How does this machine integrate into my existing plant flow\? \\nA\. The FabriCore HD Series is designed as a modular primary station\. We provide detailed interface drawings \(feed height\, discharge height\, footprint\, power connection points\) during the quotation phase\. Our engineering team can review your existing layout to ensure compatibility\.

\Q2\. What is the expected operational cost per ton crushed\? \\nA\. While site\specific\, industry testing demonstrates that operators typically achieve between \$10\%\15\%\$ lower total cost\per\ton compared to previous generation jaw crushers\. This stems from reduced energy consumption\, longer liner life\, higher availability\.

\Q3\. Are spare parts readily available internationally\? \\nA\. Yes\. We maintain regional inventory hubs on three continents\. For critical wear parts \(liners\) we guarantee stock availability against your serial number upon request\.

\Q4\. What training do you provide for our maintenance crew\? \\nA\. We include comprehensive onsite commissioning training covering operation\, daily checks\, routine maintenance procedures like greasing \,liner change protocols using our tooling system\.

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