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1.Equipment Information

Equipment type: Roller press

Rated speed: 1490rpm

Related measuring points in this case: Moving roller reducer first-stage planetary gear 5H

2.Alarm and analysis process

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

The total value of the high-frequency acceleration at the 5H measuring point of the first-stage planetary gear of the moving roller reducer began to show a slow upward trend since October 29, 2021. After a slight decline on April 20, 2022, the trend remained stable.

4# Roller Press (4940)/Fixed Roller First-stage Planetary Gear 13H/128k Acceleration Waveform (0.1-20000)_Equipment Multi-trend

The total value of the low-frequency acceleration at the 5H measuring point of the first-stage planetary gear of the moving roller reducer began to show a continuous slow upward trend since September 30, 2021; it dropped slightly around April 20, 2022.

4# Roller Press (4940)/Fixed Roller First-stage Planetary Gear 13H/128k Acceleration Waveform (0.1-20000)_Equipment Multi-trend

2.1.24# Roller Press (4940)/Fixed Roller First-stage Planetary Gear 13H/128k Acceleration Waveform (0.1-20000)_Equipment Multi-trend

The increase in the total value of low-frequency acceleration is mainly manifested in the increase of the meshing frequency and harmonic energy of the first-stage planetary gear system.

4# roller press (4940)/moving roller first-stage planetary gear 5H/256k acceleration waveform (0.1-2000)_spectrum analysis

As the total value of low-frequency acceleration increases, the impact of the first-stage planet carrier rotation frequency interval in the time domain waveform becomes significant.

4# roller press (4940)/moving roller first-stage planetary gear 5H/256k acceleration waveform (0.1-2000)_time domain waveform

The envelope demodulation spectrum is dominated by the primary planet carrier rotation frequency and rich harmonic energy.

4# roller press (4940)/moving roller first-stage planetary gear 5H/256k acceleration waveform (0.1-2000)_envelope demodulation

3.Diagnostic conclusions and recommendations

3.1 Diagnostic conclusion

2021-12-26 00:25 The physical examination report pushed the diagnostic conclusion: the first-stage planetary inner gear ring is pitted, worn, and continuously deteriorated; the wear characteristics of the high-speed shaft tooth surface are not obvious.

3.2 Inspection and maintenance suggestions

The equipment is currently in a monitorable operating state. It is recommended to arrange an inspection at an appropriate time. Pay attention to the iron chips content in the lubricating oil, pay attention to the changes in the gearbox oil temperature, and regularly check the operation of the first-stage internal gear ring tooth surface.

4.On-site inspection and maintenance process

1. 2022-01-29 18:19 The interpretation of the physical examination report informed that the planetary-level vibration of the first stage continued to increase, which should be related to the continuous deterioration of the damage to the first stage internal gear ring; Engineer Zhang reported that there was wear on the first stage internal gear ring.

2. On 2022-02-11 06:01, we informed the site that after the start-up of the 4# roller press, the vibration of the first-stage gear ring of the moving roller increased compared with the previous operation, which was related to the damage and deterioration of the gear ring and required attention. The site feedback indicated that abnormal noise was found in the first-stage gear ring when the machine was started, but the manufacturer said that the problem was not serious and allowed it to continue to run.

3. 2022-05-26 11:50 On-site feedback: The machine will be shut down for maintenance and the movable roller reducer will be replaced (pitting and peeling of the inner gear ring were found during the previous inspection). It is expected to start up on the evening of June 1.

5.On-site inspection and maintenance photos

The photos show that the inner gear ring has significant pitting and wear.

Maintenance photo_1

Maintenance photo_2

6.Verification after inspection and maintenance

Not started yet

7.Monitoring fault range

Timely and effective collection of equipment operating status data (vibration, temperature) is subject to the constraints of network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own attributes and production processes. At the same time, the analysis and diagnosis of equipment status is based on changes in vibration effects caused by rotating parts failures. Therefore, the status monitoring system cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B, and the range of faults that can be monitored and the description are as follows:

8.Notes

1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;

2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.

3. This report shall not be used as evidence for any claims, litigation, etc.;

4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

1.Equipment Information

Equipment Type: Bucket Elevator

Rated speed: unknown

Related measuring points in this case: Head wheel free end bearing seat 14H

2.Alarm and analysis process

At 22:15 on 2022-07-30, a level 3 alarm sounded at the head wheel free end bearing seat 14H.

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

The acceleration vibration of the free end of the head wheel suddenly increases.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-2000)_trend analysis

The temperature of the free end of the head wheel also increased significantly compared with the previous period.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-20000)_equipment temperature multiple trends

2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation

The time domain waveform shows obvious impact and wave breaking, and the impact interval is close to the cage failure frequency.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-2000)_time domain waveform

Envelope demodulation shows the cage failure frequency.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-2000)_envelope demodulation

High frequency acceleration can result in occasional high amplitude shocks.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-20000)_time domain waveform

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

2022-07-30 22:43 Push diagnosis conclusion: Obvious impact features can be seen at the free end of the head wheel, which is speculated to be related to damage to the bearing retainer or abnormal bearing positioning.

3.2Inspection and maintenance suggestions

It is necessary to arrange to check the actual situation of the on-site equipment as soon as possible. If the equipment runs in this state for a long time, there is a risk of failure. 1. Arrange to check and confirm the temperature and abnormal sound of the free end of the head wheel, check whether the bearing is damaged, and whether the positioning is abnormal. 2. Simultaneously check whether there are any abnormalities in the lubrication and cooling systems of the free end of the head wheel.

4.On-site inspection and maintenance process

1. After the central control was reminded by telephone at 23:43 on 2022-07-30, the on-site feedback showed that the temperature of the free end of the head wheel had risen significantly, but there was no obvious abnormal noise. The machine has been shut down and subsequent maintenance has been arranged.

2. 2022-08-01 15:59 On-site feedback: The 3311 feed hopper has been overhauled, the head wheel bearing retainer is cracked, and the outer ring is broken.

5.On-site inspection and maintenance photos

The inspection photos show that the head wheel bearing retainer is cracked and the outer ring is chipped.

Maintenance photo_1

Maintenance photo_2

6.Verification after inspection and maintenance

After the overhaul, the acceleration of the free end of the head wheel dropped significantly and the operation was stable.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-2000)_trend analysis

After maintenance, the frequent high point signals in the acceleration sampling values disappeared.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-2000)_trend analysis

The obvious cage impact feature disappears in the time domain waveform.

Three-wire feed hopper lift-3311/head wheel free end bearing seat 14H/128k acceleration waveform (0.1-2000)_time domain waveform

7.Customer feedback form

Feedback_1

8.Monitoring fault range

Timely and effective collection of equipment operating status data (vibration, temperature) is subject to the constraints of network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own attributes and production processes. At the same time, the analysis and diagnosis of equipment status is based on changes in vibration effects caused by rotating parts failures. Therefore, the status monitoring system cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B, and the range of faults that can be monitored and the description are as follows:

9.Notes

1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;

2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.

3. This report shall not be used as evidence for any claims, litigation, etc.;

4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

1.Equipment Information

Equipment type: belt conveyor main drive

Rated speed: 1493rpm

Related measurement points in this case: reducer 2, 3 axis output end 4A

2.Alarm and analysis process

Equipment alarm events:

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

The speed vibration of the gearbox measuring point continues to rise slowly.

Aggregate 3# long belt conveyor-R1212-2/reducer 2, 3 axis output end 4A/128k acceleration waveform (0.1-2000)_Equipment Multi-trend

2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation

The speed spectrum shows that the main energy is rotation frequency and harmonic energy, mainly 1X and 2X.

Aggregate 3# long belt conveyor-R1212-2/reducer 2, 3 axis output end 4A/128k acceleration waveform (0.1-2000)_spectrum analysis

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

2023-10-12 12:20 Push diagnostic conclusion: The speed vibration of the unit continues to rise slowly, which is related to the change in the coupling connection status.

3.2Inspection and maintenance suggestions

Verify and pay attention to the speed vibration changes of the motor gearbox. If abnormal, check the coupling connection and wear, and recheck the alignment of the unit.

4.On-site inspection and maintenance process

1. 2023-10-16 09:32 On-site feedback: The current vibration temperature is relatively normal, and it is planned to use the maintenance time later to inspect the bearings.

2. On 2023-10-16 19:32, the on-site motor and reducer measuring points were informed that the speed amplitudes were still increasing slowly and that inspection and processing were required.

3. 2023-10-17 12:46 On-site feedback: the R1212-2 drive plum blossom block is damaged and has been replaced.

5.On-site inspection and maintenance photos

The photos of on-site maintenance feedback showed that the coupling was cracked.

Maintenance photo_1

Maintenance photo_2

6.Verification after inspection and maintenance

After treatment, the speed vibration at the motor end dropped and the current trend is stable.

Multiple trends of speed vibration at both ends of the motor

After the maintenance, the transfer frequency harmonic energy in the speed spectrum decreased significantly.

Motor free end speed multi-spectrum

7.Customer feedback form

Feedback_1

8.Monitoring fault range

Timely and effective collection of equipment operating status data (vibration, temperature) is subject to the constraints of network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own attributes and production processes. At the same time, the analysis and diagnosis of equipment status is based on changes in vibration effects caused by rotating parts failures. Therefore, the status monitoring system cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B, and the range of faults that can be monitored and the description are as follows:

9.Notes

1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;

2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.

3. This report shall not be used as evidence for any claims, litigation, etc.;

4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.

1.Equipment Information

Equipment Information

Rated speed: frequency conversion equipment

Related measurement points in this case: Reducer 1 axis input 3H

2.Alarm and analysis process

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

The high-pressure vibration at multiple measuring points on the reducer's 1st axis increased significantly.

1309 Vertical Mill Reducer 2/Reducer 1 Axis Input 3H/128k Acceleration Waveform (2-20000)_Equipment Multi-Trend

2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation

There is no obvious regular impact in the time domain waveform.

1309 Vertical Mill Reducer 2/Reducer 1 Axis Input 3H/128k Acceleration Waveform (2-20000)_Time Domain Waveform

The low-frequency band of the spectrum has rich background noise energy, and envelope demodulation shows the characteristic frequency of the bearing outer ring and its harmonics.

1309 Vertical Mill Reducer 2/Reducer 1 Axis Input 3H/128k Acceleration Waveform (2-20000)_Envelope Demodulation

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

2023-06-25 16:59 Push diagnosis conclusion: The inner and outer ring raceways of the reducer input shaft bearing are pitting and worn, and the outer ring may have local peeling, and the deterioration is slightly faster recently.

3.2Inspection and maintenance suggestions

The equipment is currently in a monitorable operating state, and it is recommended to arrange an inspection at an appropriate time. Pay attention to the abnormal noise and vibration of the bearing at the input shaft of the gearbox, and ensure that the input shaft bearing is in good lubrication condition.

4.On-site inspection and maintenance process

2024-01-08 09:51 On-site feedback: The reducer input shaft bearing was replaced and the outer ring of the bearing was damaged.

5.On-site inspection and maintenance photos

The inspection photos show that there is shallow surface peeling on the outer ring of the reducer input shaft bearing.

Maintenance photo_1

Maintenance photo_2

Maintenance photo_3

Maintenance photo_4

Maintenance photo_5

Maintenance photo_6

Maintenance photo_7

Maintenance photo_8

Maintenance photo_9

Maintenance photo_10

6.Verification after inspection and maintenance

There is no valid startup data.

1309 Vertical Mill Reducer 2/Reducer 1 Axis Input 3H/128k Acceleration Waveform (2-20000)_Time Domain Waveform Spectrum Combination Diagram

7.Customer feedback form

None

8.Monitoring fault range

Timely and effective collection of equipment operating status data (vibration, temperature) is subject to the constraints of network connectivity and data transmission time, and also needs to consider interference from factors such as the equipment's own attributes and production processes. At the same time, the analysis and diagnosis of equipment status is based on changes in vibration effects caused by rotating parts failures. Therefore, the status monitoring system cannot guarantee monitoring of all types of faults. The monitoring system is configured according to the measurement point scheme recommended by Party B, and the range of faults that can be monitored and the description are as follows:

9.Notes

1. If the client of this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox teeth number, related bearing models and brands), the accuracy of analysis and diagnosis will be affected;

2. This report is the analysis, diagnosis and maintenance opinions of the unit by Rongzhi professional technicians, which is for reference only. The specific maintenance and repair measures shall be decided by the client.

3. This report shall not be used as evidence for any claims, litigation, etc.;

4. The client has the obligation to keep the analysis report confidential and shall not provide this report to a third party, print it into other promotional materials, or publish it on the Internet or other public information platforms without the written permission of the trustee.