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1.Equipment Information

Equipment type: Vertical mill

Rated speed: 993rpm

Related measuring points in this case: 3 points on the reducer

2.Alarm occurs

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

There is an increase in the acceleration vibration at the measuring point on the upper end of the reducer.

Horizontal acceleration vibration trend waveform spectrum of the reducer at 3 points

The speed vibration is relatively stable.

Horizontal speed vibration trend waveform spectrum of the reducer at 3 points

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

The characteristic frequency interval impact of planetary gear fault appears in the acceleration waveform, and the sideband energy near the meshing frequency in the low-frequency band of the spectrum increases significantly.

Horizontal acceleration vibration trend waveform spectrum of the reducer at 3 points

This frequency interval disturbance can also be seen in the velocity waveform.

Horizontal speed vibration trend waveform spectrum of the reducer at 3 points

3.Push diagnostic conclusions

3.1Diagnostic conclusion

2022-01-25 15:39 Push diagnosis conclusion: There is obvious damage on the tooth surface of the planetary gear of the reduction gearbox, in the form of peeling or broken teeth, and there is a trend of deterioration in the near future.

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. Check the damage of the planetary gear tooth surface of the reducer and pay attention to the metal debris content in the lubricating oil filter.

4.On-site inspection and maintenance process

2022-02-14 17:06 Feedback from the site on February 19th: According to the report, the site dismantled the five-line B vertical mill and found that the planetary gear was cracked. The inspection results were consistent with the report content, avoiding equipment failure with a long shutdown.

5.On-site inspection and maintenance photos

Maintenance photo_1

Maintenance photo_2

6.Verification after inspection and maintenance

There is no startup data 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: Roller press

Rated speed: unknown

Related measuring points in this case: The load end of the movable roller is horizontal

2.Alarm and analysis process

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

The acceleration vibration of the load end of the movable roller shaft has increased significantly recently.

Fengkai cement/cement grinding area/2# cement grinding process/2# cement roller press/main body/moving roller shaft/moving roller shaft load end level/128 K acceleration waveform (0.1-2000)_trend

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

The time domain waveform shows the frequency interval impact of the bearing cage failure.

Fengkai cement/cement grinding area/2# cement grinding process/2# cement roller press/main body/moving roller shaft/moving roller shaft load end level/128 K acceleration waveform (0.1-2000)_time domain waveform

The long waveform envelope demodulation is also dominated by the cage failure frequency.

Fengkai cement/cement grinding area/2# cement grinding process/2# cement roller press/main body/moving roller shaft/moving roller shaft load end horizontal/128 K acceleration waveform (0.1-2000)_long waveform

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

2022-10-12 21:01 Push diagnosis conclusion: The bearing cage of the load end of the movable roller shaft is significantly worn, and there is a risk of sudden fracture during long-term operation.

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. Check the movable roller shaft for abnormal noise or temperature rise as soon as possible, and check the bearing damage when the opportunity arises.

4.On-site inspection and maintenance process

2022-12-16 15:38 On-site feedback: After opening the cover of the driving end bearing of the movable roller for inspection, the inner and outer raceways were damaged and one ball was broken.

5.On-site inspection and maintenance photos

On-site maintenance photos showed that the inner and outer raceways of the bearing were damaged and one ball was broken.

Maintenance photo_1

Maintenance photo_2

6.Verification after inspection and maintenance

After maintenance, the acceleration vibration trend of the driving end of the movable roller shaft decreased significantly and the operation was stable.

Fengkai cement/cement grinding area/2# cement grinding process/2# cement roller press/main body/moving roller shaft/moving roller shaft load end level/128 K acceleration waveform (0.1-2000)_trend

7.Customer feedback form

None

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.EquipmentInformation

Equipment type: Roller press

Rated speed: 1487rpm

Related measuring points in this case: free end 8H of the movable roller shaft

2.Alarm and analysis process

The case comes from the monthly physical examination: The monthly physical examination was issued on January 12, with a message reminding that abnormal impact can be seen in the time domain waveform of the 8H measuring point on the free end of the movable roller shaft, pitting and spalling damage on the bearing rolling elements, and wear on the cage. Inspection and attention should be strengthened in the near future.

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

The low-frequency acceleration vibration trend of the 8H measuring point at the free end of the movable roller shaft is relatively stable.

2# cement roller press/moving roller shaft free end 8H/256k acceleration waveform (2-2000)_trend analysis

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

The acceleration time domain waveform shows obvious high-amplitude periodic impact, and the impact has the phenomenon of cage rotation frequency modulation.

2# cement roller press/moving roller shaft free end 8H/256k acceleration waveform (2-2000)_time domain waveform

The noise energy at the bottom of the spectrum is rich, and full-band envelope demodulation reveals the characteristic frequency harmonics of the bearing rolling elements, with cage rotation frequency sidebands.

2# cement roller press/moving roller shaft free end 8H/256k acceleration waveform (2-2000)_long waveform

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

The conclusion of the supplementary diagnosis is: the rolling elements of the free end bearing of the movable roller shaft have pitting and spalling damage, the cage is worn, and there has been obvious deterioration in the recent period.

3.2Inspection and maintenance suggestions

Pay attention to the abnormal noise and temperature rise of the free end bearing of the movable roller shaft, and check the bearing damage when the opportunity arises.

4.On-site inspection and maintenance process

1.Feedback from engineer Luo on site at 09:40 on 2023-02-02: The ball bearing of the free end bearing of the motorized roller of the 2# roller press has peeled off and the bearing has been replaced.

2.On 2023-02-21 09:59, photos of the inspection were sent from the site, which showed obvious spalling damage on the bearing rolling elements

5.On-site inspection and maintenance photos

On-site inspection and maintenance photos

Maintenance photo_1

Maintenance photo_2

6.Verification after inspection and maintenance

The machine has not been started yet after the on-site maintenance, so the equipment status after the maintenance cannot be assessed.

2# cement roller press/moving roller shaft free end 8H/256k acceleration waveform (2-2000)_Equipment Multi-trend

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.

1.Equipment Information

Equipment Type: Bucket Elevator

Rated speed: 1491rpm

Rated speed: 1491rpm

2.Alarm and analysis process

2.1Analysis process

2.1.1Explanation of trends, indicator parameters and other evidence

The low-addition trend of the reducer measuring point is relatively stable.

Guigang Cement/Production Line 2/Raw Material Preparation Process 2/Storage Elevator 42B.01/Reducer 42B.01P/Reducer 2, 3 axis output A/128 K Acceleration waveform (0.1-2000)_Trend

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

The time domain waveform mainly shows the 2-axis rotation frequency impact.

Guigang Cement/2# production line/2# raw material preparation process/2# storage elevator 42B.01/reducer 42B.01P/reducer 2, 3 axis output A/128 K Acceleration waveform (0.1-2000)_Time domain waveform

In the spectrum, it can be seen that there are many 4-axis frequency sidebands in the third-level meshing frequency band.

Guigang Cement/2# production line/2# raw material preparation process/2# storage elevator 42B.01/reducer 42B.01P/reducer 2, 3 axis output A/128 K acceleration waveform (0.1-2000)_spectrum

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

The gears on the 4th axis of the reducer suffered early and mid-term damage, mainly pitting and spalling on the tooth surface, and have slowly deteriorated recently.

3.2Inspection and maintenance suggestions

Pay attention to the abnormal noise of the 4th axis of the reducer, check the iron chips content in the gearbox oil, and check the tooth surface damage when the opportunity arises.

4.On-site inspection and maintenance process

2023-12-14 19:03 On-site feedback: pitting on the surface of the 4-axis gear, the reducer has been replaced.

5.On-site inspection and maintenance photos

On-site photos show that there are pitting and spalling on the tooth surface of reducer 4 bearing, and the damage is evenly distributed on the tooth surface, indicating that it is caused by stress fatigue generated by long-term operation.

Maintenance photo_1

6.Verification after inspection and maintenance

After the overhaul, the 4-axis frequency rotation sidebands of the third-level meshing band in the spectrum disappeared.

Multi-spectrum

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.