Supporting the "1 Cloud + 4 Edge Centers + 10 Bases" Intelligent O&M Master Plan

1.Equipment Information

Equipment Type: Reducing Diameter

Rated speed: Unknown

This case is related to the measurement point: East output shaft motor side 10H

2.Alarm and Analysis Process

Equipment Alarm Event:

2.1Analysis Process

2.1.1Explanation of Trends and Indicator Parameters

The acceleration amplitude on the east output side and west output side continues to rise slowly, with the west output side showing a slightly higher amplitude.

TMB1/West Output Shaft Rolling Mill Side 15H/128k Acceleration Waveform (0.1-20000)_Multiple Trends of Equipment

2.1.2Time-domain, frequency-domain, envelope demodulation, and other evidence explanations

The time domain waveforms of acceleration on the east output side and west output side show significant impacts.

TMB1/West Output Shaft Rolling Mill Side 15H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform

From the perspective of impact transmission, the impact energy on the east output side is mainly caused by the impact transmission from the west output shaft rolling mill side.

TMB1/West Output Shaft Rolling Mill Side 15H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform

Envelope demodulation reveals the damage characteristics of the inner ring of the bearing on the west output shaft rolling mill side and its harmonics, along with the sideband of the west output shaft rotation frequency.

TMB1/West Output Shaft Rolling Mill Side 15H/128k Acceleration Waveform (0.1-20000)_Envelope Demodulation

3.Diagnosis Conclusion and Recommendations

3.1Diagnostic Conclusion

2022-10-30 10:43 Push Diagnosis Conclusion: Mid-term damage to the bearing on the west output shaft rolling mill side, primarily characterized by pitting and spalling of the inner ring, with a recent trend of slow deterioration.

3.2Recommendations

It is necessary to arrange for an inspection of the actual condition of the on-site equipment as soon as possible, as operating in this state for an extended period poses a risk of failure. Routine inspections should focus on abnormal noises and temperature changes in the bearings on the west output shaft rolling mill side, and the condition of the inner ring damage should be checked when appropriate.

4.On-site Maintenance Process

2022-12-23 19:10 On-site feedback indicates that the inner ring of the bearing on the west output shaft rolling mill side has spalled, and it has been repaired and replaced, with photos of the bearing damage provided.

5.On-site Maintenance Photos

The on-site repair photos show that the inner ring of the bearing has significantly peeled off.

Maintenance Photo_1

Maintenance Photo_2

Maintenance Photo_3

6.Post-Maintenance Verification

After on-site maintenance, the acceleration amplitude at the 15H measurement point on the west output shaft rolling mill side has significantly decreased.

TMB1/West Output Shaft Rolling Mill Side 15H/128k Acceleration Waveform (0.1-20000)_Trend Analysis

The impact in the acceleration time-domain waveform has basically disappeared.

TMB1/West Output Shaft Rolling Mill Side 15H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform

The envelope demodulation bearing damage characteristics are not significant.

TMB1/West Output Shaft Rolling Mill Side 15H/128k Acceleration Waveform (0.1-20000)_Envelope Demodulation

7.Customer Feedback Form

None

Feedback Form_1

8.Monitoring Fault Range

The timely and effective collection of equipment operating status data (vibration, temperature) is constrained by network smoothness and data transmission time, and it is also necessary to consider the interference of the equipment's own properties and production processes. At the same time, the analysis and diagnosis of equipment status are based on changes in vibration effects caused by faults in rotating components. Therefore, the condition monitoring system cannot guarantee monitoring of all types of faults. This monitoring system is configured according to the measurement point scheme recommended by the party B, and the fault range and descriptions are as follows:

9.Notes

1. If the client of this report cannot provide basic unit parameters (such as: unit drive chain diagram, gearbox structure diagram, number of teeth in the gearbox, relevant bearing models and brands), it will affect the accuracy of the analysis and diagnosis;

2. This report is a professional analysis and diagnosis, and maintenance advice from Rongzhi technical personnel, for reference only; specific maintenance measures need to be decided by the client;

3. This report does not serve as any proof material for claims, litigation, etc.;

4. The client is obligated to keep the analysis report confidential and shall not provide this report to any third party, print it in other promotional materials, or publish it on public information platforms without the written permission of the entrusted party.

1.Equipment Information

Equipment Type: Cone Box

Rated speed: Variable frequency

Measuring point associated with this case: Three-axis helical gear side 4H

2.Alarm and Analysis Process

Pay attention to the unit during monthly check-ups.

2.1Analysis Process

2.1.1Explanation of Trends and Indicator Parameters

The overall acceleration value of the three-axis helical gear side has been increasing recently.

26# Cone Box/Three-axis Helical Gear Side 4H/128k Acceleration Waveform (0.1-20000)_Trend Analysis

2.1.2Time-domain, frequency-domain, envelope demodulation, and other evidence explanations

No significant impact is observed in the time domain waveform, which may be related to the expansion of the raceway damage area.

26# Cone Box/Three-axis Helical Bevel Side 4H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform

Envelope demodulation shows the characteristic frequency and harmonics of the bearing inner race, distributed in the lower frequency band.

26# Cone Box/Three-Axis Helical Gear Side 4H/128k Acceleration Waveform (0.1-20000)_Envelope Demodulation

3.Diagnosis Conclusion and Recommendations

3.1Diagnostic Conclusion

Monthly check-up attention status: pitting and continuous degradation of the inner race of the second shaft or synchronous shaft bearing.

3.2Recommendations

Check the bearing for abnormal noise. If the abnormal noise is obvious, consider replacing it when appropriate.

4.On-site Maintenance Process

2023-04-07 09:24 On-site Chen Gong feedback, the overall replacement of the standby machine, and sent maintenance photos.

5.On-site Maintenance Photos

The photos show circumferential pitting on the bearing inner ring, spalling on the rolling elements, and wear on the cage.

Overhaul photo_1

Overhaul photo_2

Overhaul photo_3

Overhaul photo_4

Overhaul photo_5

Overhaul photo_6

Overhaul photo_7

Overhaul photo_8

Overhaul photo_9

Overhaul photo_10

Overhaul photo_11

6.Post-Maintenance Verification

After on-site maintenance, the total acceleration value on the three-axis helical gear side decreased from 129m/s2 to 12m/s2, and the background noise in the spectrum was significantly reduced, indicating that the maintenance improved the fault characteristics.

26# Cone Box/Three-axis Helical Gear Side 4H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform Spectrum Combination Diagram

7.Customer Feedback Form

None

Feedback Form_1

8.Monitoring Fault Range

The timely and effective collection of equipment operating status data (vibration, temperature) is restricted by network smoothness and data transmission time, and the influence of equipment attributes and production technology should also be considered. At the same time, the analysis and diagnosis of equipment status are based on changes in the vibration effects caused by rotating moving parts failures. Therefore, the condition monitoring system cannot guarantee monitoring of all types of failures. This monitoring system is configured according to the measurement point scheme recommended by Party B, and the monitoring fault range and description are as follows:

9.Precautions

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

2. This report contains analysis, diagnosis, and maintenance suggestions for the unit from Richeng's professional technicians, and is for reference only. The specific maintenance measures still need to be determined by the client.

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

4. The client is obligated 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 public information platforms such as the Internet without the written permission of the trustee.

1.Equipment Information

Equipment Type: Cone Box

Rated speed: Unknown

Measuring point associated with this case: One-axis output 2A

2.Alarm and Analysis Process

Equipment alarm event:

2.1Analysis Process

2.1.1Explanation of Trends and Indicator Parameters

There is an increase in acceleration vibration at the unit's measuring point.

23# Cone Box / Tri-Axial Helical Gear Side 4H/128k Acceleration Waveform (0.1-20000)_Equipment Multi-Trend

2.1.2Time-domain, frequency-domain, envelope demodulation, and other evidence explanations

A certain impact is visible in the acceleration time-domain waveform, but the impact characteristics are relatively insignificant.

23# Cone Box / Tri-Axial Helical Gear Side 4H/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform

In the early stage of vibration increase, the spectrum shows suspected synchronous shaft bearing fault frequencies and harmonics.

23# Cone Box / Three-Axis Helical Bevel Side 4H / 128k Acceleration Waveform (0.1-20000) _ Spectrum Analysis

In the later stage of vibration increase, the acceleration spectrum shows the inner ring fault frequency and harmonics of the bearing, with obvious rotational frequency sidebands.

23# Cone Box _ Spectrum Analysis

And the impact becomes obvious in the acceleration waveform.

23# Cone Box _ Time Domain Waveform

3.Diagnosis Conclusion and Recommendations

3.1Diagnostic Conclusion

Diagnostic conclusion pushed at 09:40 on 2023-04-03: Uniform pitting corrosion and wear of the outer ring raceway of the cone box synchronous shaft bearing, showing a deteriorating trend. Diagnostic conclusion pushed at 10:34 on 2023-04-13: Significant spalling exists on the inner ring of the cone box synchronous shaft bearing, with continuous deterioration in the near future.

3.2Recommendations

It is not recommended to run for a long time. It is recommended to arrange inspection or maintenance as soon as possible.

4.On-site Maintenance Process

1. 2023-04-03 09:41 Reminder to inform the site that the outer ring raceway of the cone box synchronous shaft bearing has uniform pitting corrosion and wear, showing a deterioration trend; the site feedback indicates that there are no plans for maintenance in the near future.

2. 2023-04-13 10:34 Reiterate the reminder to inform the site that there is significant spalling on the inner ring of the cone box synchronous shaft bearing, which has been continuously deteriorating recently. It is not recommended to run it for a long time, and it is recommended to arrange inspection or maintenance as soon as possible.

3. 2023-04-17 08:32 The site reported that the No. 23 cone box of the second high-speed wire rod was completely replaced with a spare machine on April 15, and feedback showed that obvious wear was visible in the rolling elements of the disassembled bearing.

5.On-site Maintenance Photos

The inspection and maintenance photos show obvious wear on the inner and outer rings and rolling elements of the bearing.

Inspection and maintenance photos_1

Inspection and maintenance photos_2

Inspection and maintenance photos_3

Inspection and maintenance photos_4

Inspection and maintenance photos_5

Inspection and maintenance photos_6

Inspection and maintenance photos_7

Inspection and maintenance photos_8

Inspection and maintenance photos_9

Inspection and maintenance photos_10

Inspection and maintenance photos_11

6.Post-Maintenance Verification

Acceleration vibration decreased significantly after maintenance, and the current trend is stable.

The amplitude of the acceleration waveform decreased significantly after maintenance, and abnormal spectral lines and energy disappeared in the spectrum.

7.Customer Feedback Form

None

Feedback Form_1

8.Monitoring Fault Range

The timely and effective collection of equipment operating status data (vibration, temperature) is subject to network smoothness and data transmission time, and also needs to consider the interference of equipment attributes, production technology, and other factors. At the same time, the analysis and diagnosis of equipment status are based on changes in the vibration effect caused by rotating moving parts failures. Therefore, the condition monitoring system cannot guarantee monitoring of all types of failures. This monitoring system is configured according to the measurement point scheme recommended by Party B, and the monitoring fault range and description are as follows:

9.Precautions

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

2. This report contains analysis, diagnosis, and maintenance suggestions for the unit from Rote Knowledge's professional technicians, and is for reference only. The client commissioning this report should make their own decisions regarding specific maintenance and repair measures.

3. This report shall not be used as evidence for any claims, lawsuits, or other legal proceedings;

4. The client is obligated to keep the analysis report confidential and shall not provide this report to any third party, print it into other promotional materials, or publish it on public information platforms such as the internet without the written permission of the trustee.

1.Equipment Information

Equipment Type: Bar and Wire Rod Roughing and Intermediate Rolling Mill

Rated speed: Variable frequency equipment

Measuring point associated with this case: Reducer 1-axis output end 5H

2.Alarm and Analysis Process

2.1Analysis Process

2.1.1Explanation of Trends and Indicator Parameters

The high-frequency acceleration of multiple measuring points of the reducer continues to rise, and the acceleration at the input end of the reducer can reach more than 10m/s2.

11V Vertical Mill_Equipment Multi-Trend

2.1.2Time-domain, frequency-domain, envelope demodulation, and other evidence explanations

Impacts are visible in the waveform at the 1-axis input end, close to the cage fault frequency component.

11V Vertical Mill/Reducer 1-axis Input 4A/128k Acceleration Waveform (0.1-20000)_Time Domain Waveform

The envelope spectrum shows the bearing cage fault frequency and its harmonic components.

11V Vertical Rolling Mill/Reducer 1 Shaft Input 4A/128k Acceleration Waveform (0.1-20000)_Envelope Demodulation

The comparison of the front and rear frequency spectra shows a significant increase in noise energy across the entire frequency range.

11V Vertical Rolling Mill/Reducer 1 Shaft Output 5H/128k Acceleration Waveform (0.1-20000)_Spectrum Analysis

From the early signals, the damage characteristics of the inner ring of the bearing are not clear.

11V Vertical Rolling Mill/Reducer 1 Shaft Output 5H/128k Acceleration Waveform (0.1-20000)_Envelope Demodulation

3.Diagnosis Conclusion and Recommendations

3.1Diagnostic Conclusion

Diagnosis conclusion pushed on 2023-05-25 21:54: The multi-point vibration of the reducer continues to rise, related to the damage of the high-speed shaft bearing cage, currently in a state of continuous deterioration.

3.2Recommendations

It is necessary to arrange for an inspection of the actual condition of the on-site equipment as soon as possible, as the equipment has been operating in this state for a long time, posing a risk of failure. Pay attention to abnormal noises and temperature changes in the high-speed shaft bearing of the reducer, and check the bearing damage situation at an appropriate time.

4.On-site Maintenance Process

1. 2023-05-25 20:51 Notification: After the vibration of multiple measuring points rises, the trend falls back. The signal shows the characteristic of the bearing cage of the first shaft. Please pay attention to whether there is any abnormal noise in the actual operation of the equipment on site.

2. 2023-05-29 04:38 Reminder to pay attention again: The vibration of multiple measuring points of the reducer is still rising continuously, mainly related to the bearing cage at the input end. Need to strengthen attention recently.

3. 2023-05-29 21:35 On-site feedback: The bearing cage of the high-speed shaft non-drive end is broken, and the inner ring is broken.

5.On-site Maintenance Photos

The inspection photos show that the bearing cage is broken, the inner ring has been broken, and the rolling elements are squeezed and deformed.

Inspection Photo_1

Inspection Photo_2

Inspection Photo_3

6.Post-Maintenance Verification

After the overhaul, the acceleration trend significantly decreased and remained stable.

11V Vertical Mill / Reducer 1-Axis Output 5H / 128k Acceleration Waveform (0.1-20000)_Trend Waveform Spectrum

No obvious bearing damage characteristics are seen in the envelope spectrum, and the cage energy disappears.

11V Vertical Rolling Mill/Reducer 1 Shaft Output 5H/128k Acceleration Waveform (0.1-20000)_Envelope Demodulation

7.Customer Feedback Form

None

Feedback Form_1

8.Monitoring Fault Range

Timely and effective collection of equipment operating status data (vibration, temperature) is restricted by network smoothness and data transmission time, and also needs to consider the interference of equipment's own attributes, production technology and other factors. At the same time, the analysis and diagnosis of equipment status is based on the change of vibration effect caused by the failure of rotating moving parts. Therefore, the condition monitoring system cannot guarantee to monitor all types of faults. The monitoring system is configured according to the measuring point scheme recommended by Party B, and the monitoring fault range and description are as follows:

9.Precautions

1. If the client commissioning this report cannot provide basic unit parameters (such as unit transmission chain diagram, gearbox structure diagram, gearbox gear numbers, relevant bearing models and brands, etc.), the accuracy of the analysis and diagnosis will be affected.

2. This report contains analysis, diagnosis, and maintenance suggestions for the unit provided by Rote Knowledge's professional technicians and is for reference only. The client commissioning the report shall make its own decisions regarding specific maintenance measures.

3. This report shall not be used as evidence for any claims, lawsuits, or other purposes.

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