Smart Mine Demonstration Project

Case Duration:

May 2021 – Present (2+ Years)

Client Background:

Established by the Shaanxi Provincial Committee of the CPC and Shaanxi Provincial Government to leverage local coal resources, the Group has become: A state-owned mega energy and chemical enterprise; The backbone of Shaanxi's energy-chemical industry; The principal developer of Shaanxi's major coal production bases

Client Requirements & Solutions

Modernizing Equipment Monitoring for Intelligent Mining

Real-Time Diagnostics & Precise Fault Identification:

To address limited existing monitoring capabilities, RONDS:

1. Deployed 1,000+ monitoring points across 160+ critical assets at Ningtiaota Mine and Huangling No.1 Mine, including:
1) Conveyors
2) Pump houses
3) Air compressors
4) Main ventilation fans

2. Enabled real-time anomaly detection

3. Achieved precise fault location and degradation assessment

Critical Equipment Monitoring for Uninterrupted Production:

Implemented monitoring for fully-mechanized mining face equipment:

1. Transport machines

2. Crushers

3. Transfer devices

4. Entry belt conveyors

Application Value

Ensuring Safe Mine Production:

By integrating critical equipment into RONDS' remote monitoring system, we have:

1. Successfully closed multiple equipment failure cases including:
1) Bearing failures
2) Gear defects
3) Lubrication issues
4) Power frequency abnormalities

2. Effectively prevented unplanned shutdowns and potential accidents

3. Achieved safety compliance during monitoring period

Efficiency Gains & Sustainable Production:

1. Enhanced Equipment Control
1) Improved availability
2) Increased reliability
3) Maintainability optimization

2. Economic & Environmental Benefits
1) Prevented production losses
2) Reduced safety/environmental risks

Equipment Data Accumulation and Refinement of Intelligent Algorithms Facilitate Smarter Monitoring Systems:

Through the combined application of intelligent algorithms and expert diagnostic analysis, the customer has achieved real-time operational status assessment and future state prediction for key coal mining equipment.

Success Cases

Shaanxi Coal Industry Ningtiaota Coal Mine Transfer Machine

1.EquipmentInformation
Equipment type: Transfer machine
Rated speed: 1500rpm
Related measurement points in this case: Motor non-driving end 1H
2.Alarm and analysis process
Equipment alarm events:
2.1Analysis process
2.1.1Explanation of trends, indicator parameters and other evidence
The total acceleration value of the non-drive end of the motor fluctuates slightly.
Transfer machine/motor non-driving end 1H/128k acceleration waveform (0.1-20000)_trend analysis
2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation
The bearing cage shock is visible in the time domain waveform.
Transfer machine/motor non-driving end 1H/128k acceleration waveform (0.1-20000)_time domain waveform
Envelope demodulation shows the characteristic frequency and harmonics of the bearing cage.
Transfer machine/motor non-driving end 1H/128k acceleration waveform (0.1-20000)_envelope demodulation
3.Diagnostic conclusions and recommendations
3.1Diagnostic conclusion
2023-02-18 23:22 Push diagnosis conclusion: The free end bearing retainer of the motor is worn and has deteriorated slightly recently.
3.2Inspection and maintenance suggestions
The equipment is currently in a monitorable operating state. It is recommended to arrange to check the abnormal noise at the free end of the motor and improve lubrication.
4.On-site inspection and maintenance process
2023-02-27 11:49 On-site engineer He reported that the motor was replaced and the bearing retainer at the free end of the motor was broken.
5.On-site inspection and maintenance photos
The photo shows that the non-drive end bearing of the motor is broken.

Maintenance photo_1

Maintenance photo_1

Maintenance photo_3
6.Verification after inspection and maintenance
The machine has not been started after maintenance.
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.

Learn More
Shaanxi Coal Industry Ningtiaota Coal Mine Transfer Machine

1.Equipment Information
Equipment type: Transfer machine
Rated speed: 1500rpm
Related measurement points in this case: Motor drive end 2H
2.Alarm and analysis process
Equipment alarm events:
2.1 Analysis process
2.1.1Explanation of trends, indicator parameters and other evidence
There is a significant increase in the trend of the total high-frequency acceleration at the motor drive end.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_trend analysis
2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation
There are significant shocks in the acceleration time domain waveform and signs of clipping.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_time domain waveform
The noise floor energy in the spectrum graph increases significantly.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_spectrum analysis
The acceleration envelope demodulation shows the characteristic frequency components of the inner and outer bearing cages.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_envelope demodulation
The long waveform envelope demodulation before the high point rises shows the characteristic frequency of the bearing inner ring fault and its harmonics, accompanied by the frequency conversion sideband.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_long waveform
3.Diagnostic conclusions and recommendations
3.1Diagnostic conclusion
2023-07-02 02:59 Push diagnosis conclusion: The motor drive end bearing has medium-term damage, the cage is broken and deformed, the inner ring has peeled off, and there has been recent deterioration (no data from the free end sensor).
3.2Inspection and maintenance suggestions
Immediately verify the actual situation of the equipment on site, and the equipment is currently at risk of sudden failure. During inspections, pay attention to abnormal noise and temperature of the motor drive end bearings, and stop the machine at an appropriate time to check the bearing damage.
4.On-site inspection and maintenance process
1.2023-07-04 12:33 On July 2, the on-site feedback was that the motor was replaced (the motor insulation was normal, the high-speed insulation was low, it has not been disassembled yet, and feedback will be given after disassembly).
2.Damage photos were sent from the site at 15:09 on 2023-07-18, showing that the retainer was broken and deformed, and the inner ring was peeling off.
5.On-site inspection and maintenance photos
The inspection photos showed that the bearing cage was broken and deformed, and the inner ring was peeling off.
Maintenance photo_1
6.Verification after inspection and maintenance
After the unit was overhauled, the total acceleration trend at the motor drive end decreased significantly.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_trend analysis
The total value of acceleration vibration has dropped significantly, and there is no sign of clipping in the waveform.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_time domain waveform
It can be seen from the spectrum that the noise floor energy in the frequency band has dropped significantly.
Transfer machine/motor drive end 2H/128k acceleration waveform (0.1-20000)_spectrum analysis
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.

Learn More
Shaanxi Coal Industry Ningtiaota Coal Mine 762 head 1# drive unit

1.Equipment Information
Equipment type: belt conveyor main drive
Rated speed: unknown
Related measurement points in this case: Gearbox output 6H
2.Alarm and analysis process
Equipment alarm events:
2.1Analysis process
2.1.1Explanation of trends, indicator parameters and other evidence
The speed vibration at the gearbox measuring point has increased recently.
762 head 1# drive unit/gearbox output 6H/16k speed waveform (2-1000)_trend analysis
2.1.2Explanation of evidence such as time domain, spectrum, and envelope demodulation
There is no obvious impact or disturbance in the time domain waveform.
762 head 1# drive unit/gear box output 6H/16k speed waveform (2-1000)_time domain waveform
The frequency spectrum is dominated by a one-fold frequency energy rise.
762 head 1# drive unit/gearbox output 6H/16k speed waveform (2-1000)_spectrum analysis
3.Diagnostic conclusions and recommendations
3.1Diagnostic conclusion
2023-09-24 09:25 Push diagnosis conclusion: The gearbox speed vibration has increased, which is speculated to be related to coupling wear and insufficient foundation stiffness.
3.2Inspection and maintenance suggestions
During daily inspections, pay attention to the vibration of the gearbox and whether the foundation stiffness is insufficient, and check the coupling for damage when appropriate.
4.On-site inspection and maintenance process
1. 2023-09-24 10:46 On-site feedback showed that the foundation bolts were not obviously loose.
2. On-site feedback at 17:41 on 2023-09-25: The serpentine spring coupling was replaced after 11:00 noon and the coupling was worn.
3. 2023-10-08 17:59 On-site feedback: Foundation reinforcement was carried out again.
5.On-site inspection and maintenance photos
The inspection photos show wear on the coupling serpentine spring.

Maintenance photo_1

Maintenance photo_2

Maintenance photo_3

Maintenance photo_4
6.Verification after inspection and maintenance
After the overhaul, the speed vibration of the gearbox measuring point decreased slightly.
762 head 1# drive unit/gearbox output 6H/16k speed waveform (2-1000)_trend analysis
The transfer frequency energy in the spectrum decreases significantly.
762 head 1# drive unit/gearbox output 6H/16k speed waveform (2-1000)_spectrum analysis
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.

Learn More
陕西煤业柠条塔煤矿振动状态监测_101机头_101机头2#驱动部_验证报告_1

1. 案例过程
1、2021年09月18日，推送诊断结论：齿轮箱3轴输出端轴承中期损伤，以轴承滚道点蚀、剥落损伤为主，缓慢劣化。
建议：关注齿轮箱3轴输出端轴承运行异响及温度变化，检查润滑油滤芯是否存在金属碎屑，择机检查轴承损伤情况。
2、2021年09月28日，现场反馈检查发现3轴轴承剥落，并发来照片，照片显示轴承内圈存在剥落。
图1 检查照片（轴承内圈剥落）
2. 设备基础信息
电机+齿轮箱+滚筒，机组安装测点情况如下：
图2 设备全貌及测点安装位置
齿轮箱参数推导如下：
图3 齿轮箱参数
3. 诊断结论
齿轮箱3轴输出端轴承中期损伤，以轴承滚道点蚀、剥落损伤为主，缓慢劣化。
4. 检修建议
关注齿轮箱3轴输出端轴承运行异响及温度变化，检查润滑油滤芯是否存在金属碎屑，择机检查轴承损伤情况。
5. 分析过程
5.1. 趋势、指标参数等证据说明
近期齿轮箱所有测点加速度、速度振动呈现缓慢上升趋势。

图4 101机头2#驱动部_高频加速度设备多趋势

图5 101机头2#驱动部_低频加速度设备多趋势

图6 101机头2#驱动部_速度设备多趋势
5.2. 时域、频谱、包络解调等有用证据说明
加速度时域波形未见明显冲击。
图7 101机头2#驱动部\齿轮箱输入侧3H\128k 加速度波形(0.1-2000).采样值_多时域波形
频谱中低频段能量丰富，包络解调可见轴承滚道特征频率，带有丰富的3轴转频边带。

图8 101机头2#驱动部\齿轮箱输入侧3H\128k 加速度波形(0.1-2000).采样值_多频谱

图9 101机头2#驱动部\齿轮箱1/2轴输出侧4A\128k 加速度波形(0.1-2000)_包络解调
6. 检修信号验证
检修后齿轮箱各测点加速度振动下降明显，且轴承损伤特征消失，运行趋势稳定。
图10 检修后图谱
7. 监测故障范围
设备运行状态数据（振动、温度）的及时、有效采集，受网络通畅、数据传输时间的制约，也需考虑设备本身属性、生产工艺等因素的干扰。同时，设备状态的分析及诊断是基于旋转动部件故障引起振动效应的变化而进行。因此状态监测系统无法保证监控所有类型故障。该监测系统在按照乙方推荐的测点方案下进行配置，可监测故障范围及说明如下：
8. 注意事项
1.本报告委托方如不能提供基本机组参数（如：机组传动链图、齿轮箱结构图、齿轮箱齿数等、相关的轴承型号及品牌），将会影响分析诊断的准确性；
2.本报告为容知专业技术人员对机组的分析和诊断、维护意见，仅供参考，具体维护维修措施还需委托方自行决定；
3.本报告不作为任何理赔、诉讼等证明材料；
4.委托方负有对分析报告保密的义务，未经受托方书面许可不得将本报告提供给第三方、印刷成其它宣传材料或发布于网络等公共信息平台。

Learn More

Smart Mine Demonstration Project

Client Requirements & Solutions

Application Value

Success Cases

1.EquipmentInformation

2.Alarm and analysis process

2.1Analysis process

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

3.2Inspection and maintenance suggestions

4.On-site inspection and maintenance process

5.On-site inspection and maintenance photos

6.Verification after inspection and maintenance

7.Customer feedback form

8.Monitoring fault range

9.Notes

1.Equipment Information

2.Alarm and analysis process

2.1 Analysis process

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

3.2Inspection and maintenance suggestions

4.On-site inspection and maintenance process

5.On-site inspection and maintenance photos

6.Verification after inspection and maintenance

7.Customer feedback form

8.Monitoring fault range

9.Notes

1.Equipment Information

2.Alarm and analysis process

2.1Analysis process

3.Diagnostic conclusions and recommendations

3.1Diagnostic conclusion

3.2Inspection and maintenance suggestions

4.On-site inspection and maintenance process

5.On-site inspection and maintenance photos

6.Verification after inspection and maintenance

7.Customer feedback form

8.Monitoring fault range

9.Notes

1. 案例过程

2. 设备基础信息

3. 诊断结论

4. 检修建议

5. 分析过程

5.1. 趋势、指标参数等证据说明

5.2. 时域、频谱、包络解调等有用证据说明

6. 检修信号验证

7. 监测故障范围

8. 注意事项

Start Your Journey to Intelligent Industrial Equipment Maintenance