Smart Mine Demonstration Project

1. Equipment Information

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:

2.1 Analysis process

2.1.1 Explanation 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

2.1.2 Explanation 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

3.1 Diagnostic conclusion

2023-02-18 23:22 Push diagnosis conclusion: The free end bearing retainer of the motor is worn and has deteriorated slightly recently.

3.2 Inspection 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

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.

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.

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

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: 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

2.1.1 Explanation 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

2.1.2 Explanation 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

3.1 Diagnostic 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).

3.2 Inspection 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

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).

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

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.

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.

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

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: unknown

Related measurement points in this case: Gearbox output 6H

2. Alarm and analysis process

Equipment alarm events:

2.1 Analysis process

2.1.1 Explanation 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

2.1.2 Explanation 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

3.1 Diagnostic 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.

3.2 Inspection 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

2023-09-24 10:46 On-site feedback showed that the foundation bolts were not obviously loose.

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.

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

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.

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.

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

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. Case Process

1.1 On September 18, 2021, the diagnostic conclusion was issued: Mid-term damage to the output end bearing of Gearbox 3, primarily characterized by pitting and spalling on the bearing raceway, with gradual deterioration.

Recommendation: Monitor the abnormal noise and temperature changes at the bearing of the gearbox's third shaft output end, inspect the lubricating oil filter for metal debris, and schedule a bearing damage inspection when convenient.

1.2 On September 28, 2021, on-site feedback inspection revealed pitting on the third axle bearing, along with photos showing pitting on the inner ring of the bearing.

Figure 1 Inspection Photo (Inner Ring Flaking of Bearing)

2. Equipment Basic Information

Motor + gearbox + roller, the installation measurement points of the unit are as follows:

Figure 2 Equipment Overview and Measurement Point Installation Location

The derivation of gearbox parameters is as follows:

Figure 3 Gearbox Parameters

3. Diagnostic Conclusion

The mid-term damage of the output end bearing of the gearbox's 3rd shaft is mainly caused by pitting and peeling damage to the bearing raceway, which slowly deteriorates.

4. Maintenance Suggestions

Pay attention to the abnormal noise and temperature changes of the bearing at the output end of shaft 3 of the gearbox, check whether there are metal debris in the lubricating oil filter element, and inspect the bearing damage at an appropriate time.

5. Analysis Process

5.1. Evidence explanation of trends, indicator parameters, etc.

Recently, all measuring points of the gearbox have shown a slow upward trend in acceleration, velocity, and vibration.

Figure 4: Multiple Trends of High Frequency Acceleration Equipment for Drive Unit 2 of Machine Head 101

Figure 5: Multiple Trends of Low Frequency Acceleration Equipment for Drive Unit 2 of Machine Head 101

Figure 6 101 Head 2 # Drive Department_Speed Equipment Multi Trend

5.2. Useful evidence for time-domain, spectral, envelope demodulation, etc

No significant impact was observed in the time-domain waveform of acceleration.

Figure 7 shows the acceleration waveform (0.1-2000) of 3H-128k on the input side of the drive unit and gearbox of head 2 of machine 101 Sampling Value Multi time Domain Waveform

The low-frequency band of the spectrum is rich in energy, and the envelope demodulation shows the characteristic frequency of the bearing raceway, with rich 3-axis rotational frequency sidebands.

Figure 8 shows the acceleration waveform (0.1-2000) of 3H-128k on the input side of the drive unit and gearbox of head 2 of machine 101 Sampling Value Multi Spectrum

Figure 9: Acceleration waveform (0.1-2000) of 4A/128k on the output side of drive unit 1/2 shaft of 101 machine head 2 # gearbox envelope demodulation

6. Verification of Maintenance Signals

After maintenance, the acceleration and vibration of each measuring point in the gearbox decreased significantly, and the bearing damage characteristics disappeared, indicating a stable operating trend.

Figure 10: Diagram after Maintenance

7. Monitor the Scope of Faults

The timely and effective collection of equipment operating status data (vibration, temperature) is constrained by network connectivity and data transmission time, as well as the interference of equipment properties, production processes, and other factors. Meanwhile, the analysis and diagnosis of equipment status are based on the changes in vibration effects caused by rotating dynamic component faults. Therefore, the state monitoring system cannot guarantee the monitoring of all types of faults. The monitoring system, configured according to the measurement point plan recommended by Party B, can monitor the range of faults and provide the following explanation:

8. Precautions

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

This report is an analysis, diagnosis, and maintenance opinion of the unit by professional technical personnel, for reference only. Specific maintenance and repair measures need to be determined by the commissioning party themselves.

This report shall not be used as any proof material for claims, litigation, etc.

The commissioning party has the obligation to keep the analysis report confidential and shall not provide this report to third parties, 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.