Case 1: Cement Roller Press - Motor Bearing Fault

1. Measurement Point Sensor Layout Diagram

2. Platform Fault Analysis

Abnormal measurement point at the load end of the fixed roller motor. The spectrum shows obvious abnormal signals between 3500-5300Hz, with peak intervals of about 160Hz, and the baseline energy shows a clear rising trend. Suspected motor bearing fault or poor lubrication.

3. Diagnostic Conclusion and Recommendations

According to system fault prediction analysis: vibration trend changes are stable with no significant fluctuations. The unit can continue operation with attention. It is recommended to listen to the bearing sound and check the bearing condition when possible.

4. User Maintenance Confirmation

The customer conducted an on-site inspection of the equipment and found abnormal noise in the motor bearing. Upon disassembly and maintenance, damage was found on the outer raceway of the motor bearing.

Case 2: Ball Mill - Gearbox Mechanical Looseness Causing Poor Meshing Fault

1. Measurement Point Sensor Layout

2. Platform Fault Analysis

Analysis of data from the small gear output side shows an increasing trend in velocity RMS. Detailed spectrum analysis reveals the main frequencies are gear mesh frequency at 57.8Hz and its harmonics. This indicates possible poor meshing or insufficient foundation stiffness causing significant mesh frequency and harmonics.

Small Gear Output Side Vibration Trend and Waveform Spectrum Chart

3. Diagnostic Conclusion and Recommendations

System analysis diagnosis: there is poor meshing between the large and small gears or insufficient foundation stiffness. It is recommended to check the gear mesh clearance and tooth surface wear, as well as the tightness of foundation bolt connections when possible.

4. User Maintenance Confirmation

On-site inspection on March 17 found all foundation bolts of the bearing seat and upper and lower bolts of the bearing cover were loose. After maintenance, vibration decreased from 27.78mm/s to 5.69mm/s, gear mesh frequency vibration at 59.5Hz and its harmonics significantly reduced, and vibration trend stabilized.

Trend Change After Treatment on Small Gear Output Side

5. Post-Event Feedback and Commendation

Case 3: Belt Conveyor - Gear Fault

1. Measurement Point Sensor Layout

2. Platform Fault Analysis

Analysis of the gearbox input end measurement point shows many peaks below 1400Hz, most with frequency intervals around 24.67Hz, suspected to be the equipment rotational frequency. Due to lack of specific equipment parameters, further detailed analysis is not possible.

Time-domain waveform shows obvious periodic impact signals with a maximum amplitude of 40m/s^2. Combined with the spectrum, suspected gear faults such as pitting, wear, or broken teeth in the gearbox.

3. Diagnostic Conclusion and Recommendations

System analysis diagnosis: gear faults such as pitting, wear, or broken teeth exist; it is recommended to check gear mesh clearance and tooth surface wear soon.

4. User Maintenance Confirmation

In April, the user conducted a shutdown inspection and found obvious wear on the tooth surface of the first stage input gear, with tooth top peeling. (No on-site photos were provided)