The Zhongyun Technology Intelligent Operations and Maintenance Monitoring Platform Empowers Cement Enterprises—Successfully Resolved a Sand-Making Machine Failure, Ensuring Continuous Production

Recently, a major cement enterprise successfully implemented precise early warnings and efficiently resolved a hammer-head wear failure in its sand-making machine by leveraging the intelligent operation and maintenance platform provided by Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereinafter referred to as “Zhongyun Technology”). The issue was addressed by replacing the worn hammer heads, and the entire process did not disrupt the cement production workflow at any point. This fully demonstrates the platform’s critical value in predictive maintenance for high-load equipment in the cement industry.

1. Real-time monitoring and early warning to detect equipment anomalies.

The sand-making machine is the core equipment for aggregate processing at this enterprise, responsible for crushing limestone into sand. Under conditions of high dust levels and heavy loads, the bearings are prone to wear. If a failure occurs and is not addressed promptly, it could disrupt the supply of aggregates, thereby affecting the subsequent cement production process. Traditional manual inspections rely on “listening for unusual noises and touching the casing,” making it difficult to detect early signs of vibration changes. The intelligent operations and maintenance platform developed by Zhongyun Technology deploys high-precision, dust-resistant sensors at the input and output ends of the sand-making machine’s bearing housings, continuously collecting core parameters such as vibration velocity around the clock. This ensures precise adaptation to the harsh operating environment of the sand-making machine.

On November 25, 2025, after the equipment was started up, the platform detected an anomaly: the vibration velocity at the output end of the bearing housing slowly increased from 3 mm/s to 12 mm/s, triggering a “speed exceeding the set absolute threshold alarm.” The system clearly indicated the “alarm device, its affiliated department, alarm level, and both the initial and latest alarm times,” providing the operations and maintenance team with clear risk guidance.

II. Precise data diagnosis to pinpoint the root cause of the fault.

After receiving the alert, the diagnostic team at Zhongyun Technology conducted an in-depth analysis of the vibration data, taking into account the sand-making machine’s rated speed (750 r/min) and load characteristics. The final analysis determined that there was significant friction inside the sand-making machine, causing imbalance in the rotor shaft.

Diagnostic conclusion: There is obvious friction inside the sand-making machine, causing imbalance in the rotating shaft and placing the equipment in a warning state.

Maintenance recommendation: The current vibration velocity has increased significantly, so the machine should be promptly stopped for inspection to identify any abnormalities inside the sand-making machine.

III. Implement closed-loop management to mitigate the risk of production disruptions.

The platform features a closed-loop, end-to-end process of “early warning—diagnosis—intervention—validation,” which is tailored to meet the core requirement of cement enterprises for “continuous operation” and ensures efficient fault handling.

1. Planned shutdown for replacement, with targeted measures: Based on the diagnostic recommendations, the company scheduled a equipment shutdown inspection for November 27, 2025. On-site inspection confirmed that “the hammer heads of the sand-making machine showed obvious wear and chipping.” The operations and maintenance team immediately replaced the worn hammer heads, completing the maintenance work.

2. Data validation confirms the effectiveness; equipment has stabilized. Following the equipment restart on November 28, 2025, real-time monitoring by the platform shows a significant decrease in the vibration velocity at the bearing housing output end, stabilizing below 6 mm/s. Currently, the equipment’s operational trend is stable, and it has returned to normal working conditions.

4. The platform’s core value: aligning with the operation and maintenance needs of the cement industry.

This case of troubleshooting the sand-making machine vividly demonstrates the three core values of Zhongyun Technology’s intelligent operations and maintenance platform:

1. Break the limitations of routine inspections: Replace manual periodic inspections with 24-hour real-time monitoring to precisely detect hidden faults and achieve "early fault detection";
2. Reduce O&M costs: By leveraging data-driven, precise diagnostics, we can avoid unnecessary disassembly and repairs, minimize component wear and tear, extend equipment lifespan, and achieve "low-cost maintenance."
3. Upgrade the management model: Adopt a closed-loop approach of “early warning—diagnosis—intervention—verification” to help enterprises shift from “reactive maintenance” to “predictive maintenance” and accelerate the digital transformation of equipment management in the cement industry.

In the future, Zhongyun Technology will continue to iterate its AI diagnostic algorithms and sensor technologies, providing cement enterprises with end-to-end intelligent operation and maintenance solutions that offer “precise early warnings, efficient handling, and stable assurance,” thereby helping the industry achieve digitalization in equipment management and intelligent decision-making in operations and maintenance.