Zhongyun Technology's Intelligent Operations and Maintenance Monitoring Platform Empowers Cement Enterprises—Successfully Addressed a Roots Blower Failure, Ensuring Continuous Production

Recently, a major cement enterprise leveraged the intelligent monitoring platform provided by Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereafter referred to as "Zhongyun Technology") to accurately predict and efficiently address a gear failure in a Roots blower. By conducting timely maintenance, the company prevented the issue from escalating into a production shutdown or environmental risks, thereby fully demonstrating the platform's critical value in predictive maintenance for equipment within the cement industry.

1. Real-time monitoring and early warning to detect equipment abnormalities in high-dust environments

The Roots blower is a critical auxiliary equipment in cement production, and its stable operation directly affects the continuity of the manufacturing process. Traditional manual inspections often fail to detect subtle, progressive changes indicative of hidden faults such as gear wear. However, Zhongyun Technology’s intelligent operations and maintenance monitoring platform addresses this issue by deploying sensors at the blower’s core measurement points, enabling 24-hour uninterrupted data collection and dynamic analysis.

In August 2025, the platform detected a significant abnormal trend in equipment vibration data: At the input end of the positive screw of the fan, the acceleration increased from 3 m/s² to 10 m/s², while the velocity rose from 5 mm/s to 8 mm/s. Meanwhile, at the output end of the negative screw, the acceleration climbed from 3 m/s² to 12 m/s², and the velocity jumped from 5 mm/s to 8 mm/s—triggering a threshold alarm. Concurrently, the mechanistic model identified characteristic patterns indicative of "acceleration waveform bearing failure" and "acceleration waveform mechanical structure fault," generating a medium-level fault warning. The alert clearly specifies the affected equipment, measurement point, as well as the actual and alarm thresholds (velocity: 9.33/8 mm/s), along with the initial alarm time (2025-08-08 23:15:13) and the most recent alarm time (2025-08-17 06:04:08), providing clear guidance for operations and maintenance.

Figure 1: Detailed Alert Information for the Mixer-Assisted Roots Blower

Figure 2: Vibration Data Trend Chart of the Fan's Male Screw Input End

Figure 3: Trend Chart of Vibration Data from the Compressor's Male Screw Output End

II. Precise Data Diagnosis Pinpoints the Root Cause of Gear Failure

After receiving the alert, the Zhongyun Technology diagnostic team conducted a thorough analysis of the vibration data from the screw measurement points. Combining this with the fan’s rated speed (525 r/min), they ruled out a simple bearing failure and determined that the root cause of the issue was "significant wear and tooth breakage in the fan gears."

Figure 4: Waveform and Spectrum of the Fan’s Male Screw Input端

Diagnostic conclusion: The fan gear is operating in a warning state, with a risk of severe wear and tooth breakage failure.

Maintenance recommendation: The acceleration value is increasing rapidly—please stop the machine immediately to inspect for wear on the male and female screw gears.

3. Implement closed-loop management to mitigate production and environmental risks

The platform features a closed-loop, end-to-end process of "early warning - diagnosis - response - verification," ensuring efficient and controllable fault management.

1. Planned Shutdown Maintenance

Following the diagnostic recommendations, the company scheduled equipment shutdown for inspection on August 18, 2025. On-site inspection confirmed significant faults in the fan gear and pins, aligning perfectly with the platform's diagnostic findings. Maintenance personnel immediately initiated repairs, spending over a week to complete the replacement of the gear and pins, along with the necessary adjustments and testing.

Figure 5: Screenshot of On-site Communication Records

2. Data validation ensures effectiveness

After the equipment was restarted on September 7, 2025, platform monitoring showed that vibration data from the wind turbine screw measurement points had significantly decreased—acceleration levels dropped below 2 m/s², and velocity readings fell below 4 mm/s. Overall, the equipment is running smoothly with stable operational trends.

Figure 6: Vibration Trend Chart After Maintenance of the Fan's Male Screw Input End

Figure 7: Vibration Trend Chart After Maintenance of the Fan's Male Screw Output End

Figure 8: Comparison of Acceleration Spectra Before and After Maintenance (Top: During Fault; Bottom: After Repair)

4. The platform's core value drives industry operations and maintenance upgrades.

This incident highlights the three core values of Wuhan Zhongyun Kangchong's intelligent operation and maintenance monitoring platform in the cement industry:

1. Break the limitations of manual inspections: Replace human patrols with 24-hour real-time monitoring to precisely detect sudden equipment failures.

2. Reduce operational and maintenance costs: By accurately diagnosing and pinpointing the core faulty components, we can avoid unnecessary disassembly and repairs, shorten the inspection and repair cycle, and minimize equipment wear and tear.

3. Ensure Continuous Production: Help enterprises transition from "reactive maintenance" to "predictive maintenance," ensuring the stable operation of critical equipment and providing reliable support for uninterrupted production processes.

In the future, Zhongyun Technology will continue to iterate its diagnostic algorithms and sensor technologies, expanding applications to more core equipment across various industries, and providing businesses with precise, efficient, and intelligent operations-and-maintenance solutions.