Zhongyun Technology's Intelligent Operations and Maintenance Monitoring Platform Empowers Cement Enterprises—Successfully Addressing Cooler Fan Failure, Ensuring Continuous Production

Recently, a major cement enterprise leveraged the intelligent operations and maintenance platform provided by Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereafter referred to as "Zhongyun Technology") to accurately predict and efficiently address motor bearing wear and electrical erosion issues in grate cooler fans. The problem was resolved by replacing the insulation bearings—without disrupting the core clinker calcination process at any point. This successfully highlighted 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

The grate cooler fan is a core auxiliary equipment in the cement clinker calcination process, and its stable operation directly affects clinker cooling efficiency, equipment lifespan, and production continuity. In cement manufacturing, these fans typically operate under high-load and high-vibration conditions for extended periods. As a result, traditional manual inspections often fail to promptly detect the rapid deterioration of hidden faults, such as bearing wear. To address this challenge, Wuhan Zhongyun Kangchong’s intelligent operations and maintenance platform leverages high-precision sensors deployed at critical measurement points on the fan—specifically at the motor drive end and the fan blade end—to enable 24-hour uninterrupted data collection and dynamic analysis.

In early September 2025, the platform detected severe anomalies in equipment vibration data: the vibration acceleration at the motor drive end remained consistently high, peaking at 100 m/s²—far exceeding the safety threshold—and triggering multiple alerts on the platform, including "Acceleration Exceeds Set Absolute Threshold Alert," "Acceleration Exceeds Dynamic Threshold Alert," and "Acceleration Trend Fitting Anomaly Over Time Alert." The system clearly labeled "Alerted Equipment, Affiliated Department, Alarm Level, and Both Initial and Latest Alarm Times," providing the operations and maintenance team with a clear guide to assess the associated risks.

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

After receiving the alert, the Zhongyun Technology diagnostic team conducted an in-depth analysis of the motor-driven end vibration data, leveraging the grate cooler fan’s rated speed parameters and operational characteristics. They ruled out interference factors such as shaft imbalance and foundation loosening, ultimately pinpointing the root cause of the fault as "wear and pitting on the outer race and rolling elements of the motor bearing."

Diagnostic conclusion: The motor bearing is operating in a warning condition, with wear and pitting observed on the outer race and rolling elements.

Maintenance recommendation: The equipment should be shut down as soon as possible to inspect the bearings for any signs of failure or wear.

3. 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 - handling - verification," perfectly aligning with the core requirement of cement enterprises to prioritize continuous clinker production, thereby ensuring efficient fault resolution.

1. Planned shutdown for replacement, with precise implementation: Following the diagnostic recommendations, the company scheduled a equipment shutdown for inspection on September 21, 2025. On-site inspection confirmed significant wear and electrical erosion on the motor-driven end bearing. The operations and maintenance team immediately initiated corrective actions, replacing the bearing with an insulation-bearing model designed to handle high-load conditions. The entire process was carefully coordinated to avoid disrupting peak production hours, ensuring no impact on the subsequent clinker transportation phase.

2. Data validation proves effective, and equipment has returned to stable operation. Following the equipment restart on September 27, 2025, real-time monitoring on the platform showed a significant drop in vibration acceleration at the motor drive end, stabilizing below 10 m/s². Meanwhile, the equipment’s operational trend remained smooth, confirming a return to normal working conditions.

IV. Platform's Core Value: Tailored to Meet Equipment Maintenance and Operation Needs in the Cement Industry

This case of handling the cooler fan failure vividly demonstrates the three core values of Wuhan Zhongyun Kangchong Intelligent Operations and Maintenance Platform:

1. Break the limitations of routine inspections: Replace manual, periodic checks with 24-hour real-time monitoring to precisely detect hidden faults and enable "early fault detection";
2. Reduce operational and maintenance costs: By leveraging data-driven, precise diagnostics, we can avoid unnecessary disassembly and repairs, minimize component wear, extend equipment lifespan, and achieve "low-cost maintenance."
3. Upgrade the management model: Adopting a closed-loop approach of "early warning - diagnosis - action - verification" to help enterprises shift from "reactive maintenance" to "predictive maintenance," thereby accelerating 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 a comprehensive, intelligent operation-and-maintenance solution that delivers "precise early warnings, efficient handling, and reliable support," helping the industry achieve digitalization in equipment management and intelligent decision-making for maintenance operations.