The Zhongyun Technology Intelligent Operations and Maintenance Monitoring Platform Empowers Cement Enterprises—Successfully Resolved Mixer Belt Failure, Ensuring Continuous Production

Recently, a major cement enterprise successfully achieved precise early warning and efficient resolution of a conveyor belt failure in its mixers by leveraging the intelligent operations and maintenance platform provided by Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereinafter referred to as “Zhongyun Technology”). The issue was addressed by replacing the damaged belt, and the entire process did not disrupt the subsequent production workflow, fully demonstrating the platform’s critical value in predictive maintenance for transmission equipment in the cement industry.

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

The mixer is the core equipment in the “raw material blending” stage of cement production at this enterprise, responsible for uniformly mixing raw materials or concrete ingredients. Its stable operation directly affects subsequent clinker formation and the quality of the finished cement. The equipment operates under conditions of high dust levels and continuous heavy loads. As a critical transmission component, the motor belt is prone to early wear, which can easily cause abnormal vibrations. Traditional manual inspections, relying solely on “visual inspection and listening for unusual noises,” struggle to detect early changes in vibration, posing a significant risk of undetected faults escalating into more serious problems. To address these challenges, Zhongyun Technology’s intelligent operations and maintenance platform has deployed highly accurate, dust-resistant sensors at key locations—such as the horizontal plane at the motor drive end—to continuously collect core parameters like vibration velocity around the clock, precisely adapting to the harsh operating environment.

On December 1, 2025, after the equipment was started up and began operating, the platform detected an anomaly: the vibration velocity at the drive end of the right motor increased from 3 mm/s to 13 mm/s, triggering both a “speed exceeding the set absolute threshold alarm” and a “belt failure mechanism alarm.” The system clearly labeled the “alarm device, affiliated department, alarm level, and the times of the initial and latest alarms,” 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 from Zhongyun Technology conducted an in-depth analysis of the vibration data from the right motor’s drive end, taking into account the equipment’s rated speed (840 r/min). Preliminary findings indicate that there is a clear fault in the belt connecting the right motor of the second-line mixer to the driven equipment.

Diagnostic conclusion: The belt connecting the right motor of the secondary mixer to the driven equipment exhibits a clear fault, and the equipment is operating in a warning state.

Maintenance recommendation: The vibration velocity value has significantly exceeded the standard, and the machine should be promptly stopped for inspection to identify any abnormalities in the belt connecting the right motor to the driven equipment.

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—response—validation,” which is tailored to meet the core requirement of cement enterprises for “continuous operation” and ensures efficient fault resolution.

1. Planned shutdown for replacement with targeted measures: Based on the diagnostic recommendations, the company scheduled a equipment shutdown inspection on the evening of December 5, 2025. On-site inspection confirmed that “the right motor belt showed obvious damage.” The operations and maintenance team immediately replaced it with a matching model of drive belt, completing the repair without disrupting the next day’s production.

2. Data validation confirms the effectiveness; equipment has stabilized. Following the equipment restart on the morning of December 6, 2025, real-time monitoring on the platform showed a significant decrease in the vibration velocity at the motor drive end, stabilizing below 4 mm/s. Currently, the equipment’s operating trend is stable and has returned to normal working conditions.

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

This case of handling the mixer belt failure 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 early, hidden faults and achieve “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 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.

Zhongyun Technology will continue to iteratively enhance its AI diagnostic algorithms and sensor technologies, providing cement enterprises with a full-process intelligent operation and maintenance solution that offers “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.