The Zhongyun Technology Intelligent Operations and Maintenance Monitoring Platform Empowers Cement Enterprises—Successfully Resolved Resonance Fault in Return Material Conveyor, Ensuring Continuous Production

Recently, a major cement enterprise successfully used the intelligent operation and maintenance platform provided by Wuhan Zhongyun Kangchong Technology Co., Ltd. (hereinafter referred to as “Zhongyun Technology”) to accurately predict and efficiently resolve a resonance fault in a return-material belt conveyor. By optimizing the rigidity of the equipment supports, the issue was rectified without disrupting the subsequent production process at any point. This fully demonstrates the platform’s core value in predictive maintenance for equipment in the cement industry.

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

The return-material belt conveyor is a critical piece of equipment for material flow in cement production, and it operates continuously under conditions of high dust levels for extended periods. Traditional manual inspections, which rely solely on sensory judgment, often fail to detect the early, gradual trends in equipment vibration. The Zhongyun Technology Intelligent Operations and Maintenance Platform addresses this challenge by deploying high-precision sensors at the motor drive end of the equipment, enabling 24-hour uninterrupted monitoring of vibration data.

Starting November 20, 2025, each time the equipment is started up, the platform will detect that the vibration velocity at the loaded end of the motor exceeds the specified threshold. The platform will automatically trigger a threshold alarm and, through mechanistic diagnosis, conclude that “mechanical structural resonance” is the underlying cause. Simultaneously, the platform will generate detailed information on the root cause of the fault and provide corresponding troubleshooting recommendations. The system clearly labels “alarm device name, device type, alarm level, and the timestamps of the initial and most recent 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 at Zhongyun Technology conducted an in-depth analysis of the vibration data, taking into account the equipment’s operating speed (2930 r/min). Based on the equipment’s operational structure, they determined that the motor was experiencing resonance or foundation loosening. The platform’s intelligent diagnostic conclusion was consistent with the manual diagnostic conclusion.

Maintenance recommendation: The vibration velocity exceeds the standard. Strengthen equipment monitoring during operation. Upon shutdown, promptly inspect the motor foundation platform for any signs of loosening. If no abnormal loosening is detected, it is recommended to reinforce the foundation platform by welding.

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 handling.

1. Planned shutdown for replacement with targeted measures: Based on the diagnostic recommendations, the company scheduled a equipment shutdown inspection for the morning of December 9, 2025. On-site inspection confirmed “resonance in the motor equipment.” The operations and maintenance team immediately reinforced the base platform by welding, completing the repair on the same day without disrupting subsequent production.

2. Data validation confirms effectiveness; equipment has stabilized. After the equipment was restarted on the evening of December 9, 2025, real-time monitoring on the platform showed a significant decrease in vibration velocity at the motor drive end, with the vertical direction not exceeding 5 mm/s. The current operational trend is stable, and the equipment 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 resonant fault handling 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.