A New Breakthrough in Equipment “Auscultation”: The Zhongyun Technology Intelligent Operations and Maintenance Platform Accurately Predicts Gearbox Bearing Failures, Ensuring Smooth Continuous Production.

Recently, a major cement company experienced a latent fault in its critical hoisting equipment during operation. Thanks to the intelligent operations and maintenance monitoring platform developed by Zhongyun Technology, which employs keen “data stethoscopes,” an early warning was issued regarding bearing wear inside the gearbox. The platform also provided end-to-end guidance throughout the entire repair process, enabling the company to carry out precise maintenance and successfully transform a potential sudden shutdown into a planned, highly efficient preventive maintenance effort.

1. Real-time monitoring: Detecting equipment operation anomalies

This chain bucket elevator is a critical conveying device in the cement production line. Starting December 19, 2025, the Zhongyun Technology platform detected an abnormal surge in the vibration acceleration value at the input end of Gearbox No. 1. The value rapidly climbed from approximately 10 m/s² to 15 m/s² and has remained consistently above the threshold. The platform immediately triggered a threshold alarm and simultaneously generated a fault diagnosis conclusion. The system clearly labels “alarm equipment name, equipment type, alarm level, initial alarm time, and latest alarm time,” providing the operations and maintenance team with clear risk guidance.

II. Intelligent Diagnosis and Precise Verification

After receiving the alert, the Zhongyun Diagnostic Team conducted an in-depth analysis of the vibration data, taking into account the equipment’s operating speed (1500 rpm). Based on the reducer’s operational structure, they determined that the rolling bearings in the reducer showed significant wear. The intelligent diagnostic conclusions from the platform were highly consistent with the manual diagnostic findings.

3. Closed-loop handling: From platform alerts to on-site repair and verification.

1. Planned Shutdown and Validation:

Based on the platform’s threshold alarms and fault conclusions, the company scheduled a planned shutdown for December 20. After on-site shutdown and inspection, the fault scenario was found to be highly consistent with the platform’s diagnostic findings—the intermediate shaft bearing of the gearbox showed obvious signs of wear.

2. Efficient Maintenance and Data Validation:

The on-site team immediately replaced the worn-out bearing. The equipment was put back into operation on the evening of December 24. According to the platform monitoring data, the vibration acceleration at the input end of Gearbox No. 1 dropped significantly and stabilized below 3 m/s². The equipment’s operational characteristic curve has returned to a stable state, completely eliminating the hidden danger.

IV. Core Value: A Model Practice in Predictive Maintenance

The successful handling of this reducer bearing wear failure vividly demonstrates the capabilities of Zhongyun Technology’s intelligent operations and maintenance platform. Three Major Values ：

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:

Through data-driven, precision diagnostics, we can avoid unnecessary disassembly and repairs, reduce component wear, extend equipment lifespan, and achieve "low-cost maintenance."

3. Upgrade the management model:

With a closed-loop approach of “early warning—diagnosis—intervention—validation,” we help enterprises shift from “reactive maintenance” to “predictive maintenance,” accelerating 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 industrial enterprises with end-to-end intelligent operation and maintenance solutions that offer “precise early warnings, efficient response, and stable assurance,” thereby helping the industry achieve digitalization in equipment management and intelligent decision-making in operations and maintenance.