Precise early warning turns potential hazards into safety: Zhongyun Technology’s intelligent O&M platform successfully detected a coupling failure in the eddy current classifier.

Recently, a key piece of equipment—a vortex powder separator—at a major building materials enterprise suddenly experienced severe vibration during operation. The Zhongyun Technology Intelligent Operations and Maintenance Platform promptly detected abnormal data, accurately issued an early warning of a coupling failure, and guided the enterprise through a closed-loop process—from maintenance to reinforcement—effectively preventing equipment damage and production disruptions.

1. Real-time Monitoring: A sudden surge in vibration triggers a high-risk alert.

On December 1, 2025, the platform detected that the vibration velocity at the motor drive end of the classifier had sharply increased from 25 mm/s to 60 mm/s, severely exceeding the safety threshold. The system immediately issued a high-risk alarm and simultaneously pushed a diagnostic conclusion indicating “misalignment of the shaft.” The alarm information—clearly including the alarmed equipment, its affiliated department, the alarm level, as well as the initial and latest alarm timestamps—was promptly sent to the operations and maintenance team. This enabled early detection of latent faults and provided the operations and maintenance team with clear, timely risk guidance and actionable evidence for troubleshooting.

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 (1125 r/min). Based on the structural design of the classifier, they initially determined that there was a clear abnormality in the coupling. The platform’s intelligent diagnostic conclusion was consistent with the manual diagnostic conclusion, and it was recommended to promptly shut down the machine for an inspection of the coupling’s abnormal condition.

III. Closed-loop Management: From Emergency Alerts to System Recovery

1. Planned Shutdown and On-site Verification

Based on the early warning, the company scheduled a shutdown for inspection on December 28. On-site inspection confirmed that one of the nylon rods in the coupling had broken, which was fully consistent with the platform’s diagnostic findings.

2. Professional Repair and Effect Verification

The maintenance personnel replaced the nylon rods and recalibrated the alignment. To further eliminate potential hazards, the motor foundation was reinforced on January 14. After the equipment was restarted, the vibration velocity steadily decreased and stabilized below 10 mm/s, and the operating condition returned to normal.

IV. Core Value: Shift from passive response to proactive management.

The successful early warning and handling of this coupling failure vividly demonstrate the core value 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 hidden equipment faults and achieve “early fault detection.”
2. Reduce operational and maintenance costs: By leveraging data-driven, precise diagnostics, 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 iterate its AI diagnostic algorithms and sensor technologies, providing industrial enterprises with a full-process intelligent operation and maintenance solution that delivers “precise early warnings, efficient response, and stable assurance,” thereby helping the industry achieve digitalization of equipment management and intelligent decision-making in operations and maintenance.