Precisely Identifying Abnormal Belt Risks: Zhongyun Platform Successfully Issues Early Warning of Crusher Belt Failure

Recently, a key piece of equipment at a cement enterprise—a heavy-hammer impact crusher—exhibited abnormal vibration during operation. Leveraging its intelligent operations and maintenance platform, Zhongyun Technology conducted real-time monitoring and accurately identified signs of equipment loosening, successfully issuing an early warning for belt slackness. This enabled the enterprise to carry out preventive tightening, effectively preventing unexpected shutdowns caused by drive failure.

I. Real-Time Monitoring: Sudden Surge in Vibration Levels Triggers High-Risk Alert

On March 15, 2026, platform monitoring data showed that the vibration velocity at the free-end horizontal measurement point of the crusher motor surged to 18.9 mm/s, while the corresponding value at the drive-end horizontal measurement point simultaneously rose to 15.44 mm/s—both far exceeding the safety threshold. This triggered a system alert, which promptly issued a diagnostic conclusion of “loose mechanical structure.” The platform automatically dispatched the alarm notification to the operations and maintenance team, clearly indicating the alarmed equipment, its affiliated department, the alarm severity level, and both the initial and most recent alarm timestamps. This capability enables the early detection of latent faults, providing the O&M team with clear, timely risk guidance and a solid basis for corrective action.

II. Precise Validation of Intelligent Diagnosis

Upon receiving the alarm, the Zhongyun Diagnostics team conducted an in-depth analysis of the vibration data. Based on the crusher’s structure and operating parameters, they determined that the root cause of the fault was “looseness in the motor or transmission components.” The platform’s intelligent diagnostic conclusion was highly consistent with the manual diagnosis, and it was recommended to immediately shut down the equipment for inspection.

III. On-site Handling: Belt Tightening Verification for Diagnostic Accuracy

Based on the platform’s recommendation, the enterprise scheduled a shutdown for inspection on the afternoon of March 16. On-site inspection revealed significant belt slack, which was in close agreement with the diagnostic conclusion. Operations and maintenance personnel immediately tightened the belt. Following equipment restart, platform monitoring data showed that the vibration velocity at the horizontal measurement point on the motor’s free end dropped markedly to below 6 mm/s, while the corresponding value at the motor’s drive-end measurement point also declined in tandem. The equipment’s operating trend subsequently stabilized, and the potential hazard was completely eliminated.

IV. Value Closed Loop: Ensuring That “Loose” Risks Have Nowhere to Hide

The successful early warning and effective handling of the belt loosening fault in this crusher once again demonstrate the core capabilities of the Zhongyun Intelligent O&M Platform for industrial equipment:

1. Continuous perception for early detection of potential hazards

Replacing manual inspections with 24/7 continuous online monitoring enables the timely detection of early, latent faults at their very inception, thereby truly achieving “prevention before problems arise.”

2. Spectrum diagnosis: identifying the root cause through characteristic analysis

Leveraging data-driven insights and intelligent algorithms, we precisely pinpoint the root cause of failures, thereby avoiding indiscriminate disassembly and over-replacement, and effectively reducing spare-parts consumption and downtime.

3. Rapid closed-loop management to ensure continuity

By establishing a comprehensive closed-loop system encompassing “monitoring–diagnosis–maintenance–verification,” enterprises can shift from reactive emergency repairs to proactive preventive maintenance, thereby accelerating the digital and intelligent transformation and upgrading of equipment management.

Zhongyun Technology will continue to deepen its expertise in intelligent diagnostic technologies, leveraging more precise algorithms and more reliable solutions to deliver end-to-end intelligent operations and maintenance services for cement enterprises that feature “precise early warning, efficient response, and stable assurance,” thereby supporting the industry in achieving digitalization of equipment management and intelligent decision-making in O&M.