Cracks in the belt roller cause excessive vibration; the Zhongyun platform provides precise localization and efficient repair.

In automotive final assembly workshops, lift systems are critical equipment for ensuring the continuous operation of the production line. Recently, at a renowned automobile manufacturer, a conveyor-entry lift experienced cracking in its belt-driven pulley, causing vibration velocity to rise steadily from 1 mm/s to 8 mm/s—far exceeding the safety threshold. The Zhongyun Technology Intelligent Operations and Maintenance Platform accurately identified the underlying risk of pulley loosening, guided the company in replacing the belt pulley, and promptly reduced vibration back below 2 mm/s, thereby safeguarding stable production-line operations.

I. Vibration Continues to Rise; Platform Provides Full-Process Monitoring

On January 26, 2026, the platform detected a significant increase in the vibration velocity at the right-side bearing housing of the elevator belt roller, rising from 1 mm/s in December 2025 to 8 mm/s, thereby triggering a threshold alarm. Simultaneously, the system issued a diagnostic conclusion stating “loose mechanical structure” and fully transmitted the equipment information, sensor location,超标 data, and corresponding time stamps to the operations and maintenance team, ensuring that potential hazards remain under continuous monitoring.

II. Diagnosis and Identification of the Risk of Roller Loosening

Upon receiving the alarm, the diagnostic team analyzed the equipment’s rotational speed and vibration characteristics and determined that the vibration was primarily caused by abnormalities in the rotating components. They identified potential loosening of the right-side belt pulley as the root cause and recommended that the enterprise promptly shut down the equipment for inspection.

III. On-site Replacement Verification: Vibration Rapidly Declines

Based on the platform’s recommendation, the enterprise scheduled a shutdown for inspection on January 30 and confirmed the presence of obvious cracks in the right-side belt pulley, which was highly consistent with the diagnostic conclusion. The maintenance team then replaced the faulty pulley. Following the equipment restart on February 1, platform monitoring showed a significant reduction in vibration velocity to below 2 mm/s, and the equipment subsequently resumed stable operation.

Figure 4: On-site Maintenance Feedback Diagram

IV. Core Value: Shifting from Reactive Response to Proactive Prevention

The successful early warning and handling of the belt roller crack fault in this elevator system vividly demonstrates the core value of Zhongyun Technology’s intelligent operations and maintenance platform:

1. 24/7 monitoring for early hazard detection: Replacing manual inspections with real-time 24-hour data to precisely identify early anomalies, enabling “early detection.”
2. Precision diagnostics for cost reduction and efficiency gains: Leveraging data-driven insights to pinpoint the root cause of failures, eliminating guesswork in repairs, minimizing material waste, and achieving “low-cost maintenance.”
3. Closed-loop management and model upgrading: Establish a “early warning–diagnosis–response–verification” closed loop to shift enterprises from reactive repair to proactive prevention, thereby accelerating the digital transformation of equipment management.

Zhongyun Technology will continuously iterate its AI diagnostic algorithms and sensor technologies to deliver end-to-end intelligent operations and maintenance solutions that provide “precise early warning, efficient response, and robust reliability” for industrial enterprises, thereby supporting the industry’s digital and intelligent transformation.