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Prolonged High-Load Operation of Equipment Leading to Critical Motor Failure?

Case｜Prolonged High-Load Operation of Equipment Leading to Critical Motor Failure?

Continuous high-load operation of equipment can result in vibrations caused by prolonged usage or external environmental factors. If these critical devices fail, they could result in significant losses.

Critical Equipment Failures?

In automated plants, equipment operating under high loads over long periods can easily generate vibrations due to extended operation or external environmental influences. Critical machinery such as pumps, centrifuges, mixers, and presses, if they fail, can lead to production line shutdowns and enormous losses. Emergency repairs after a failure are not only time-consuming but also costly, impacting production efficiency. Relying solely on human experience and periodic inspections without scientific data support may fail to prevent potential equipment failures.

Vibration measurement is a key preventive maintenance measure
Vibration monitoring allows for timely detection of abnormal vibrations, which are often precursors to mechanical failures such as bearing wear, imbalance, misalignment, and looseness. Various types of failures can occur in equipment, and most of these can be diagnosed through motor monitoring, such as: bearing wear leading to increased vibration and noise, rotor damage affecting motor efficiency and causing instability, misalignment causing imbalance, and insufficient lubrication accelerating wear, increasing friction, and temperature.

Vibration measurement plays a crucial role in preventive maintenance, helping to detect abnormalities and potential issues early, thereby avoiding unexpected shutdowns and major failures.

Solutions and Monitoring Explanation

SMS-RC Rotating Machinery Vibration Detection Analyzer and Vibration Sensors
A portable analysis instrument that allows inspection personnel to conveniently carry and instantly detect motor conditions, accurately capturing vibration data during equipment operation.

Implementation Steps:
Determine Measurement Points: Based on the equipment structure and operational characteristics, select critical measurement points such as bearing locations and rotor ends.
Install Sensors: Attach vibration sensors to the measurement points, ensuring stable and secure placement to avoid measurement errors.
Data Acquisition: Start the equipment, allow it to reach a stable operational state, and collect vibration data using the testing instrument.
Result Evaluation: Built-in ISO standards can quickly analyze the collected vibration data and provide a results assessment.
Data Analysis: Additionally, spectrum analysis functions can identify vibration characteristics and determine potential causes of abnormalities.