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Innovating Bearing Failure Analysis for South American Quarry with Sensoteq Tau


The customer was responsible for maintaining a large banana screener at a remote site in South America. They had constant problems with bearing failure causing frustration for the end user, as they could not predict when the bearings would fail. 


Screens purposely create a large rotating pattern to separate materials of different sizes. The large vibrating profile of the pattern can cause challenges when attempting to monitor the small vibration signals that a faulty bearing would generate. Existing wired sensing technology is very prone to failure within the cabling, and is not appropriate for this application.



Tau Sensor on Bearing Machine


Implemented Solution


The customer installed Sensoteq’s Tau Bearing and Tau Structure sensors onto the screen to gather more information. By moving to a wireless, battery-powered solution, the risk of broken cabling is removed.

 


Findings

Within weeks of the sensors being installed an automated alarm was generated, signalling a high-frequency anomaly was detected on Analytix. The frequencies generated were indicative of those associated with a bearing fault and the waveform showed clear impacting.



Analysis

Tau Spectrum analysis on Sensoteq Analytix
“Power bands” within the spectrum highlighted a problem area.

Tau Time Waveform analysis on Sensoteq Analytix

Tau Time Waveform analysis on Sensoteq Analytix
Impacting can be seen in the waveform. After a high pass filter, this is even more evident.

Recommendation

Replace the damaged bearing and continue monitoring.


Outcome

Thanks to Tau's analysis, Alarm levels dropped to normal levels, and no impacting is evident in the waveform.


Tau Spectrum analysis on Sensoteq Analytix
“Power bands” within the spectrum highlighted return to normal levels.


Tau Time Waveform analysis on Sensoteq Analytix

Tau Time Waveform analysis on Sensoteq Analytix
Impacting is no longer visible in the waveform.

Looking at the crest factor trend, it is visible to see the increase in the parameter up to the point of replacement (event 1 highlighted on the graph). After replacement, the parameter returns to a more expected value.



Tau Crest Factor Trend on Sensoteq Analytix
















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