Kappa X was deployed in a food production factory to monitor the efficiency and reliability of two gearboxes crucial for the operation of a vibrating cleaning screen. Due to a known bearing defect, the second gearbox required consistent monitoring using Sensoteq wireless sensors. Kappa X effectively tracked machine degradation until the end of the initiative, helping to avoid the significant expenses required to replace the gearbox.
Machinery and Operations
The client required a solution to monitor a vibrating cleaning screen, a critical machine in their food production factory. This essential machine operates with two robust gearboxes running at 200mm/sec RMS and a speed of 840 RPM. By fitting the cleaning screen with sensors, the client aimed to ensure continuous monitoring of this vital machine.
Implementation
Kappa X wireless sensors were installed on the fans of two gearboxes to monitor their condition. The client’s primary goal was to ensure the reliable operation of the second gearbox, despite its bearing defect. The sensors were intended to help the site understand the state of the machine and maintain it until it was no longer required. This proactive approach would allow the factory to avoid the downtime associated with an immediate replacement. Rather than a costly shutdown to replace the gearbox, Kappa X sensors provided extensive data on the machine's health, enabling informed decisions to be made regarding maintenance.
The Problem
Over four months, comprehensive measurements revealed that, although velocity levels remained consistently stable, there was a concerning upward trend in the G's PK-PK values. This raised the warning alarm on multiple occasions, demonstrating the need for further data collection and analysis to uncover the underlying issues.
By collating further data, including spectrum, time waveform and circular waveform plot, the comprehensive machine issues become more evident and easier to determine.
The Time Waveform below reveals periodic peaks, often exceeding 40 G’s PK-PK and spiking to alarming levels of 80 G’s PK-PK on one occasion.
However, the circular time waveform plot is the clearest indicator of a fault, showing excessive peaking across predominantly one side.
The spectrum below shows peaks in the frequency around 5kHz as well as a raised noise floor with several sidebands, further suggesting that the machine has a comprehensive underlying issue.
Additionally, the spectrum reveals unsynchronized harmonics at a magnitude of 9.22 orders with concerning sidebands, indicating an inner race defect in the bearing.
The graph below shows two crucial and distinct acceleration waterfall plots for the second gearbox; the 2.5kHz waterfall plot and the 10kHz waterfall plot. These plots, which include readings between December and March, illustrate the rapid machine degradation across the four months. The frequency spikes around 5kHz are particularly concerning, highlighting the growing machine problems. This alarming trend demonstrates the need for continued observation and detailed analysis throughout the campaign.
Why Kappa X is Crucial
Kappa, the previous iteration of our sensor, recorded a maximum spectrum frequency of 2.5kHz, a typical data capture level in our industry. However, our revolutionary sensor Kappa X can read frequencies up to 10kHz, providing additional data crucial for maintenance. As illustrated in the contrasting waterfall plots, the primary spike and sidebands in the frequency are only visible between 4-6kHz. Machines limited to data collections of 2.5 kHz would be unable to access this critical range of information.
Without the essential readings between 2.5kHz and 10kHz, the site would have a limited understanding of their machine’s functionality. Therefore, Kappa X showcases its unique and vital ability to capture extensive and detailed machine data, providing additional insights that can save the site from substantial costs and downtime.
The Solution and Result
Thanks to the invaluable data provided by the Kappa X sensors, the machine’s four-month degradation trend could be analysed and understood. The second gearbox was carefully managed, nursed until the end of the production campaign and subsequently shut down. Upon examining the machine, the analysts discovered a significant inner race defect on one of the bearings. This defect explained the rapid degradation observed over the past four months.
Our innovative Kappa X sensors saved the plant from closing to replace the gearbox, drastically minimising the potential costs and downtime. By the end of the campaign, the site calculated an estimated cost savings of £42,000, underscoring the need for Kappa X’s groundbreaking data capture technology.
Kappa X is a game-changing solution for your factory’s cost avoidance. Our cutting-edge sensors provide essential vibration data, critical to understanding your machine’s reliability and efficiency. Kappa X can radically reduce your expenses and minimise your machine downtime. Book a demo today and gain critical insight into key maintenance events.