CASE STUDY Early Vibration Detection Prevents Press Screw Conveyor Failure
At tobacco manufacturing facilities, the press screw conveyor is a critical component of stock preparation. When Waites' sensors detected a sharp rise in peak-to-peak vibration on the gearbox drive side, analysts identified abnormal waveform impacts not previously observed. Left unaddressed, the defect could have escalated into catastrophic equipment failure, risking production stoppages and significant repair costs.
Waites' analysts observed increasing peak-to-peak vibration and waveform patterns consistent with rotating looseness in the DS gearbox.
Time waveform data on the Z-axis revealed new impacting events, with a Pk-Pk acceleration of 4.60 g. These previously unobserved shocks indicated emerging gearbox distress and potential lubrication contamination, prompting an immediate inspection.
Maintenance crews replaced the screw, stub shaft, and tail bearing, then thoroughly evaluated the drive and screw under operating and no-load conditions. Alarms were adjusted to reflect new baseline vibration levels.