Infinite Uptime Case Studies Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox

	Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox Infinite Uptime

Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox

Infinite Uptime

Technology Category	Analytics & Modeling - Predictive Analytics Analytics & Modeling - Real Time Analytics Functional Applications - Remote Monitoring & Control Systems Sensors - Acoustic Sensors Sensors - Vibration Sensors
Applicable Industries	Equipment & Machinery
Applicable Functions	Maintenance
Use Cases	Predictive Maintenance
Challenge	The calendar machine run by a motor has a shaft mounted gearbox connected to the roller. This gearbox allows maximum paper load and feeds the paper with reduced speed to the roller. In spite of scheduled preventive maintenance, it was observed that gearbox used to fail frequently. The rise in vibrations leading to the eventual failure of gearbox adversely affected the quality of the paper. Monitoring the gearbox was thus vital and critical. Read More
About Customer	A global leading Indian paper manufacturing company specializes in technologically advanced and most eco-friendly paper and paperboards business. Read More
Customer Name	Undisclosed Read More
Solution	Industrial Data Enabler was installed at the bearing location supporting the output shaft of the gearbox to capture tri-axial vibrations and acoustic signals in real-time. After 3 months of deployment, IDE detected a steady rise in the vibrations. A rise in corresponding noise levels was also recorded. Alert notifications were sent via SMS and emails to the registered local as well as remote authorities. Read More Log in to view content
Contents

Technology Category

Analytics & Modeling - Predictive Analytics

Analytics & Modeling - Real Time Analytics

Functional Applications - Remote Monitoring & Control Systems

Sensors - Acoustic Sensors

Sensors - Vibration Sensors

Applicable Industries

Equipment & Machinery

Applicable Functions

Maintenance

Use Cases

Predictive Maintenance

Challenge

The calendar machine run by a motor has a shaft mounted gearbox connected to the roller. This gearbox allows maximum paper load and feeds the paper with reduced speed to the roller. In spite of scheduled preventive maintenance, it was observed that gearbox used to fail frequently. The rise in vibrations leading to the eventual failure of gearbox adversely affected the quality of the paper. Monitoring the gearbox was thus vital and critical.

About Customer

A global leading Indian paper manufacturing company specializes in technologically advanced and most eco-friendly paper and paperboards business.

Customer Name

Undisclosed

Solution

Industrial Data Enabler was installed at the bearing location supporting the output shaft of the gearbox to capture tri-axial vibrations and acoustic signals in real-time. After 3 months of deployment, IDE detected a steady rise in the vibrations. A rise in corresponding noise levels was also recorded. Alert notifications were sent via SMS and emails to the registered local as well as remote authorities.

Impact #1	[Efficiency Improvement - Production] The remedial measure proved to be successful in meeting the product quality.
Impact #2	[Process Optimization - Predictive Maintenance] IDE played a significant role in detecting the unexpected failure of the gearbox.

Impact #1

[Efficiency Improvement - Production]

The remedial measure proved to be successful in meeting the product quality.

Impact #2

[Process Optimization - Predictive Maintenance]

IDE played a significant role in detecting the unexpected failure of the gearbox.

Benefit #1	Had the corrective measures not been taken, it would have certainly resulted in calendar roll shaft breakage causing a production downtime to the tune of USD 60 Thousand.

Benefit #1

Had the corrective measures not been taken, it would have certainly resulted in calendar roll shaft breakage causing a production downtime to the tune of USD 60 Thousand.

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Overview

Wireless Condition Monitoring Predicts Failure Of Calendar Roll Gearbox

Operational Impact

Quantitative Benefit