Equipment Type
Fan
Equipment Name
Fan
Faults
Rotor Unbalance
Early Detection of Fan Rotor Unbalance Fault
How Frequency Exploration Ensured Continuous Operation at an Automobile OEM
Automotive
Introduction
This case study details the successful diagnosis of a fan rotor unbalance fault in a critical fan system at an Automobile Original Equipment Manufacturer (OEM) using an AI-powered condition monitoring solution. The early detection allowed for timely maintenance, preventing potential production interruptions.
Equipment Overview
The fan's operation is driven by a motor. When the motor starts, the curved blades begin to rotate, generating airflow and simultaneously creating a low-pressure area inside the casing. This low-pressure area draws in ambient air or gas, which is then pushed toward the fan's outlet by the continued rotation of the blades. The fan's design regulates the gas flow and discharge pressure to suit various industrial needs. Its design and size are determined by specific application requirements, including gas type, temperature, flow, and pressure. Efficient fan design helps to improve overall system efficiency, reduce energy consumption, and lower operating costs.
The Challenge
Preventing unplanned downtime for critical fan equipment in an automobile manufacturing environment is difficult due to:
High-Consequence Failure: Unexpected failure of the fan can interrupt the critical manufacturing process (e.g., paint shop or production line), leading to immediate production shutdown and substantial losses.
Complex Fault Characteristics: Rotor unbalance faults can stem from various physical issues (e.g., uneven wear, component shedding, manufacturing errors), making precise and early identification of the developing fault challenging without continuous, high-fidelity monitoring.
Continuous Operation Necessity: The fan is a central utility for maintaining environmental conditions or specific processes, requiring continuous, stable operation to ensure the factory's operational continuity.
Wisper Solution
Frequency Exploration conducted health status monitoring on the fan at the automobile OEM. On July 2, 2024, monitoring detected an abnormal characteristic at the bridge bearing output end, which was diagnosed as a rotor unbalance fault. The AI Equipment Guardian immediately triggered a corresponding diagnostic report, alerting on-site personnel to closely monitor the equipment’s running status and indicator score changes. On July 13, 2024, the customer performed inspection and maintenance on the equipment based on the diagnostic report triggered by the AI Equipment Guardian and combined with actual on-site production conditions. After maintenance, the rotor unbalance indicator recovered to a healthy operating state, and the on-site inspection results verified the accuracy of the diagnostic report.
Timeline of Events
July 2, 2024 – Monitoring discovered an abnormal feature at the bridge bearing output end; the AI system diagnosed a rotor unbalance fault and triggered a diagnostic report.
The outcome
The timely intervention based on the AI's accurate diagnosis ensured continuous operation at the automobile OEM. The restoration of the rotor unbalance indicator to a healthy state after maintenance fully confirmed the system's accuracy and dependability.
Minimized Downtime:
Early detection allowed for planned maintenance before a severe failure could occur, preventing potential production loss associated with interruptions to the manufacturing process.
Accurate Fault Diagnosis:
The diagnosis of a rotor unbalance fault was fully consistent with the on-site inspection and subsequent successful repair.
understanding the root cause
Rotor unbalance is typically caused by one or more of the following factors:
Local damage or shedding of rotor components.
Uneven wear or scaling on the rotor.
Displacement of rotating parts caused by rotor deformation.
Low dynamic balancing precision.
Manufacturing and assembly errors or loose fit of the rotor.
