Equipment Type
Mixer
Equipment Name
Mixer
Faults
Gear Mesh Fault
Early Detection of Mixer Gear Meshing Fault
How Wisper CMS Ensured Continuous Operation in a Chemical Plant
Chemical
Introduction
In the chemical manufacturing sector, operational uptime is more than a Key Performance Indicator; it is a fundamental requirement. Unforeseen equipment malfunctions can precipitate production deficits, regulatory non-compliance, and substantial fiscal consequences.
This case study illustrates the application of an AI-driven condition monitoring solution in the early detection of a meshing fault within a critical mixer gear system. This proactive identification enabled maintenance personnel to intervene promptly, thereby averting unscheduled operational interruption.
Equipment Overview
A mixer is a device used in a chemical plant that facilitates uniform mixing of media such as liquids and gases by forcing convection. The motor transmits power via a transmission device to the mixing shaft, which drives the blades to rotate, generating shear force and extrusion pressure. The process involves the blades pushing material in a circulating flow—up from the bottom and down from the top—leading to shearing, squeezing, and mixing.
The Challenge
Poor Gear Meshing can be caused by multiple factors, including:
Tooth profile error from gear deformation and wear.
Uniform wear caused by abrasive particles and corrosion.
Gearbox load fluctuation.
Parallel but unaligned shaft system.
Fatigue tooth breakage and overload tooth breakage.
Unbalanced vibration caused by gear eccentricity.
Axial movement of the gear shaft.
Bearing damage.
Wisper Solution
The Wisper CMS condition monitoring solution is deployed.
On September 20, 2024, at the start of equipment commissioning, the system detected an abnormal feature.
The fault was identified as poor gear meshing due to a drop in the optimized peak indicator.
The outcome
The inspection and repair results validated the accuracy of the AI diagnosis. After the repair and subsequent restart, the abnormal indicators returned to a healthy operating state, successfully resolving the issue.
understanding the root cause
Poor Gear Meshing can be caused by multiple factors, including:
Tooth profile error from gear deformation and wear.
Uniform wear caused by abrasive particles and corrosion.
Gearbox load fluctuation.
Parallel but unaligned shaft system.
Fatigue tooth breakage and overload tooth breakage.
Unbalanced vibration caused by gear eccentricity.
Axial movement of the gear shaft.
Bearing damage.
