Equipment Type
Compressor
Equipment Name
Screw Air Compressor
Faults
Screw Meshing Abnormality
Early Detection of Screw Compressor Screw Meshing Abnormality
How Wisper CMS Ensured Continuous Operation at an Auto Parts Manufacturing Factory
Automotive
Introduction
This case study details the diagnosis of a screw meshing abnormality in a critical screw air compressor at an auto parts manufacturing facility. Screw air compressors are composed of two mutually meshing screw rotors that compress air through rotation. Their reliable operation is paramount to maintaining stable production in the factory. This example demonstrates how an AI-powered condition monitoring solution detected an early-stage fault, enabling proactive maintenance and ensuring operational continuity.
Equipment Overview
A screw air compressor consists of two intermeshing screw rotors (male and female). As the rotors turn, the space between the rotor grooves is greatest when it aligns with the intake port, allowing outside air to be drawn in and flow axially into the grooves. After intake, the rotor tips seal against the casing, trapping the gas. As the rotors continue to rotate, the meshing surface moves toward the discharge end, compressing the gas and increasing its pressure. When the meshing end face aligns with the casing's exhaust port, the compressed gas is discharged, completing the compression cycle.
The Challenge
In high-volume environments like auto parts manufacturing, continuous and uninterrupted machine performance is essential. Unexpected failure of critical assets, such as the air compressor, risks halting the entire production line. Therefore, precise and early detection of mechanical faults, such as slight abnormalities in screw meshing, is crucial to prevent rapid escalation into catastrophic and costly unplanned downtime.
Wisper Solution
Wisper CMS monitored the health status of the factory's screw air compressor. On November 2, 2024, the system first detected a gear meshing abnormality at the compressor's input end, with the overall status noted as 'Available Up.' A report was issued to the client.
Wisper CMS diagnostic report (Nov 2, 2024)
The condition worsened, and on November 26, 2024, the system monitored a confirmed gear meshing fault, with the equipment's status degrading to 'Available Down.' A second diagnostic report was issued, alerting the customer to the equipment's status change.
The outcome
The on-site inspection results were fully consistent with the AI diagnostic reports, confirming the system's accuracy and the effectiveness of the proactive maintenance action in ensuring continuous operation.
understanding the root cause
A gear meshing abnormality and the resulting component damage can be caused by various factors, including:
Gear deformation or wear causing tooth profile errors.
Uniform wear of the gear caused by abrasive particles or corrosion.
Load fluctuations in the gearbox.
Misalignment or unbalance within the shaft system.
Bearing damage.
Thermal expansion or rotor displacement due to uneven machine running temperatures.
