A conveyor gearbox was failing, but the site team caught it in time to avoid unplanned downtime.
Detecting the Problem
Atomation sensors monitoring a conveyor gearbox detected two concerning trends: rising vibration levels and elevated temperature. The site manager tracked the data over several days to understand how quickly the condition was deteriorating. The vibration signatures showed a gradual climb, while temperature readings confirmed increasing friction and heat generation.
The pattern indicated the gearbox had a limited time before failure, giving the team a clear window to take action.
Planning the Response
With early detection, the team had time to make informed decisions. They sourced a spare gearbox, staged the replacement equipment, and scheduled the swap during an already-planned maintenance day. The conveyor continued running until the scheduled maintenance window.
Potential for Rebuild
Because the failure was caught before the gearbox destroyed itself, the team may be able to rebuild the original unit rather than replace it outright. Early detection turned what could have been a total loss into a potentially refurbished spare.
The root cause is still under investigation, but the proactive approach prevented unplanned downtime and may have saved significant replacement costs.
Continuous Visibility Between Inspections
This situation demonstrates a common challenge in maintenance programs. Manual inspections provide snapshots of equipment condition at specific intervals, but conditions can change significantly between those checks. A gearbox running normally during a Monday inspection could develop critical symptoms by Wednesday.
Wireless vibration and temperature monitoring provides continuous visibility. When conditions begin to drift, maintenance teams have immediate awareness with enough lead time to plan an appropriate response.
Supporting Existing Maintenance Programs
The conveyor team didn't overhaul their maintenance approach. They added continuous monitoring to complement their existing inspection schedules. When the sensors flagged the developing issue, they had the information needed to coordinate a planned response rather than an emergency repair.
Wireless condition monitoring extends the reach of maintenance teams by monitoring equipment continuously between manual checks, turning potential surprises into manageable maintenance events.
Interested in adding continuous monitoring to your critical equipment? Learn more about Atomation's wireless vibration and temperature sensors at www.atomation.net.