Diagnosis of the straightening annealing line without stopping production
Acoustic testing helps detect signs of bearing and reducer failures on the production line – so that maintenance can be planned before a major failure occurs.
According to the materials provided by the project, the absence of stops refers to the survey, not to subsequent repairs or the entire operation of the line.
About the project
- Enterprise
- Manufacturer of high-tech steel
- Industry
- Metallurgy
- Object of control
- Straightening and tempering line
- The task
- Reduced risk of unplanned stops and repairs
- Controlled nodes
- Bearings for alkaline-based machines and gear reducers for helical gears
- Format of work
- Regular surveys, recording acoustic data, and subsequent analysis
Objective: To detect the defect before the line stops
The straightening annealing line is used in the production of cold-rolled electrical steel. The strip passes through a roller system, and the condition of the bearings and drives affects the continuity of the technological process.
The company needed to identify developing defects in the closely located bearing units and gearboxes. High operating temperatures deteriorated the lubrication condition, and failure of the unit could lead to lengthy repairs. The control methods used did not always provide the necessary information.
An contactless method was needed to locate the source of the unusual sound and determine which node should be checked first.
Estimates from the project materials. Includes possible consequences of downtime.
Solution: Regular acoustic examinations
They organized inspections using a sound visualization system. It helped to locate the acoustic signal of a specific node in the background of the operating production and to preserve recordings for subsequent analysis.
The survey materials were collected in the archive. Comparing the recordings allowed for tracking changes in the sound, identifying suspicious areas, and preparing reports for the maintenance service.
The diagnosis was performed using working equipment. The decision on testing, replacement of a component, or repair was made by specialists of the enterprise based on the results of the survey.
From bypassing to a service plan
Choose control nodes
Determine the bypass route and the points of observation for the bearings, reducers, and drives.
Record an acoustic signal
Locate the source of the sound and preserve the data while the equipment is operating.
Compare the status of the nodes
Compare the recordings with previous surveys and identify changes in the acoustic signal.
Hand over the results of the operation
Prepare a report and identify the components that require additional inspection or maintenance.
Result: service until major failure
According to project materials, dozens of inspections identified areas where components or consumables could be replaced promptly. This helped prevent malfunctions from escalating to line shutdowns and more complex repairs.
The surveys became the basis for determining service priorities: specialists received information about the location of the suspicious node and the nature of its sound changes.
Practical benefit: Early detection of signs of malfunction helps plan inspections and repairs in advance, reduce the risk of unscheduled downtime, and maintain stable equipment operation.
Where else might this approach be useful?
A similar approach can be considered for production facilities with roller mechanisms, bearings, and gearboxes. The feasibility of inspection depends on the availability of an acoustic signal and the equipment's operating conditions.
Solutions for a similar problem
To organize acoustic surveys and work with the results, you can consider the NAC-PA portable camera and Aura SVS software.
Need to monitor similar equipment?
Tell us about the units and operating conditions – we’ll discuss the possibilities of acoustic diagnostics and the examination format.
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