Prevent Issues with Vibration Analysis

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3 Ways to Prevent Issues with Vibration Analysis


When coupled with routine maintenance, anticipating the needs of your equipment is an important way to ensure screening performance and productivity. Consistently monitoring your vibrating screen with predictive analysis programs help to not only keep it merely up and running but helps to do so efficiently.

Predictive analysis is important for products like screen media. Since screen boxes and screen media are used consistently and undergo a lot of day-to-day stress, it’s important they be monitored to avoid unexpected breakdowns and maintenance. Vibration analysis is one way that producers can identify and prevent issues with their operation in real-time. During a scheduled visit, an expert can address problems, make recommendations and provide advice on an optimal screen media solution.

Along with unforeseen shutdowns and maintenance, there are three key issues that vibration analysis can help prevent.

Address improper settings

Applying the incorrect settings to a screening operation can result in lowered production capabilities and output. If an operator adjusts the machine after a certified dealer sets it up, issues can arise. Changes from the baseline operating data, such as adding more material than recommended or adjusting speeds, can cause poor performance and potential damage to the machine. Vibration analysis helps provide data to identify issues and makes it easy for a dealer to work with the operation to get things back on track.

Accurately measure changes

The data that comes from a vibration analysis delivers quantitative measurement of changes in the screens’ performance. The sensor measures g-force, stroke, rpm and orbit, including lateral movement — a measurement that not all vibration analysis systems offer. The detailed measurements can help operators and their FLEX-MAT dealers determine whether fine-tuning of the machine is necessary.

Identify maintenance issues

While the FLEX-MAT Sensor isn’t designed as a vibrating screen diagnostic tool, the information it provides can help pinpoint possible problems with the equipment. Unaddressed issues, such as cracked side plates, weak or damaged screens and loose bolts, can cause increased wear and poor performance down the road. Identifying these issues early on can help prevent unexpected downtime to fix issues later.

In one example, a mining company benefited from the preventative observations found by a FLEX-MAT Sensor. During a scheduled visit to the operation, a MAJOR dealer conducted tests and noticed an anomaly on one corner of the discharge end. After confirming the anomaly with several follow-up tests, the dealer consulted with MAJOR to see if any similar irregularities at other operations had been recorded. They had not.

A site technician took a closer look at the vibrating screen. The bearing temperature revealed that the bearing was running hot and had damaged the shaft. It was deemed that there was no risk of critical failure for both the bearing and the shaft before the next preventative maintenance day.

The team ordered replacement parts, and performed a replacement during the next scheduled maintenance shutdown. Without performing a FLEX-MAT Sensor vibration analysis, this could have led to an unplanned outage, which could have resulted in extra costs for the company. 

Because of the constant use and day-to-day stress that screen media undergoes, it’s important to be on the lookout for potential issues. Producers can utilize vibration analysis technology, like the FLEX-MAT Sensor, to optimize performance while increasing uptime and profits.

Contact your local MAJOR authorized dealer today to schedule a FLEX-MAT Sensor analysis.