GRANULATOR BEARING FAULT (VALIDATED AFTER INITIAL DISMISSAL)
Diagnosed issue
In January 2026, Sonora detected vibration patterns indicating potential bearing wear on a granulator motor at De Heus. The issue was initially dismissed as a false positive and attributed to increased vibration under heavy load conditions.
However, continued monitoring and further analysis revealed persistent harmonic activity consistent with bearing deterioration. After revisiting the case and incorporating additional machine data – including bearing types and coupling configuration – Sonora identified a likely defect on the bearing outer raceway. Despite temporary stabilisation after lubrication and machine adjustments, RMS levels continued to increase and exceeded acceptable limits in one axis, indicating progressing mechanical degradation.
Even after roller-related maintenance on the machine, elevated vibration levels persisted, confirming that the root cause had not yet been resolved.
Following continued monitoring and recommendations, the bearings in the motor were eventually replaced. The defect was validated as a true positive, confirming that the initial detection was correct and not related to load conditions.
Results
Continuous monitoring enabled the identification of a real defect that was initially dismissed as load-related vibration. By tracking harmonic patterns and RMS trends over time, Sonora helped distinguish between process-related vibration and true mechanical degradation. This ensured that the issue was not overlooked, supported timely corrective action, and prevented potential equipment failure.