GEARBOX FAULT DETECTED ON A CONVEYOR DRIVE
Diagnosed issue
In February 2026, Sonora detected abnormal harmonic patterns on a conveyor drive motor at CCC, indicating a potential gearbox defect. The vibration spectrum showed repeating harmonics spaced at approximately 160 Hz, a pattern typically associated with gear mesh or output pinion defects inside the gearbox.
During the first maintenance intervention, technicians repaired a mechanical issue in the belt pathway caused by defective roller pins. However, vibration data after the repair showed no significant change, indicating that the root cause was not related to the belt system. Further analysis confirmed that the fault likely originated from the gearbox or its bearings.
Based on the vibration trends and continued harmonic activity, the entire motor and gearbox assembly was replaced. After replacement, the sensor was reinstalled in the same location near the coupling to continue monitoring the new unit.
Results
Continuous vibration monitoring enabled early identification of gearbox-related anomalies before catastrophic failure occurred. By distinguishing between belt-path issues and internal gearbox faults, Sonora helped maintenance teams pinpoint the true root cause and proceed with the correct repair, preventing prolonged troubleshooting and potential system downtime.