Illustrative scenario
Conveyor-drive bearing degradation detected six weeks before failure
Illustrative scenario, representative of common industrial IoT applications
Predictive maintenanceBulk Handling & Rail LogisticsManufacturing: Automotive, Plastics & Rubber
The bearing’s vibration signature began changing approximately six weeks before the projected failure point.
A bulk handling facility
How it went.
Every study on this site runs the same four beats, in the same order.
01
Alert
A drive bearing on a main conveyor is a single point of failure for a whole line, and it gives very little audible warning.
02
Cost
6 weeks of warning. Between the first signature change and projected seizure.
03
Fix
Vibration and temperature sensor on the drive bearing · Runtime hours from the motor current · Trend alerting against the asset's own baseline
04
Restored
A planned Saturday bearing change
In full.
Illustrative scenario, representative of common industrial IoT applications.
The problem
A drive bearing on a main conveyor is a single point of failure for a whole line, and it gives very little audible warning.
What would be installed
- Vibration and temperature sensor on the drive bearing
- Runtime hours from the motor current
- Trend alerting against the asset’s own baseline
What changes
Before: A line stoppage waiting to happen After: A planned Saturday bearing change
The number
6 weeks of warning. Between the first signature change and projected seizure. Illustrative scenario, not a client result. Figure is representative, not measured.
In one line
The same repair, done on a Saturday instead of in a crisis. That difference is worth more than the part.
What the data looked like.
Hover or arrow-key across the trace to read any interval. The flagged point is the one that started the conversation.
| Interval | Drive end (mm/s) | Non-drive end (mm/s) |
|---|---|---|
| D1 | 1.86 | 1.79 |
| D2 | 1.88 | 1.88 |
| D3 | 1.98 | 1.81 |
| D4 | 1.87 | 1.87 |
| D5 | 1.93 | 1.72 |
| D6 | 1.83 | 1.84 |
| D7 | 1.94 | 1.73 |
| D8 | 1.90 | 1.73 |
| D9 | 1.84 | 1.79 |
| D10 | 1.94 | 1.81 |
| D11 | 1.93 | 1.77 |
| D12 | 1.99 | 1.73 |
| D13 | 1.94 | 1.84 |
| D14 | 1.93 | 1.77 |
| D15 | 1.84 | 1.80 |
| D16 | 1.96 | 1.73 |
| D17 | 1.89 | 1.86 |
| D18 | 1.95 | 1.86 |
| D19 | 1.91 | 1.80 |
| D20 | 1.85 | 1.71 |
| D21 | 1.89 | 1.82 |
| D22 | 1.97 | 1.85 |
| D23 | 1.86 | 1.80 |
| D24 | 1.86 | 1.87 |
| D25 | 1.82 | 1.76 |
| D26 | 1.91 | 1.89 |
| D27 | 1.88 | 1.89 |
| D28 | 1.82 | 1.76 |
| D29 | 1.94 | 1.85 |
| D30 | 1.90 | 1.86 |
| D31 | 1.94 | 1.80 |
| D32 | 1.92 | 1.78 |
| D33 | 1.96 | 1.71 |
| D34 | 1.88 | 1.76 |
| D35 | 1.95 | 1.86 |
| D36 | 1.82 | 1.80 |
| D37 | 1.97 | 1.81 |
| D38 | 1.88 | 1.88 |
| D39 | 1.92 | 1.75 |
| D40 | 1.97 | 1.86 |
| D41 | 1.90 | 1.79 |
| D42 | 1.83 | 1.73 |
| D43 | 1.89 | 1.85 |
| D44 | 1.97 | 1.79 |
| D45 | 1.97 | 1.73 |
| D46 | 1.89 | 1.81 |
| D47 | 1.87 | 1.86 |
| D48 | 1.98 | 1.73 |
| D49 | 1.87 | 1.85 |
| D50 | 1.89 | 1.83 |
| D51 | 1.81 | 1.80 |
| D52 | 1.84 | 1.80 |
| D53 | 1.89 | 1.87 |
| D54 | 1.86 | 1.76 |
| D55 | 1.86 | 1.81 |
| D56 | 1.95 | 1.75 |
| D57 | 2.01 | 1.82 |
| D58 | 2.22 | 1.78 |
| D59 | 2.32 | 1.72 |
| D60 | 2.27 | 1.88 |
| D61 | 2.36 | 1.76 |
| D62 | 2.46 | 1.73 |
| D63 | 2.60 | 1.79 |
| D64 | 2.63 | 1.75 |
| D65 | 2.83 | 1.80 |
| D66 | 2.84 | 1.71 |
| D67 | 3.00 | 1.86 |
| D68 | 3.09 | 1.79 |
| D69 | 3.24 | 1.76 |
| D70 | 3.25 | 1.82 |
| D71 | 3.41 | 1.79 |
| D72 | 3.39 | 1.87 |
| D73 | 3.52 | 1.78 |
| D74 | 3.57 | 1.82 |
| D75 | 3.78 | 1.74 |
| D76 | 3.71 | 1.81 |
| D77 | 3.84 | 1.87 |
| D78 | 4.01 | 1.73 |
| D79 | 4.03 | 1.87 |
| D80 | 4.10 | 1.83 |
| D81 | 4.28 | 1.81 |
| D82 | 4.40 | 1.83 |
| D83 | 4.42 | 1.77 |
| D84 | 4.55 | 1.85 |
| D85 | 4.55 | 1.85 |
| D86 | 4.75 | 1.85 |
| D87 | 4.82 | 1.87 |
| D88 | 4.85 | 1.77 |
| D89 | 4.92 | 1.75 |
| D90 | 5.09 | 1.86 |
| Before | A line stoppage waiting to happen |
|---|---|
| After | A planned Saturday bearing change |
What changed.
Before
A line stoppage waiting to happen
After
A planned Saturday bearing change
6 weeks
of warning
Between the first signature change and projected seizure.
Source: Illustrative scenario, not a client result. Figure is representative, not measured.
Where to go next.
The sector, the sibling studies, and the calculator that runs this same arithmetic on your own numbers.
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The vibration signature changed about three weeks before anyone would have heard it.
3 weeksof warning
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A failing diaphragm pump, caught before it failed
Carlsberg Canada
A failing diaphragm pump caught before it failed, and 540,000 L/day of loss prevented.
540,000 Lper day
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