Let's proceed with the vibration analysis to identify the exact fault. Please provide the vibration analysis data, including:

1. Frequency Analysis Data:

   • Frequency observations with respect to rotating speed.
   • Amplitude of the observed frequencies.
   • Position of the sensor (part of the machine and direction of measurement).

2. Phase Analysis Data:

   • Position of sensors (part of the machine and direction of measurement).
   • Phase angles (absolute and relative).

This information will help us analyze the vibration data accurately and identify the potential fault.

Based on the provided vibration spectrum analysis data, we can proceed with the diagnostic process. Here’s a structured approach to identify the fault:

1. Understanding Observations and Connecting Them to Known Frequency Groups [F_G]

Frequency Analysis:

• Frequency Observations:
  • Highest peak at 7.32X on the DE side of the motor.
  • Non-integral peaks near both motor DE and NDE.
  • High overall vibrations at NDE (18 mm/sec rms) and DE (4.2 mm/sec rms).

Frequency Variables [V]:

• n (Harmonic Multiplier or Divider): Not applicable as the peaks are non-integral.
• m (Modulation Frequency): Not applicable as modulation is not indicated.
• k (Non-Integral Multiplier): The highest peak is at 7.32X, indicating a non-integral multiplier.

Identify Frequency Group [F_G]:

• Non-Synchronous [F_G_6]: The highest peak at 7.32X indicates a non-synchronous fault.

2. Iterative Fault Analysis and Hypothesis Refinement

Filter Fault Table [F_T] by [F_G] and [D_D_R]:

• Since the highest peak is at 7.32X (non-integral), we will focus on faults associated with the Non-Synchronous frequency group [F_G_6].

Potential Faults:

1. Bearing Frequency Outer Race (Bfo)
2. Electrical SCR Frequency (Edc)
3. Electrical Frequency (Ef)

Develop Hypotheses [F_H]:

• Hypothesis 1: Bearing Frequency Outer Race (Bfo)
  • Reasoning: Non-integral peaks can be associated with bearing faults, especially outer race defects.
• Hypothesis 2: Electrical SCR Frequency (Edc)
  • Reasoning: Electrical issues can cause non-synchronous peaks, but this is less likely given the recent motor replacement.
• Hypothesis 3: Electrical Frequency (Ef)
  • Reasoning: Electrical faults can cause non-synchronous peaks, but this is less likely given the recent motor replacement.

3. Enhance Knowledge on Hypothesis from Documents

Let's retrieve detailed information on Bearing Frequency Outer Race (Bfo) from the vector store to refine our hypothesis.

Query:

• "Bearing Frequency Outer Race (Bfo) characteristics and diagnosis"

I'll perform the search now.

Diagnosis and Recommendations

Summary

The vibration analysis data indicates high non-integral peaks near both the Drive End (DE) and Non-Drive End (NDE) of the motor, with the highest peak at 7.32X on the DE side. The overall vibrations are significantly higher on the NDE side. Based on the provided data and further research into bearing fault characteristics, the most plausible fault is a defect in the outer race of the bearing.

Detailed Analysis

1. Frequency Analysis:

   • Observed Frequencies:
     • Highest peak at 7.32X on the DE side.
     • Non-integral peaks near both DE and NDE.
   • Frequency Group [F_G]: Non-Synchronous [F_G_6]

2. Potential Faults:

   • Bearing Frequency Outer Race (Bfo): High likelihood due to non-integral peaks and typical bearing fault characteristics.
   • Electrical SCR Frequency (Edc) and Electrical Frequency (Ef): Less likely due to recent motor replacement and no electrical issues reported.

3. Enhanced Knowledge from Documents:

   • Bearing defects, especially on the outer race, generate non-integral frequencies and can cause high vibration levels.
   • The presence of high non-integral peaks and elevated overall vibrations are indicative of bearing outer race defects[0][1][2].

4. Validation of Fault:

   • Mathematical Reasoning: Bearing defect frequencies are not integrally harmonic to running speed. The observed non-integral peak at 7.32X aligns with bearing outer race defect frequencies[3][4].
   • Inferential Causal Reasoning: The high vibrations and non-integral peaks are consistent with a bearing outer race defect, especially considering the recent motor replacement and the absence of electrical issues.
   • Statistical or Historical Reasoning: Historical data and documented cases of bearing outer race defects show similar vibration patterns and frequency characteristics[5][6].

Final Diagnosis

The most likely fault is a Bearing Outer Race Defect. This is supported by the high non-integral peaks observed in the vibration spectrum, particularly the 7.32X peak on the DE side, and the high overall vibrations on the NDE side.

Recommendations

1. Immediate Actions:

   • Inspect the bearing for visible defects, particularly on the outer race.
   • Check for any signs of wear, spalling, or damage on the bearing surfaces.

2. Maintenance:

   • Replace the bearing if any defects are found.
   • Ensure proper lubrication and alignment during reinstallation to prevent recurrence.

3. Monitoring:

   • Conduct regular vibration analysis to monitor the condition of the new bearing.
   • Implement a predictive maintenance schedule to detect early signs of bearing wear and prevent unexpected failures.

By following these recommendations, you can address the current issue and enhance the reliability and performance of the Aumund Feeder in the Raw Mill 1 area. If further assistance is needed, please feel free to reach out.

Vibration Analysis Report

Equipment Details:

• Area: Raw Mill 1
• Equipment: Aumund Feeder
• Equipment Code: R1J02
• Motor Power: 45 KW
• Motor Speed: 1500 RPM

Vibration Analysis Observations:

• Drive End (DE) Side:
  • Highest Peak: 7.32X (4.2 mm/sec rms)
  • Frequency Group: Non-Synchronous [F_G_6]
• Non-Drive End (NDE) Side:
  • Overall Vibration: 18 mm/sec rms
  • Frequency Group: Non-Synchronous [F_G_6]

Dominant Directional Response:

• Data Unavailable: Directional response data is not provided.

Fault Mode and Effects Analysis (FMEA)

Fault Mode:

• Identified Fault: Bearing Outer Race Defect (Bfo)

Effects:

• Drive End (DE) Side:
  • High Vibration: Non-integral peak at 7.32X indicates a potential defect in the bearing's outer race.
  • Potential Damage: Prolonged operation with this defect can lead to further damage to the bearing, motor shaft, and housing, which is critical and requires immediate attention to prevent further damage.
• Non-Drive End (NDE) Side:
  • High Overall Vibration: Elevated vibration levels without distinct peaks suggest a generalized bearing defect affecting the entire motor assembly, which is indicative of potential future issues.

Mitigation Steps

Immediate Actions:

1. Inspection:

   • Conduct a thorough inspection of the bearing on the DE side for visible defects, particularly on the outer race.
   • Check for signs of wear, spalling, or damage on the bearing surfaces.

2. Replacement:

   • Replace the bearing if any defects are found, which is critical and requires immediate action.
   • Ensure proper installation and alignment during the replacement process to prevent recurrence.

Maintenance:

1. Lubrication:

   • Ensure the bearing is properly lubricated to minimize friction and wear.
   • Use the recommended type and amount of lubricant for the bearing.

2. Alignment:

   • Verify and correct the alignment of the motor and connected components to reduce undue stress on the bearing.

3. Balancing:

   • Perform balancing of the motor and connected components to minimize vibration levels.

Monitoring:

1. Regular Vibration Analysis:

   • Conduct periodic vibration analysis to monitor the condition of the new bearing.
   • Track vibration levels and identify any early signs of bearing wear or defects.

2. Predictive Maintenance:

   • Implement a predictive maintenance schedule to detect and address potential issues before they lead to significant failures.
   • Use advanced diagnostic tools and techniques to monitor bearing health and performance.

Conclusion

The vibration analysis indicates a Bearing Outer Race Defect on the Drive End (DE) side of the motor. Immediate inspection and replacement of the bearing are recommended to prevent further damage and ensure reliable operation, which is critical and requires immediate attention. Regular monitoring and maintenance will help in early detection and mitigation of potential issues, enhancing the overall reliability and performance of the Aumund Feeder.

If you need further assistance or have additional data to share, please feel free to reach out.