Case Study: DataMind AI™ Flags Hidden Friction in Lubrication Pump – Prevents Centrifuge Failure
July 31, 2025
In coal mining, high-speed centrifuges play a critical role in reducing moisture content in fine coal during the dewatering process. But these machines rely on something deceptively simple: a dedicated lubrication pump that keeps their bearings running smoothly.
At one site, DataMind AI™ was deployed to monitor the lubrication system supporting a critical centrifuge. The system detected abnormal high-frequency vibration in the lubrication pump’s gearbox – early signs of gear friction developing internally. Although traditional condition monitoring raised no alarm, DataMind AI™ escalated the event to “Critical”, prompting immediate investigation.
The root cause? Friction within the gearbox of the lubrication pump – undetectable by traditional methods. If left unresolved, this could have led to lubrication failure, bearing damage, and an unplanned stoppage of the centrifuge.
The maintenance team proactively replaced the entire pump assembly, including the gearbox, during a scheduled shutdown. DataMind AI™ validated the repair: post-replacement data showed a significant reduction in vibration, confirming the friction had been resolved.
Results at a Glance
- ~$240,000 saved
- 7 Hours of unplanned downtime prevented
- Failure Avoided: Lubrication pump breakdown & centrifuge stoppage
- Increased Reliability: Friction resolved early, zero disruption to production
Action Taken
- DataMind AI™ flagged elevated gear friction in the lubrication pump
- System escalated to “Critical”, prompting
inspection - Maintenance team replaced the pump assembly
- Post-replacement data confirmed vibration
levels returned to normal
Conclusion
This case highlights how AI-powered sensor fusion enables early detection of faults that legacy systems overlook – empowering smarter maintenance, minimizing failures, and safeguarding uptime in mission-critical operations.
