{"id":14408,"date":"2023-05-04T00:06:25","date_gmt":"2023-05-03T21:06:25","guid":{"rendered":"https:\/\/www.razor-labs.com\/el-valor-de-la-deteccion-temprana-previniendo-fallos-en-engranajes-de-hpgr-con-fusion-de-sensores\/"},"modified":"2025-09-08T14:31:32","modified_gmt":"2025-09-08T11:31:32","slug":"el-valor-de-la-deteccion-temprana-previniendo-fallos-en-engranajes-de-hpgr-con-fusion-de-sensores","status":"publish","type":"post","link":"https:\/\/www.razor-labs.com\/es\/el-valor-de-la-deteccion-temprana-previniendo-fallos-en-engranajes-de-hpgr-con-fusion-de-sensores\/","title":{"rendered":"El Valor de la Detecci\u00f3n Temprana: Previniendo Fallos en Engranajes de HPGR con Fusi\u00f3n de Sensores"},"content":{"rendered":"\t\t
High-Pressure Grinding Rolls (HPGR) machines are commonly used in the mining industry for comminution, which is the process of reducing the size of ore particles. HPGRs use high pressure and roller rotation to crush the ore, producing a product that is finer and more uniform in size than traditional methods.<\/span><\/p>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t Despite their increased efficiency, reduced energy consumption, and improved mineral liberation, HPGR machines are not immune to failures, and gear failure is one of the most common types of failures in these machines. The HPGR gear system is subjected to high loads and stresses during operation, which can cause various types of gear failures.\u00a0<\/span><\/p>\n Some of the common gear failures in HPGR machines are:<\/span><\/p>\n The costs and negative consequences of gear failure can be significant, including direct costs for repairs and replacements, labor costs associated with downtime and maintenance, lost production and revenue, and potential secondary damage to other components of the machine.<\/span><\/p>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t In a recent incident,\u00a0 we detected a potential crack in the epicyclic gear set driving a critical HPGR machine based on the data of vibration and oil sensors fusion. Upon checking with the site maintenance, it seemed like the HPGR machine was operating normally, and no anomalies were apparent.<\/span><\/p>\n Upon the detection, the site maintenance team requested guidance to understand how fast the deterioration was going. This HPGR machine was critical, and a failure could result in a potentially hazardous environment, unplanned shutdown time, and lost production.\u00a0<\/span><\/p>\n Therefore, it was crucial to understand how fast the deterioration was occurring and whether the customer had time to keep the machine working until after the New Year break when the planned maintenance shutdown was scheduled, and whether there was enough time to order the replacement parts.<\/span><\/p>\n Razor Lab’s conditioning monitoring professionals analyzed the vibration reports, and it was found that once the crack occurred, the deterioration wasn’t progressing as fast, and the HPGR machine could continue working until the beginning of January.\u00a0<\/span><\/p>\n During the planned maintenance, the site operations team examined the gear and discovered the crack of the planet and the pitting of the ring gear.<\/span><\/p>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t The crack in the HPGR bearing, planet\u200b<\/em><\/p>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\t The crack has also caused the pitting in the ring gear<\/em><\/strong><\/p>\n\t\t\t\t\t\t<\/div>\n\t\t\t\t<\/div>\n\t\t\t\tThe common failures of HPGR Machines<\/span><\/h1>\n
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Detecting a critical failure\u00a0<\/span><\/h1>\n
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