Advanced Vibration Analysis and Condition Monitoring of Flender DMG2 Gearbox

State-of-the-art modal analysis and technical diagnostic of a 4.4 MW cement industry drive, identifying critical wear patterns to ensure maximum reliability in heavy-duty milling operations.

We executed a sophisticated on-site technical inspection and diagnostic measurement of a Flender DMG2 gearbox, a high-capacity parallel shaft unit operating in the demanding cement industry in Egypt. With a massive rated power of 4,480 kW, this gearbox is a central asset in the production process, where mechanical integrity is synonymous with plant productivity.

To provide a truly forensic assessment, Wikov specialists went beyond visual checks, utilizing advanced modal analysis and vibration spectrum monitoring. By analyzing the unit's dynamic behavior under load, our engineers precisely evaluated the condition of the bearings, shafts, and internal gears. The diagnostic results revealed specific frequency anomalies indicating the need for intervention. Based on these findings, Wikov provided a professional recommendation for a comprehensive gear overhaul and bearing replacement. This predictive maintenance approach allows the operator to address potential failures before they occur, effectively extending the lifecycle of the drive and preventing the extreme costs associated with unscheduled downtime in heavy industry.

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