Advanced Modal Analysis and Condition Assessment of Flender KMPS 546 Gearbox

Comprehensive diagnostic audit of a 3.2 MW cement mill drive, utilizing precision vibration frequency monitoring to identify subsurface wear and optimize maintenance strategy.

We executed a high-level on-site technical inspection and diagnostic measurement of a Flender KMPS 546 gearbox, a massive parallel shaft unit serving the cement industry in Egypt. With a rated power of 3,200 kW and a significant reduction ratio of 52.632:1, this gearbox is a critical component of the vertical mill or kiln drive system, where mechanical stability is essential for continuous heavy-duty operation.

Wikov specialists performed a forensic evaluation of the drive's health, focusing on the condition of the bearings, shafts, and internal gear geometry. To move beyond standard visual checks, our team utilized advanced modal analysis and vibration spectrum monitoring. By capturing the dynamic response of the gearbox under load, we identified specific frequency anomalies indicative of emerging fatigue patterns. Based on these findings, Wikov provided a professional recommendation for a comprehensive gear overhaul and bearing replacement. This proactive service approach allows the operator to plan an overhaul during scheduled maintenance windows, effectively preventing catastrophic failure and minimizing the extreme costs of unplanned production losses in a cement plant environment.

Project details

We are ready to help

Reach us via 24/7 hotline on WhatsApp or fill out our interactive on-line form and we will get back to you.

Photo gallery