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Grain mill gearbox frequent damage — root cause eliminated

By:

SKYLER

The Challenge

Before Skyler sensors were installed, the grain mill gearbox experienced critical failures approximately every 6 to 9 months.

Although the gearbox was replaced multiple times, the underlying cause remained unidentified. Each repair of this type of a gearbox costs around $7000.

grain-mill-gear-box
grain-mill-gear-box_chart-1

In early June 2023, Skyler analytics detected an increase in the trend.

grain-mill-gear-box_chart-2

Spectral analysis showed 7 Hz harmonics matching the belt pass frequency.
A report flagged potential belt wear and pulley misalignment.

Inspection done in the beginning
of July revealed:

  • Damaged belt

  • Severe misalignment of the pulley system driving the gearbox, visible with bare eye!

  • Severely damaged intermediate gear tooth.

The gearbox was replaced and pulleys aligned— no further damage reported to date (May 2025).

grain-mill-gear-box-2

The Result?

Root cause failure identification saves
grain mill $28,000 (so far).

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