Grain mill gearbox frequent damage — root cause eliminated
Case Study
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.
In early June 2023, Skyler analytics detected an increase in the trend.
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 gear visible with bare eye!
- Severely damaged intermediate gear tooth.
The gearbox was replaced and pulleys aligned— no further damage reported to date (May 2025).
The Result?
Root cause failure identification saves grain mill $28,000 (so far).
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