How can overheating bearings stop the entire conveying process in a silo?

The bearings in the scrapers operate under high load, high temperature and constant friction. They are the ones that drive the moving platforms that transport the gypsum, and their failure can stop the whole process. If the temperature rises too high, the bearing can seize, leading to equipment damage, costly repairs and unplanned downtime.

The sooner a problem is detected, the easier it is to avoid serious consequences. This is why temperature monitoring is crucial. Traditional hard-wired sensors, however, proved ineffective - the cables could not withstand the movement of the platforms and were quickly damaged. Each failure meant further downtime and additional maintenance costs.

A solution was needed that would allow continuous temperature monitoring without risking damage to the cabling. A wireless temperature monitoring system enabled continuous monitoring of the bearings, ensuring reliability and safety. Exactly what challenges did the client face? That is discussed in the next chapter.

How to ensure continuous monitoring of bearing temperatures in moving platforms? Customer challenge

Bearings in scrapers operate under extreme conditions - high temperatures, heavy loads and constant movement of the platforms. Any failure could have meant stopping gypsum transport, costly downtime and risking damage to the equipment. The customer needed a system that would provide continuous monitoring of bearing temperatures before they overheated.

The problem was moving platforms prevented the use of traditional wired sensors. Cables were quickly wearing through or breaking, and replacing them was cumbersome and expensive. A solution was needed that did not require wires and would perform well in harsh environments.

An additional challenge was the need for easy installation and minimal maintenance. The sensors had to operate reliably without the need for frequent service interventions, especially as access to the bearings was limited.

The final requirement was reliable data transfer to the power plant control system. Operators needed to have a complete view of the temperature in real time and the ability to react immediately in case of problems.

How have wireless sensors improved the measurement of bearing temperature in a transport silo? Our solution

The customer needed a system that would provide continuous monitoring of bearing temperature, withstand harsh conditions and not require cables that would be damaged. The solution turned out to be wireless temperature sensors from the JUMO Wtrans range, adapted to the extreme environment of a gypsum silo.

The mineral-insulated wireless thermocouples were mounted directly on the scraper bearings. Their resistance to high temperatures and vibrations made them ideal for intensive conveying systems.

The sensor signals are transmitted by JUMO Wtrans B transmitters, which eliminate the need for cables. This is crucial in this environment - the absence of cables means there is no risk of abrasion, breakage or failure due to platform movement.

The data collected goes to a JUMO Wtrans T01 receiver, mounted in the control cabinet of the power station. From there, the system transmits information to the main control system, enabling continuous temperature monitoring and immediate response to any deviations from the norm.

How has intelligent monitoring of bearing temperatures increased control of the gypsum mixing process in the silo? Customer benefits

The new temperature monitoring system has eliminated the risk of seizure of bearings, ensuring that they are constantly monitored and that abnormalities are quickly detected. As a result, the scrapers run smoothly and the risk of sudden failures has been reduced to a minimum.

Safety at the power plant has increased significantly. The system immediately sends alerts in the event of a temperature rise, allowing operators to react quickly. An earlier detected fault means less risk of equipment damage and downtime that could disrupt the entire gypsum transport process.

Thanks to the elimination of cables and the use of sensors wireless sensors, the system is virtually maintenance-free. The absence of cables means there is no risk of abrasion or damage, resulting in lower service costs and fewer technical interventions.

The result? Better work organisation and greater operational efficiency operational efficiency. The transport systems in the silo run smoothly and the power plant can focus on efficient energy production instead of worrying about potential breakdowns.

About the author

My name is Ewelina Szmit and I have been working in content marketing for several years, combining my professional skills with my passion for writing. I am convinced that even the most technical topics can be presented in an interesting and accessible way for everyone. Outside of work, I unleash my creativity by creating newspaper collages. I like to spend my free time being active, walking my dog or running.

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