Predictive maintenance for crushers
How do you catch a crusher rotor drifting out of balance before it cracks a bearing housing?
A crusher lives on impact loads: every batch of material changes the rotor balance, and the bearings take the shock.
DHMSCare sensors on the rotor bearing seats and the drive motor catch unbalance, misalignment and bearing wear before the housing fails.
Typical faults
Uneven wear or material build-up on the rotor changes its mass. The spectrum shows a dominant peak at the rotor rotation speed.
Crusher bearings carry the full impact load. Wear raises the high-frequency noise floor first, then adds discrete peaks at the bearing characteristic frequencies.
A misaligned drive shaft shows a strong peak at twice the rotation speed and loads both bearings unevenly.
Loose foundation bolts or worn mountings produce a train of rotation-speed harmonics — easy to spot before the housing shakes itself apart.
Where sensors go
Sensors are bonded next to the bearing seats — no machine modification. Each sensor is bound to its measuring point in the app with a tap, and the gateway is wall-mounted nearby.
DT310 wireless vibration and temperature, 3-axis, 0–6000 Hz. Use DT311, with an external antenna, where a point sits inside an enclosed metal structure.
DMG310 (Ethernet / Wi-Fi): up to 60 sensors each, 60–80 m range in a typical plant (about 300 m line of sight). DMG311 (4G / Ethernet) for sites without Wi-Fi.
How to read a typical spectrum
A balanced crusher shows a small peak at the rotor speed. Uneven wear makes that peak dominate the spectrum, and the trend over days tells you when the rotor needs rebalancing — before the bearings take the load.
Questions
How many sensors does one crusher need?
Typically 4: two on the rotor bearing seats and two on the motor.
Do the sensors survive the crusher environment?
Sensors are bonded in place and sealed for industrial environments. Where a point sits inside an enclosed structure, DT311 with an external antenna is used.
How often do I get a diagnosis?
On the AI Care plan, Mina runs an automatic diagnosis on every machine each day, and an alert is raised when a change is confirmed. See the help centre for the full cycle.
Map the measuring points on your equipment before the first call.