I recently assisted a customer with a strange vibration issue on a small, belt-driven air handler. Typically, these types of machines are not considered critical assets, but in this case, they were. The fan was experiencing broadband vibration, which didn’t seem to line up with any of the expected frequencies.
Putting Tools to Use
I recommended a visual inspection. Since we were on-site conducting a Reliable Precision Maintenance (RPM) class, it was a good time for them to try out their new belt and sheave wear gauges. We always encourage hands-on learning during these trainings. This situation provided a perfect real-world example of how inspection tools can quickly identify mechanical issues.
Severe Sheave Wear Found
The image speaks for itself.
When sheaves are operated while misaligned, this is the type of wear that can be expected. It’s not just about alignment. Neglected wear like this can snowball into bigger problems.
Wear Leads to Vibration
As wear progresses within the sheave groove, mechanics often have to re-tighten the belts to prevent slippage. But in this case, the wear on the sheave was substantial enough for the belt to “grab” down into the groove, causing the erratic vibration. This is a great reminder that vibration symptoms don’t always originate where you expect them. Even simple components can create complex issues.
Modern Tech Still Needs You
The moral of the story…
AI, combined with other modern technologies such as vibration analysis, has the ability to make our jobs easier, more precise, and more productive.
But it can’t do everything! These tools are incredibly powerful, but they rely on skilled humans to interpret results and investigate anomalies.
Sometimes, it takes a good, old-fashioned, visual inspection of the machine itself. In this case, all that was needed was to replace the belts and sheaves, along with aligning and setting the proper belt tension. It’s a simple fix, but only if you catch it early.
Stop Sheave Wear Before It Starts
Want to prevent sheave wear and weird vibration? The Acoem Belt Hog laser belt and pulley alignment tool is a fast, accurate solution for aligning sheaves on belt-driven machines. Its compact design and simple laser-target system make it easy to detect and correct angular, parallel, and sheave misalignment. extending belt life, reducing vibration, and improving overall efficiency. This is a must-have for maintenance teams committed to reliability.
¹ Featured image includes a page from Millwrights and Mechanics Guide by Audel, used for illustrative purposes. This does not imply endorsement by the author or publisher.
