Like any type of equipment, industrial machines can be prone to wear and tear over time. For businesses like workshops and manufacturing plants that are highly reliant on such machinery, wear and tear can lead to costly downtime if not addressed quickly.
Industrial machines are complex systems and a lot can go wrong with them. However, there are some faults that are more common than others. Being aware of these faults can help you to identify them more quickly when they occur. There may even be ways to prevent or prolong such mechanical issues. This post explores 5 of the most common mechanical faults experienced by industrial machinery – and how to identify, fix and prevent them.
Hydraulic leaks
Hydraulic systems operate under immense pressure, which can make them prone to leaks. Seals and hoses can often wear out, which can lead to fluid loss and inconsistent machinery performance.
Signs of a hydraulic leak include visible puddles of hydraulic fluid, slower machinery cycle times and jerky/straining machinery. Such leaks are easy to fix (replacing the seal or hose may be all that’s needed), but such leaks can cause knock-on damage to other parts if not fixed promptly.
Make sure to regularly inspect seals and hoses on hydraulic machinery for damage, and take steps to control system pressure to help prevent leaks.
Cable wear
Many machines are powered by electricity via cables. These cables can become damaged or frayed over time – especially if exposed to corrosive liquids or extreme temperatures.
Such damage is often easy to spot. If cables become severely damaged, you may experience power outages. Replacing the cable can prevent this from happening, as well as preventing the risk of a fire.
To prevent cable wear, make sure that cables are suitable for the environment. Specialist solutions such as an SY cable can enhance durability and reduce the likelihood of wear. HMWPE-coated cables may be required in harsh environments where corrosion is a risk.
Motor overheating
Motors can overheat for various reasons. This can often lead to decreased efficiency, and in some cases complete breakdowns or even machinery fires.
Many modern machines have gauges or electronic screens for displaying the operational temperature and will automatically shut down if they get too hot. It is important to let machinery cool down before restarting it, and to assess why it overheated.
What are some common reasons for an overheating motor? It’s possible you may be working a machine too long and too hard. Alternatively, there may not be enough ventilation, cooling systems may not be working properly or filters may be blocked. Address these issues to prevent future overheating.
Bearing jams
Bearings are designed to reduce friction on moving parts. However, they can stop working properly if not well lubricated or if they become worn.
Early warning signs of bearing issues include grinding/squealing sounds or severe vibrations. Bearing jams may cause an entire machine to seize up. Replacing this bearing quickly is important to prevent further damage.
You can prevent bearing jams by making sure that your machine is well lubricated, as well as preventing contamination from chemicals (which could include hydraulic leaks or fumes from other machines).
Worn belts
Finally, it’s worth looking out for belt wear. Many machines use belts to connect moving parts. These belts can become worn, cracked or stretched over time. If ignored, they can snap – and could cause major damage to your machine.
Regularly inspect belts to make sure that they are not too worn. If you notice that they look frayed or mishapen, replace them as soon as you can.
Belt wear is inevitable over time, however it may be possible to extend the life of belts by making sure they are properly tensioned.
