Case Study: Large Paper Plant diagnoses gearbox damage with SymphonyAI Industrial

Diagnosing a low-speed gearbox problem

Large Paper Plant, a customer in the paper industry, faced a suspected low-speed gearbox issue after oil analysis revealed iron particles in the lubricant. SymphonyAI Industrial was brought in to diagnose the problem using vibration analysis, especially synchronous averaging of the gearbox vibration signature to isolate the source of contamination.

SymphonyAI Industrial synchronized and averaged vibration waveforms on the gearbox components, which showed no defect in the bull gears but revealed severe non-uniform meshing on the pinion. An inspection confirmed a badly worn keyway, loose interference fit, and damage to the pinion bore and teeth; the shaft and pinion required replacement to avoid catastrophic failure. The result was a clear diagnosis that prevented a major breakdown and improved confidence in the plant’s vibration monitoring program.