Mulcher rotor balancing

Forest mulchers like Nokamic are powerful equipment used for clearing forest areas and preparing road construction sites. Bearings play a crucial role in the uninterrupted operation of these machines. Unfortunately, even the most reliable equipment can fail. A recent breakdown of a Nokamic forest mulcher due to bearing damage highlights the importance of preventive maintenance and its role in saving costs and ensuring a smooth workflow.

Diagnosing the Problem: Increased Vibration and Bearing Damage in Forest Mulchers

Operators of the Nokamic forest mulcher noticed a significant increase in vibration levels during operation. Such malfunctions can quickly escalate, leading to breakdowns and costly downtimes. Closer inspection revealed that the malfunction was caused by bearing damage in the rotor.

Understanding the Causes: What Leads to Bearing Damage in Mulchers

Bearings are critical components of rotating equipment, providing smooth operation and reducing friction. Major causes of bearing damage include:

• - Insufficient lubrication: Without proper lubrication, parts overheat, causing excessive wear and accelerated failure.
• - Unbalanced rotor: Even slight imbalances create additional stress on bearings, leading to premature wear.
• - Overloading: Operating the mulcher beyond its working range places significant stress on the entire mechanism, including bearings.
• - Improper installation: Even when high-quality spare parts are used, improper installation can seriously damage new bearings.

Resolving the Issue: Bearing Replacement and Rotor Balancing

To address the damage and restore the Nokamic forest mulcher to operation, the following procedures were necessary:

• - Bearing replacement: Both damaged bearings were removed and replaced with high-quality parts.
• - Rotor balancing: Special attention was given to balancing the rotor after bearing replacement. This procedure is crucial for eliminating any imbalances that cause increased vibration and stress on bearings. Balanset-1 was used for precise balancing.

The Importance of Rotor Balancing in Forest Mulchers

The rotor is the heart of the forest mulcher. It rotates at high speeds and is equipped with heavy cutting tools. Any degree of imbalance in the rotor can amplify vibrations. A severe imbalance can lead to:

• - Increased bearing wear and premature failure.
• - Uneven stress on the mulcher frame, leading to cracks and deformations.
• - Degraded cutting quality and insufficient performance.
• - Increased noise levels, creating discomfort and potentially hazardous working conditions.

Results: Elimination of Vibration and Return to Operational State

After the replacement of bearings and rotor balancing, specialists conducted final tests. The vibration levels, which were dangerously high at 100 mm/sec, were significantly reduced to an acceptable level of 1 mm/sec. This indicates achieving perfect balancing, which contributes to smooth and efficient equipment operation.

Preventive Maintenance: Key to Extending the Life of Your Forest Mulcher

To prevent equipment failure, owners and operators of Nokamic or similar forest mulchers are advised to:

• - Follow the lubrication schedule: Strictly adhere to the manufacturer's instructions for types and intervals of lubricating parts and bearings.
• - Vibration monitoring: Regularly check vibrations using a portable vibration analyzer. Any sudden increase in vibration levels is a reason for a more thorough inspection of the mulcher.
• - Regular balancing: Conduct scheduled rotor balancing procedures according to the manufacturer's recommendations or after significant repairs.
• - Operate within design limits: Avoid overloading the forest mulcher and do not exceed the permissible operating parameters.
• - Qualified technicians: Trust your equipment for diagnosis and repair only to specialists familiar with the construction of forest mulchers.

Conclusion

This case study shows that a seemingly simple part, such as bearing damage, can have serious consequences. Timely intervention and careful rotor balancing of the forest mulcher ensured safe and efficient operation. Regular maintenance is the best insurance for equipment functionality, preventing costly breakdowns and downtimes.