Wobbler Bar Shaft Reliability Issues

We recently worked with a client to resolve persistent quality issues with the Wobbler Bar Shaft—an essential component in material screening equipment used across mining and aggregate processing.

Wobbler Bar Shafts are designed to handle heavy loads and variable feed material, helping to separate fines from larger rocks before they enter downstream crushers. Their design must account for constant impact, torsional loads, and abrasive wear. Any weakness in material integrity—such as cracks or porosity—can quickly lead to equipment failure or unplanned downtime.

Our client had been experiencing exactly these problems. Cracks and internal defects were appearing early in the lifecycle of the shaft, and ultrasonic testing (UT) failure rates were high. This not only disrupted production but also raised concerns about operational safety.

Working in collaboration with our partner Y&J Industries, we began with a detailed feasibility study and failure analysis. Using simulation-driven casting methods, Y&J redesigned the casting process to eliminate defect-prone zones. The shafts were then subjected to 100% ultrasonic (UT) and magnetic particle (MT) testing, ensuring full traceability and confidence in their structural integrity.

The results have been consistent: all shafts have passed testing and are now supporting long-term, stable operation in the field. The success of this project has led to an ongoing supply relationship and a significant reduction in maintenance issues for the client.

This case demonstrates the value of upfront engineering analysis and rigorous quality assurance when dealing with high-load mechanical components in demanding environments.