Equipment lubrication management is often overlooked by managers in many manufacturing enterprises, and employees also think it doesn't matter. As a result, the burden on equipment is increased, and many equipment problems are highlighted. The following views are proposed to address this issue.
【1】 Revise the equipment lubrication management system, establish an internal lubrication management network for the enterprise, and establish an enterprise equipment lubrication management committee.
Team composition: Enterprise Equipment Lubrication Chief Engineer, Branch Equipment Lubrication Chief Engineer, and Oil Monitoring Station Chief Engineer. From the perspective of enterprises, standardize the principles of equipment oil selection, strengthen the responsibilities of professional personnel at all levels in equipment lubrication management, and ensure that each person bears their own responsibilities; Implement a reporting system for equipment oil usage plans, with the equipment director in the production workshop reporting to the Mechanical and Electrical Department, and the lubrication engineer in the Mechanical and Electrical Department reviewing, signing, and transferring to the supply department for procurement, confirming the authority of the lubrication engineer; Hold quarterly internal equipment lubrication management exchange meetings within the company.
[2]Standardize equipment oil usage, and the amount of oil to be added to the equipment is determined by the lubrication engineer of the unit.
Lubricating oil is the blood of machines, and the life of machines lies in lubricating oil. According to statistics, 75-85% of hydraulic system failures are related to lubrication, and over 60% of gearbox and rolling bearing failures are related to lubrication. The qualities that lubrication engineers should possess include: firstly, having management functions and authority; 2、 Understand the equipment structure; 3、 Has a strong knowledge of lubrication technology.
[3]Establish an oil monitoring station to monitor the lubrication and wear status of equipment.
1) Establish physical and chemical index inspections for lubricating oil products within the enterprise, perform 100% testing on the physical and chemical index of new oil entering the factory, and conduct oil testing for online equipment oil according to the importance of the equipment. Important equipment is inspected every three months, and general equipment is randomly inspected. To achieve comprehensive equipment lubrication management, it is necessary to carry out oil condition wear monitoring.
2) Monitoring and control of pollution levels in oil, without monitoring, there is no control. Wear on equipment is caused by solid particles in oil, which are mainly composed of on-site dust and mechanical wear. The wear of workpieces depends on the hardness of the solid particles. As a company, we should equip a particle automatic counter to monitor the size and quantity of pollutants in the oil. Only by detecting the presence of particles can we develop plans and corrective measures.
3) Particle wear analysis mainly uses emission spectroscopy and iron shop analysis instruments to analyze the wear particles in online equipment oil samples, which can distinguish whether it is bearing wear or gear wear. It is different from pollution degree, which only monitors the size and quantity of particles. Particle wear analysis can monitor what particles are and how many particles are, track and analyze them, predict the degree of wear in specific parts, and develop solutions. Spectral analysis and iron shop analysis instruments are expensive and complex to operate, with high operating costs. It is not cost-effective for enterprises to purchase them. According to market research, there are relatively complete professional testing institutions in China that carry out this work. For example, some mechanical research institutes have equipment lubrication and wear status monitoring centers that have been engaged in specialized oil monitoring for more than 20 years, and can be commissioned for monitoring and analysis.
[4]Realize online filtration for large-scale equipment, and offline filtration for general equipment using oil.
As mentioned above, the particles contained in oil pose a huge threat to equipment wear and tear. What should be done when monitoring pollution particles that exceed the standard? The only way to reduce wear and tear on equipment and maintain long-term oil usage is through purification and filtration. The Swedish SKF manufacturer has concluded through testing that removing solid particles above 5 μ m from oil can extend the bearing life by 50 times, while the normal SKF life is 10 years; If the water content in the oil exceeds 0.1%, the bearing life will be reduced by 60-70%. The above data indicates that pollution has a significant impact on the lifespan of bearings and equipment. In order to ensure the rationality of equipment lubrication management, it is necessary to carry out online equipment filtering.
【 V 】The energy-saving application of new technologies and materials is regulated through the establishment of regulations by enterprises to regulate the application methods of lubricating new materials.
In recent years, lubrication materials and technologies in China have been developing rapidly. The application of new materials can solve on-site equipment operation problems, such as the lubrication problem of rotary kiln rollers. In the past, cylinder oil was used, and the bearings of the rollers were severely worn, often heating or even overturning the bearings. Due to the high friction coefficient, the operating current was high and energy was wasted. Switching to roller specific oil has achieved energy-saving and consumption reduction effects, achieving a 20% electricity consumption savings.
[Six]The oil used for new equipment (including enterprise basic construction, research and development, technical renovation, major repairs, and maintenance projects) should refer to the recommended oil in the equipment manual and be approved by the lubrication engineer of the unit where the equipment is located.
Oil products purchased by oneself must be inspected by the enterprise's oil testing station and issued a certificate of conformity before they can be added to the equipment, and refueling must be supervised by the user. Especially when refueling imported equipment, strict control should be exercised, as adding the wrong lubricating oil can lead to equipment failure.
[Seven]Strengthen lubrication training for personnel at all levels of the equipment, using a combination of external teacher training and internal personnel training.
The first level of training is for the main equipment management personnel, and external teachers are invited to give lectures. Special training on lubrication knowledge will be provided to the equipment factory directors (managers), mobile department heads, and workshop equipment directors of various units in the enterprise, clarifying that equipment lubrication management is not about lubricating oil, and lubrication technology is not about lubricating oil technology. It is about the comprehensive management level of equipment from selecting appropriate lubricating oil and maintaining lubricating oil, that is, to make equipment managers at all levels aware of the significance and importance of lubrication.
The second level of training is for lubrication workers, maintenance workers, and equipment related personnel, using internal lubrication engineer lectures. Key content to help them understand why the oil is too dirty? It's not because the oil is not good, it's because the lubricating oil is contaminated and spoiled. The pollution not only comes from equipment wear and tear, but also from on-site dust and moisture. It comes from the equipment changing oil without cleaning the oil tank oil circuit. Enterprises do not have dedicated lubrication workers and need to provide training for equipment operators.
The third level of training is for full-time lubrication engineers, using external teachers for internal training and going out to participate in professional training. They are required not only to know the importance of lubrication, but also to understand and be familiar with the use and selection of lubrication knowledge. In addition, they should also understand the structure of the managed equipment and the material of the friction pair. The selection of lubrication engineers requires a strong sense of responsibility.
[Eight]Modern equipment lubrication is a combination of management, technology, and education.
Equipment management personnel at all levels of enterprises should establish three major concepts: modern equipment lubrication management is the concept of a gold mine being explored; The concept that lubricating oil is the blood of equipment; Improving the oil level of equipment and selecting reasonable lubrication is an economical and practical concept.
[Nine]Establish a dedicated lubrication worker system.
Each unit's production workshop shall have 1-2 dedicated lubrication workers (according to the number of equipment) responsible for refueling and replenishing the equipment, which can avoid equipment mixing. Lubrication workers should understand the structure of the equipment under their jurisdiction, the location of lubrication points, and the amount of oil added.
The responsibility of a lubrication worker is to inspect the oil level of the equipment and determine the equipment that needs to be refueled; Quantitatively add oil to the equipment according to the lubrication card formulated by the lubrication engineer of the Mobility Department, and wipe the position of the oil hole clean before adding oil; Different lubricating oil drums are marked with colors to achieve dedicated use for each drum; Keep a record of refueling. If there is oil mixing in the equipment, it is naturally a problem with the lubrication worker. The responsibility is clear and easy to investigate, in order to facilitate rectification.
[Ten]For units that violate the lubrication management system of the enterprise and fail to pass the oil inspection for online equipment, and fail to change the oil as required, the assessment intensity will be increased in the equipment standardization assessment.
If the above ten measures are implemented, the cost of maintenance and spare parts for enterprises can be greatly reduced. The specific amount of reduction depends on how to calculate, because the economic benefits brought by lubrication are lagging and imperceptible. As an enterprise, the maintenance of equipment is variable, and only the extension of the maintenance cycle for a single equipment and the reduction of the total consumption of bearings can be counted. The growth of economic benefits should be compared with the current equipment maintenance costs, spare parts replacement cycles, and the use of lubricating oil in the implementation of modern equipment lubrication management. There should also be a comparison of the operating current of the equipment.
Solution:
After professional evaluation by equipment management personnel, for the treatment of waste oil, firstly, for some equipment, the waste liquid can be replaced and stored, and offline waste oil purification can be unified. Secondly, for some equipment that is inconvenient to replace waste oil, online oil purification can only be used. Meifel Environmental Technology's centrifugal oil purifier can purify oil online and offline, without the need for consumables, making it easy to move and operate. Suitable for purifying and separating hydraulic oil, lubricating oil, gear oil, and oil film bearing oil with viscosity ranges from 25 # to 460 #. It can better purify the lubricating oil of equipment and reduce the wear and tear of operating equipment, while also reducing production costs for enterprises.
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