SKF bearing manufacturer is the most famous company in the world. Through a large number of experiments, they deeply studied the influence of various factors such as load, oil viscosity and particulate pollutants on the bearing life, and concluded that the fatigue life of rolling bearings can be extended to 10-50 times by removing 2-5 micron solid particles from lubricating oil. According to the comprehensive research theory of engine, the life of engine is prolonged by 8 times by using improved clean engine oil. During the period of 1997, the steel maintenance committee of BHP (Institute of Maintenance Technology, University of Melbourne, Australia) studied the lubrication problems of two major rolling mills of BHP Steel Company in Japan. During the period of 1975- 1985, the equipment failure rate of NSC Steel Plant decreased from 342 to 85 per year. The equipment failure rate is reduced by 87%. During this period, through the implementation of lubrication pollution prevention technology in the whole plant, remarkable benefits have been achieved. The purchase rate of bearings in the whole plant is reduced by 5%, the renewal rate of hydraulic pumps is reduced by 80%, the consumption of lubricating oil is reduced by 83%, and the frequency of lubrication failures is reduced by 90% [4]. China Tianjin Port Authority is one of the major foreign trade ports, with 66 berths, 2,272 sets of various machinery and 44 ships, and the total fixed assets of equipment reached 65.438+0.7 billion yuan. Since 1990s, the Bureau has been engaged in oil purification, which has greatly reduced the failures of various engines, forklifts, cranes and loaders. The loss of downtime and maintenance is greatly reduced, and the annual oil and maintenance costs are as high as 5 million yuan. Now some companies even filter new oil products (of course, not high-cleanliness oil) before using them. In view of this global technical problem, an American company put forward the concept of "Total Cleanliness Control" (TCC), which aims to reduce the incidence and influence of pollutants in the whole production process from the production system of a single part to the future working life, similar to TQC. TCC also needs the participation of "whole process, whole system and whole staff", especially the hydraulic system. In addition to the unqualified quality of the system itself, its failure is often related to the failure to implement effective rules, regulations and norms in system management. Therefore, in order to really implement TCC, we must realize the "three all" management. At present, the domestic output of high-purity oil is not much, that is, the output is large. In the process of operation, online filtering is also the best. Because the particulate matter in the oil is separated, the fatigue life of the bearing will be increased by 10-50 times. It's easy to get huge benefits, who doesn't want it! A filtering device of an oil filter can be bought for tens of thousands of dollars, obviously with little investment. The key is to understand the problem. Production must be safe, and safety is for production. The reform and upgrading of lubricating oil has solved many hidden dangers of enterprise safety. For example, automobile brake fluid is the liquid that transmits pressure in the braking system to stop the wheels from rotating, and its quality is directly related to driving safety. At present, the brake fluid on the market is chaotic. From 65438 to 0998, the State Bureau of Technical Supervision announced that the qualified rate of automobile brake fluid in China was only 4 1.7%. Recently, Jiangxi Quality Supervision Bureau announced the inspection results, and nearly 60% of brake fluid safety failed to meet the standard. For example, the kinematic viscosity is not up to standard, the flow lubrication performance is poor, the braking lag phenomenon occurs in winter, and the brake fluid is easy to vaporize to produce air resistance, resulting in weak braking. As far as brake fluid is concerned, there are three kinds: alcohol, mineral oil and synthetic. Alcohol brake fluid has low price and poor high and low temperature performance. China was eliminated in May 1990. But so far, the market should be production and sales. Mineral oil type is prepared from tackifier, antioxidant and antirust agent, which has better adaptability than alcohol type, but has swelling effect on natural rubber. When in use, the leather cup hose should be replaced with oil-resistant rubber products. Synthetic type usually consists of additives, such as ethylene glycol ether, diethylene glycol ether, silicone oil, etc. It has wide adaptability to working temperature, good viscosity-temperature performance and good compatibility with rubber. It is suitable for high-speed, high-power and heavy-load frequent braking, and it is the most used one at present.
For another example, the wire rope is used in industrial and mining, and the author saw that some units with a large amount of wire rope have been replaced at the scene. As the carrier of lifting, traction and traction, steel wire rope is subjected to traction, torsion, sudden change of load, intermission, wind, sun and rain, and its working conditions are very bad, especially outdoors. There is an oil core in the middle of steel wire rope when it leaves the factory, which can store oil for lubrication between steel wires, but the actual effect is not ideal. Now, due to the development of permeable cable oil, not only the lubrication between steel wires is solved, but also the lubrication between the steel wire surface and the guide wheel is solved. Dalian Beiliang Port used imported permeable cable oil and achieved satisfactory results.
For another example, we used a lot of reciprocating air compressor oil, and in the past we used 13# and 19#. Due to serious carbon deposition, safety accidents often occur. Compared with 13# and 19#, the air compressor oil produced by DAA, DAB and DAC decreased by 4/5. Greatly reduce the explosion accidents caused by excessive carbon deposition. Maintenance comes first. In China, every enterprise has a group of maintenance personnel and spare parts in stock for many years. It seems to be the maintenance mode of some domestic enterprises to repair faults as soon as they appear. However, the emergence of advanced active maintenance methods will have a huge impact on the traditional model. Active maintenance is to monitor and control the root cause of equipment damage, delay the occurrence of faults, and eliminate the symptoms of faults in the bud. Minimize downtime and achieve a relatively low-cost maintenance method. Some developed countries have begun to make the equipment cycle cost the most economical. As far as equipment is concerned, the core is to minimize the cycle cost of equipment from post-maintenance and regular maintenance to preventive maintenance and then to maintainability and adaptive maintenance. The development of lubrication technology adapts to this situation. Improper use of lubricant causes excessive wear of friction pair, which damages assembly accuracy, temperature rise, vibration and noise. Finally, it leads to invisible wear and sudden accidents. Now the degree of mechanization and automation is getting higher and higher. What many equipment maintenance workers can do is to "change the oil". It is impossible to disassemble and unload as in the past.
The LCC cycle abroad has been overhauled without disintegration. The key here is maintenance. It is very important to choose the right oil. Monitoring, purifying and filtering the running oil products has become a daily work. In fact, it is a liquid maintenance technology, which is carried out in advance. For example, when the Caterpillar loader of the former port company of China Qingdao Port Administration did not dismantle and repair more than 15000 running platforms, Jiayou DC-25 tire crane did not dismantle and repair as many as 35000. Is to work hard on lubricants first. Of course, although the cost of active maintenance is low, it also needs time and money, while negligence will bring more money and time. Some people estimate that the input-output ratio generated by active maintenance is greater than 10, but according to some foreign data, it is far beyond this ratio. Take precautions and get twice the result with half the effort.