A Brief Discussion on the Lubrication and Maintenance Management of Mechanical Equipment

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Abstract: In corporate production, equipment serves both as a crucial medium for production and as the material foundation upon which enterprises depend for their survival. The proper operation of equipment is directly related to a company’s production, operations, and profitability. Therefore, equipment lubrication and maintenance are of utmost importance. They serve as the foundation for equipment usage and management, and are also crucial means of ensuring that equipment operates normally and remains in good condition; they are an essential requirement for the proper functioning of equipment. The ability of a device to operate for extended periods depends largely on the level of lubrication and maintenance it receives. Proper lubrication and maintenance are essential to identify and address any issues that may arise promptly, thereby creating a favorable environment for the device’s operation and preventing problems before they occur. Therefore, reasonable, scientific, and effective lubrication management and maintenance can ensure the normal operation of equipment, reduce wear and tear, lower maintenance costs, and extend the service life of equipment. 01 The significance and role of lubrication and maintenance for mechanical equipment. Equipment lubrication management is an important means of ensuring the proper operation of equipment, reducing wear on its components, improving production efficiency, enhancing the effectiveness of equipment use, lowering the rate of equipment failures, and reducing maintenance costs. In the operation and management of equipment, it relies on the principle of “three parts treatment and seven parts maintenance”. Therefore, equipment lubrication and maintenance are crucial components of the entire life-cycle management of equipment. It is necessary to carry out proper lubrication management, promptly inspect and address various issues within the equipment itself, eliminate unnecessary wear, improve its operating conditions, and prevent problems before they arise. Establishing lubrication and maintenance on a scientific management basis is of utmost importance for ensuring the normal operation of enterprises, maintaining the good condition of equipment, maximizing its efficiency, reducing equipment failures, and improving the economic performance of enterprises. The functions of equipment lubrication and maintenance include: reducing friction, minimizing wear, cooling, cleaning, and sealing. Reduce friction: Lowering frictional resistance helps save energy, minimize wear and tear, extend the operational life of equipment, and improve a company’s economic efficiency. Reduce wear: The oil film formed between friction pairs in relative motion can reduce friction, minimize surface wear and scratches, and maintain the precision of the parts’ fit. Cooling: A circulating lubrication system using liquid lubricants can remove the heat generated by friction. Preventing corrosion: The oil film formed between friction pairs in relative motion covers the friction surfaces, acting as a barrier against air and corrosive gases; this helps to prevent the friction surfaces from being corroded or rusting. Force transmission: Some lubricants can serve as media for transmitting force, such as hydraulic oil. Shock absorption: It disperses loads and mitigates impacts, serving to absorb shocks and provide cushioning. Insulating properties: Lubricants such as mineral oil have very high electrical resistance; therefore, they can be used as electrical insulating oils and transformer oils. Cleaning effect: As the lubricating oil circulates, it carries away impurities such as contaminants and wear particles from the friction surfaces; these are then filtered out by a filter. Sealing function: Lubricants create a seal around certain exposed components, preventing condensation water, dust, and other contaminants from entering, and maintaining a sealed condition between the cylinder and the piston. 02 Selection of lubricants for mechanical equipment. Lubricants are lubricating media used to reduce the frictional resistance between equipment components and slow down their wear. Among mechanical equipment failures, 60% are caused by improper lubrication. Therefore, the selection of lubricants is of great importance and constitutes the primary step in lubrication management. 1 Classification of lubricants There are many types of lubricants, and the classification methods vary. Generally, they are divided into four categories based on their physical state: (1) Liquid lubricants In industrial and manufacturing enterprises, liquid lubricants are usually used in the largest quantities and come in the most varieties, such as hydraulic oil and machine oil. (2) Semi-solid lubricants (greases): For example, lithium-based greases among soap-based greases; they are widely used in large quantities and possess various excellent properties. (3) Solid lubricants The most commonly used solid lubricants are molybdenum disulfide, graphite, and polytetrafluoroethylene. (4) Gas lubricants: Under certain conditions, they can also act as lubricants, just like liquids. 2 Selection of main performance indicators for lubricants Table 1: Selection of main performance indicators for lubricants 3 Simple methods for inspecting lubricants Table 2: Simple methods for inspecting lubricants 4 Principles for selecting lubricants Generally speaking, the main indicator for lubricating oils is viscosity, while the main indicator for greases is penetration. Table 3: Principles for selecting lubricants 03 Strengthening the management of lubrication and maintenance for mechanical equipment. In managing the lubrication and maintenance of mechanical equipment, attention is the key factor; it is only by leveraging people’s initiative that better results can be achieved in this area. The core of equipment operation management lies in ensuring that all aspects of management shift from a passive to an active approach, and from relying on experience to following established standards. “\"Standardization\" is a key aspect of equipment operation management, and the standards for the lubrication and maintenance of mechanical equipment are crucial for its proper operation. Therefore, strengthening the management of equipment lubrication and maintenance is key to extending the operational life of equipment. (1) Establish a sound and complete equipment lubrication management system. Many enterprises lack a comprehensive equipment lubrication management system. It is not possible to manage it strictly in accordance with the \"five fixed principles\" for machinery lubrication (five fixed principles: fixed location, fixed timing, fixed quality, fixed quantity, fixed person) and three-stage filtration. Enterprises should establish corresponding organizational structures, improve rules and regulations for lubrication management, refine detailed procedures for lubrication management, and ensure strict implementation. (2) Develop a lubrication and maintenance plan based on the actual operating conditions of the equipment. Equipment maintenance personnel, when they notice that the equipment is running low on oil during operation, only add more oil without having a plan for oil replacement; there are no adequate methods for monitoring the quality of the oil or controlling oil contamination, and they rely solely on experience to assess the oil quality. Prolonged operation of equipment leads to oil contamination and deterioration in oil quality, which accelerates equipment wear. It is therefore necessary to establish appropriate lubrication and maintenance plans as well as lubrication charts, and to detail the processes for cleaning and changing oil. This helps to guide maintenance personnel in carrying out lubrication and maintenance tasks properly, thereby improving the situation related to equipment lubrication. (3) Strengthen lubrication knowledge training and select lubricants appropriately. Enterprises should enhance training in the knowledge and techniques related to lubrication maintenance, with dedicated personnel in charge to ensure that everything from the selection of lubricants to their use and subsequent recycling is carried out in a scientific and rational manner. At the same time, it is necessary to study and promote new products and technologies in order to effectively extend the service life of equipment. (4) Conduct oil analysis on critical equipment. Perform regular oil analysis on critical equipment as well as those that require oil replacement based on quality criteria, in order to understand the lubrication and wear conditions of the equipment and enable predictive maintenance. (5) Reasonably control the amount of oil applied. In summary, the lubrication and maintenance management of mechanical equipment is an essential aspect for the survival and development of a company. The quality of the equipment has a direct impact on the economic performance of the entire enterprise. In the management of the equipment’s entire life cycle, it is necessary to manage its technical condition, diagnose any faults, as well as oversee aspects related to operational efficiency and energy use. Lubrication and maintenance management is therefore an important part of equipment management, and it also constitutes a crucial component of equipment repair. Therefore, in the management of mechanical equipment, in order to extend its service life, managers should pay close attention to the lubrication and maintenance of such equipment during its operation. By taking into account the actual operating conditions of the equipment, they should carry out lubrication management in a scientific and rational manner, thereby ensuring reliable and stable operation of the equipment, reducing corporate costs, and enhancing the company’s competitiveness.