Stone equipment lubrication management technology and method

Machinery is the main production tool for stone companies and an important part of fixed assets. In the process of using machinery, it is not only the process of producing products, creating profits, but also the process of its own wear and tear, and wear is one of the most important reasons for mechanical failure. Equipment lubrication is an important means to prevent and delay parts wear and other forms of failure. Lubrication management is the basic work of equipment management, and is a vital link in the equipment "pipe, use, maintenance, repair", to strengthen the lubrication of equipment, to ensure The normal production, reducing the physical wear and tear of the equipment, extending its service life and parts replacement cycle, reducing equipment accidents and failures, and improving the economic benefits of stone enterprises is of great significance.

1 basic knowledge of equipment lubrication management

1.1 Purpose and task of lubrication management

A series of technical methods and organizational methods for controlling equipment friction, reducing and eliminating equipment wear, collectively referred to as equipment lubrication management.

1.1.1 Purpose of equipment lubrication management

(1) Properly lubricate the equipment, reduce and eliminate equipment wear and extend the service life of the equipment;

(2) Ensure the normal operation of the equipment to prevent equipment accidents and reduce equipment performance;

(3) reduce frictional resistance and reduce kinetic energy consumption;

(4) Improve the production efficiency of the equipment and the processing precision of the products to ensure that the enterprise obtains good economic effects;

(5) Reasonable lubrication, saving oil and avoiding waste.

1.1.2 The basic task of lubrication management is

(1) Establish equipment lubrication management system and work rules, and formulate the duties of lubrication workers;

(2) Collect lubrication technology, manage data, establish lubrication technical files, compile lubrication cards, and guide operators and full-time lubricants to do a good job of lubrication;

(3) Approving the lubrication materials of a single equipment and its consumption quota, and preparing the lubrication material plan in time;

(4) Check the procurement quality of lubricating materials, and do a good job in the management of lubricating materials into storage, storage, and distribution;

(5) Prepare equipment for regular oil change, and recycle waste oil;

(6) Check the lubrication of the equipment, solve the existing problems in time, replace the defective lubricating components, devices, refueling tools and appliances, and improve the lubrication method;

(7) Take active measures to prevent and control equipment leakage;

(8) Do a good job in technical training for relevant personnel and improve the level of lubrication technology;

(9) Implement the “five-fix” and “three-filter” principles of lubrication, summarize and promote and learn to apply advanced lubrication technology and experience to achieve scientific management.

1.2 "Five-set" and "three-filter" for equipment lubrication management

The “five-set” and “three-filter” systems for equipment lubrication are the specific systems for the standardized management of enterprise equipment lubrication and should not be ignored. “Five” is the designated point, qualitative, quantitative, regular, and fixed. which is:

(1) Fixed point: determine the lubrication part and lubrication point of each equipment, keep it clean and intact, and implement fixed-point oil supply;

(2) Qualification: According to the grease brand specified in the lubrication card, the lubricating material and the blended oil must pass the inspection, and the lubricating device and the fueling device should be kept clean;

(3) Quantification: On the basis of ensuring good lubrication, implement daily fuel consumption quota and quantitative oil change, do a good job of waste oil recovery and retreat, and manage equipment oil leakage to prevent waste;

(4) Periodically: refueling, adding oil and clearing oil according to the cycle specified by the lubrication card. For large reserves of oil, it should be sampled and tested according to the specified time, and the cleaning and oil change, cycle filtration and sampling cycle should be determined according to the oil quality condition;

(5) Determining people: According to the regulations on the lubrication chart, clear the division of labor for the daily refueling, oiling and cleaning of the equipment by the operators, maintenance workers and lubrication workers, each of them shall be responsible for each other, and shall determine the sampling and inspection personnel. .

“Three filtration” means in-storage filtration, distribution filtration and refueling filtration. This is a purification measure to reduce the content of impurities in the oil and prevent impurities from entering the equipment with oil. Specifically, when the oil is pumped from the input library into the oil tank for storage, it must be strictly filtered; when the oil is injected into the lubrication container, it must be filtered (ie, the filtration is dispensed); when the oil is added to the oil storage part of the equipment, it must be filtered first (ie, the oil filter ).

2 equipment lubrication management technology

2.1 Selection and storage of lubricating oil

The company has a large variety of equipment, operating speed, load and working environment are different, and the lubricating oil labels used are also different. There are many types and labels of lubricants. It is especially important to choose the type and label of the lubricant and to enhance the storage of the lubricant.

2.1.1 Selection of lubricating oil

(1) Select according to the type and label specified in the equipment manual. However, it should be noted here that manufacturers often do not fully understand the production of lubricants, and there is a phenomenon of low and high in oil recommendation, so it should be revised in conjunction with the actual operation of the equipment.

(2) Select according to the working conditions of the equipment. When the working temperature of the friction pair is high, the oil with a higher viscosity or the grease with a small penetration degree should be selected to ensure the thickness of the oil film under normal working conditions; otherwise, the oil with a small kinematic viscosity or a grease with a high penetration degree is selected. This ensures the fluidity of the lubricating material at low temperatures. When the working temperature of the friction pair changes frequently, the selected oil or grease should have good viscosity-temperature performance, that is, the viscosity of the oil used or the consistency of the fat does not change much with the rise or fall of the working temperature, and the thickness of the oil film is required to be stable. Within a certain range, to ensure the lubrication of the sports pair. When the working speed is high, the oil with less viscosity or the grease with higher penetration degree should be selected to ensure the good fluidity and permeability of the oil. Otherwise, the oil with high viscosity or the grease with small penetration degree should be selected to avoid Loss of grease. Of course, the viscosity and consistency of the grease should not be too large. If it is too large, it will increase the friction resistance and increase the energy loss. When the load is relatively large, the oil with a higher viscosity or the grease with a small penetration degree should be selected, so as to ensure the thickness of the oil film under normal working conditions; otherwise, the oil with a smaller viscosity or the grease with a higher penetration degree is selected. When purchasing lubricants, pay attention to the physical and chemical properties of the lubricant, such as the viscosity, corrosion resistance, rust resistance, flash point, water content, impurity content and acid value of the lubricating oil; The performance, operating environment and lubricant manufacturer's instructions, in consideration of comprehensive economic benefits, and can meet the lubrication requirements, and facilitate management, reduce the type and label of lubricants as much as possible to reduce procurement and storage costs. Imported lubricants must be used in key parts of imported equipment to improve lubrication performance and extend the service life of the equipment; domestic lubricants can be used for unimportant parts to reduce costs.

2.1.2 Storage and storage of lubricating oil

The storage and storage of lubricating oil has an important influence on the performance of lubricating oil. Lubricating oils are prone to decomposition when in contact with light, heat and non-ferrous metals, especially with copper, or chemically react with oxygen in the air to form extremely unstable oxides and even form colloidal and acidic substances, thus seriously affecting Its performance, causing corrosion during use, damages the machine. In order to prevent oxidation and deterioration of lubricating oil, it should not be in contact with non-ferrous metals such as copper and lead during storage. The original barreled lubricating oil should be kept clean, protected from light, cool and ventilated during storage, and all kinds of lubricants should be conspicuous. Identification to avoid confusion between categories and labels. Lubricating oil storage time should not be too long, generally should not exceed one year, so as to avoid deterioration of lubrication effect, so we must strictly control the storage quantity. Some lubricants need to be naturally precipitated for a certain period of time before they can be used. For example, hydraulic oil can be put into use after being stored for one week.

2.2 problems should be paid attention to when lubricating

In work practice, nearly half of the causes of equipment failure are caused by poor lubrication. The reasons for poor lubrication are: whether the oil is used properly, whether the oil circuit is unblocked, whether the oil is contaminated, whether the fueling method is correct, and whether the oil change is timely. Etc. These can lead to increased mechanical wear and mechanical failure.

2.2.1 Eliminating misunderstandings in equipment lubrication Common misunderstandings of equipment lubrication are:

(1) The purpose of lubrication is to speed up the operation of the equipment. The real purpose of lubrication is to properly lubricate the equipment so that the equipment does not malfunction during operation to keep the equipment running properly, thereby increasing productivity and economic efficiency.

(2) Lubrication operation is to refuel. When the equipment is oiled, refueled, and the inspection cycle is determined, it shall be operated and inspected according to the refueling part, refueling cycle, fueling amount, refueling method and lubricant used of the equipment, according to shift, daily, and weekly. More and more demanding, not once and for all.

(3) More fuel is better. A piece of equipment is strictly specified in the design of the amount of fuel, the operator should add lubricant according to the instructions and daily observation of the oil mark, sight glass and so on. In the actual operation of the equipment, if more oil is added, it will have certain side effects. For example, air compressors, crankcases add too much oil, but increase the resistance of the crankshaft; in the reduction gearbox, in order to reduce the resistance of the gears and prevent the oil temperature from rising, the depth of the gear immersed in the oil is 1}2 teeth. It is better, when the speed is high, it should be shallower; when the rolling bearing is greased, it is impossible to fill the bearing cavity completely, otherwise it will increase the bearing running resistance, easy to heat, cause the oil temperature to rise, the grease will flow away, causing lubrication. Bad or damaged bearings.

(4) It can be lubricated with oil. When designing a piece of equipment, the designer specifies the lubricant used in the equipment according to the mechanism, and not all the lubricating oil can lubricate. In order to make the equipment properly lubricated under different environments, a certain amount of additives must be added to the lubricating oil. The additives added to the various lubricating oils are different, and the performance is also different. Therefore, it depends on the equipment and use. The environment should choose a suitable lubricant to achieve good lubrication.

2.2.2 Prevent abrasive wear

Many machine rotating parts support points are susceptible to dust contamination, resulting in increased frictional resistance and increased mechanical wear. In the maintenance and lubrication process of the equipment, the wear of the abrasive particles is particularly prevented. Abrasive wear is an abnormal wear caused by worn particles (fine sand, iron filings, dust, etc.) on the two friction surfaces, which is extremely serious to mechanical wear. Due to poor maintenance and lubrication management, dust that is left at the lubrication point during installation, dust that is not properly sealed, dust that is invaded by the outside world, poorly managed grease, and metal powder generated during the initial operation of the running-in, and poor lubrication system of the lubrication system can cause grinding. Particle wear. Abrasive wear has a great impact on the life of the machine. According to statistics, the wear and tear in the industry accounts for about 50%. It is regarded as the enemy of industrial machinery damage and should be paid enough attention. In abrasive wear, the source of abrasive particles is related to maintenance operations and lubrication quality, and also to the amount of dust in the atmosphere.

2.2.3 Maintaining good lubrication when the equipment is being repaired

Whether the equipment maintenance method and lubrication method are correct, the impact on the wear condition of the friction pair is extremely important, whether the maintenance process is clean, whether the test cloth is clean, etc. will affect the wear process. In the maintenance, the replacement of accessories and lubricants should be done carefully. When replacing the accessories, the wipes must be cleaned. The wipes of important parts should be cleaned before use to avoid dust pollution. The newly replaced parts should be lubricated. Thoroughly clean and thoroughly clean the installation site. For the new gear replacement of the gearbox, it should be re-cleaned and replaced after the running-in, and then put into normal operation. If the bearing is replaced when replacing the bearing, the bearing has been added with grease, no need to add grease, protect the sealing cover from damage during installation to avoid grease spillage and dust intrusion; and do not use hot charging during installation to prevent lubrication The grease melts and overflows. At the same time, when cleaning the bearing, pay attention to the cleaning work. The dust, impurities or moisture in the lubricating grease will wear more to the bearing. When the content of impurities increases to 0.5%, the wear can be increased by 5-10 times. Grease should be added in an appropriate amount, generally 1/2 to 1/3 of the bearing cavity.

2.2.4 Strict equipment lubrication management in production

During the production of the equipment, the equipment lubrication management regulations shall be implemented and carefully implemented.

(1) For the requirements of full-time lubrication management personnel: 1 According to the scientific method of oil quality monitoring oil change, organize lubrication business learning, popularize lubrication knowledge, summarize and actively promote advanced science and technology. 2 According to the lubrication requirements of the various components of the equipment, determine the use, preparation or substitution of the oil to solve the lubrication technical problems. 3Familiar with the lubrication condition of the equipment and the requirements of the oil quality and oil quantity of the required lubricating oil, and recycle the waste oil for the failed lubricating oil. 4 Insist on the inspection and oil monitoring of the equipment, carefully check the working condition of each oiler or oil pump at the lubrication point, find the problem, solve it immediately, eliminate the lubrication fault in time, improve the sealing condition, eliminate the run and run of the lubrication system, Drops and leaks.

(2) For the requirements of the equipment operators: 1 Before the equipment is started, carefully check the oil supply of the equipment, find the fault, immediately report the relevant management personnel, and repair and repair by the maintenance personnel. Do not activate the equipment until the inspection work has been completed. 2 According to the lubrication diagram of the equipment, according to the “five-set” principle of lubrication “set, timing, quality, quantitative, fixed point”, each lubrication part is lubricated. 3 Regularly clean equipment linoleum, oil line, oil hole, oil mark, oil filter, etc. 4 Maintain the lubrication device of the equipment, such as: oil cup, grease nipple, etc.

(3) Correct the misunderstanding of lubrication: 1 think that the more lubricant oil, the better. In the lubrication of equipment, the amount of lubricating oil is not as good as possible. When the amount of oil is too much, it will cause the movement resistance and oil temperature to rise, the oil is easy to bubble, and it is accompanied by spillage. 2 think that the lubrication operation is to refuel. The lubrication requirements of the equipment are very strict. It requires the equipment operator to lubricate the equipment according to the “five-fix” principle of lubrication, instead of simply refueling, only surface work. 3 think that waste oil can no longer be used. After the oil is replaced by the equipment, the corresponding measures are taken. For the oil entering the oil, it can be dehydrated by the oil-water separator; for the mechanical impurities and sludge in the lubricating oil, it can be removed by the filter.

3 equipment lubrication status detection

The detection of equipment lubrication is an indispensable part of equipment lubrication management. Due to the influence of internal and external factors, equipment lubricants will gradually undergo physical and chemical reactions and deteriorate, generating harmful substances, thereby deteriorating the technical state of equipment, shortening the service life of equipment, and even equipment accidents. There are many reasons for the deterioration of lubricating oil, and oxidation, moisture increase and impurity mixing are more important factors. In order to ensure the normal operation of the equipment, it is necessary to strengthen and standardize the detection of equipment lubrication. At present, there are mainly three ways to test the oil status according to the "quality" oil change:

(1) Quantitative analysis. It is also called physical and chemical analysis, that is, the change of the kinematic viscosity, acidity, flash point, mechanical impurities, moisture and other indicators of the oil, so as to reflect the lubrication state of the lubricating oil more comprehensively, and the analysis result is more reliable. However, most of the instruments and equipment used in such analysis are expensive, such as: spectrum analyzer, iron spectrum analyzer, gas chromatograph analyzer, infrared spectrum analyzer, etc. This method is only suitable for lubrication condition monitoring of high, fine and sharp equipment. .

(2) Visual diagnosis. Take three test tubes to hold the standard new oil, scrap oil and oil sample of the same grade, compare them, and combine test strips and other test methods to determine the oil status by experience. The method is simple and easy to implement, but it is difficult to comprehensively, reliably and scientifically reflect the state of the oil due to the operator's experience and other conditions. Therefore, it has a large use limitation and can only be used as an auxiliary means for oil condition monitoring.

(3) Qualitative monitoring. Comprehensive performance indicators such as the deterioration of the test oil and the degree of contamination, fully reflect the state of the lubricant. The test instrument used in the method has a relatively low price and a fast detection speed, and the oil quasi-determinism can be completed in only 5 to 10 minutes, and the operation is simple, the carrying is convenient, and the application surface is wide. Objectively speaking, various oil quality testing technologies have their limitations. It is necessary to comprehensively utilize the length of each technology, and the equipment lubrication management method can be called scientific. For example, most modern high-precision, sharp-point mechanical equipment lubrication systems use online automatic monitoring and oil change, equipped with automatic measurement and control and safety interlocks, monitor their operating status and continuously send signals to remind people to keep track of equipment operation. Lubrication system technical status during the process. However, once this automatic control and the monitoring device itself fails, people rely on and rely too much on the device to perform equipment operation, which will inevitably cause serious equipment lubrication accidents. Therefore, if you can use a variety of methods such as visual diagnosis or oil rapid analyzer, you can monitor the lubrication status of the equipment at the same time. To ensure reliable lubrication of the equipment.

4 lubrication of common parts

Common parts account for the vast majority of the machine, and the lubrication of common parts is done well. The lubrication work of the machine can be said to be a matter of course.

(1) Rolling bearings. Ball and cylindrical roller bearings using mechanical oil, L-AN22, L-AN32, L-AN46 viscosity grade lubricants are generally available at medium, low and normal temperatures; bearings with high speed and large inner diameter are less selectable. Lubricating oils, low-speed, low-inner bearings can be used with higher viscosity lubricants. Tapered roller bearings, thrust roller bearings, due to the radial and axial loads at the same time, in the same temperature conditions, relative to the ball cylindrical roller bearings to use higher viscosity lubricant; in the normal speed, normal temperature strip Next, the oil viscosity of the tapered roller bearing is limited to the oil of L-AN32 viscosity, and the viscosity of the thrust roller bearing is limited to L-AN46 viscosity mechanical oil.

(2) Sliding bearings. The viscosity of the oil is selected in relation to the journal diameter, the placement of the shaft and the load per unit area. The viscosity is selected in the range of L-AN15}L-AN68. Bearings with high speed and large journal diameter can be used with low oil viscosity, low speed and small journal diameter, and the oil viscosity can be higher.

(3) Gear transmission. Since the actual contact stress between the gears is often too high, the engagement time of each point on the tooth surface is short, and the sliding and the rolling occur simultaneously during the meshing, so the effect of forming the liquid oil film is very weak, and the lubrication of the gear is mainly realized by the boundary oil film. The larger the gear load, the higher the viscosity of the selected oil; the higher the speed, the lower the viscosity of the selected oil; the higher the working environment temperature, the higher the viscosity of the selected oil. In general, the mechanical oil of L-AN46 viscosity can meet the lubrication requirements.

General stone enterprise lubricant costs account for a small amount of mechanical maintenance costs and product costs, but have a great impact on maintenance and production. The damage caused by poor lubrication of the equipment is serious. Especially after the damage of key equipment, the procurement period of the accessories is long, resulting in long downtime, affecting the completion of the production plan and causing significant losses to the enterprise. Therefore, the starting point for the equipment lubrication work is to ensure the normal operation of the equipment, save energy, reduce maintenance costs, and prolong the service life, which is to improve the overall economic benefits of the enterprise. In order to give full play to the effectiveness of mechanical equipment and improve the reliability of equipment use, the following work can be further done on the basis of current equipment lubrication management: First, the equipment management computer system is used to realize single-machine management, and the implementation of “oil according to technical status” "For each piece of equipment, "tailor-made" lubrication program to optimize the lubrication state of the equipment; second, the correct use of lubricants and additives, the machine does not disassemble maintenance, reduce "run, run, drip, leak , seepage phenomenon, reduce equipment maintenance costs.  

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