Industrial production scenarios are complex, and harsh environments such as dust, high temperature, humidity, and heavy loads will accelerate equipment wear and tear. Maintenance cycles and projects must be optimized based on general maintenance.
1. Dust working conditions (cement factory, coal mine, building materials factory, grinding workshop)
Core pain points: Dust easily enters sealing gaps and mixes with lubricating oil, exacerbating gear and bearing wear and blocking heat dissipation channels.
Optimization plan: ① Double the cleaning cycle: add surface dust removal once a day, and deep clean the heat sink and breathable cap every week; ② Encrypt oil quality inspection: check the oil quality every 10 days, and change the oil immediately if the oil is found to be dusty; ③ Replace seals in advance: shorten the seal replacement cycle to 3-4 months; ④ Install a dust cover: install a dust-proof device at the shaft end and breathable cap to block dust intrusion.
2. High temperature working conditions (metallurgy, forging, drying equipment supporting)
Core pain points: high ambient temperature + equipment heating during operation, resulting in a decrease in lubricating oil viscosity, accelerated aging of seals, and easy overheating of equipment.
Optimization plan: ① Use high-temperature special gear oil to adapt to high-temperature environments; ② Increase the frequency of temperature monitoring and record the box temperature every 2 hours; ③ Enhance heat dissipation: clean the heat sink regularly and install an auxiliary cooling fan if necessary; ④ Shorten the oil change cycle: the lubricating oil change cycle is shortened to 4-6 months; ⑤ Use high-temperature resistant seals to replace ordinary rubber seals.
3. Humid/acid-base working conditions (chemical industry, water treatment, outdoor equipment)
Core pain points: Water vapor and acid-base gases can easily cause corrosion of boxes and bolts, electrical components become damp, and seals corrode.
Optimization plan: ① Check the corrosion of the equipment every week, and apply anti-rust grease to the exposed bolts and shafts; ② Check the sealing integrity of the box to prevent water vapor from penetrating into the box; ③ Make the electrical terminals moisture-proof; ④ Use acid and alkali resistant seals to extend the service life of the seals; ⑤ Open the cover once a month and inspect internal components to eliminate potential corrosion risks.
4. Intermittent operating conditions (assembly lines, lifting equipment, intermittent start-stop equipment)
Core pain points: Frequent starts and stops will cause impact wear of gears and bearings. Oil is prone to deposits and seals shrink when the equipment is left standing.
Optimization plan: ① Strictly control the frequency of start and stop, with the number of starts and stops not exceeding 10 times per hour; ② If the equipment is shut down for a long time (more than 15 days), manually turn the machine 2-3 times a week to prevent local corrosion and jamming of bearings and gears; ③ Before restarting the equipment, you must check the oil level and quality, and run without load for 10 minutes before loading; ④ Apply grease to the oil seal lip regularly to prevent shrinkage and cracking.
