潤滑系統(tǒng)的維護與管理：提高性能的方法（中英文）
潤滑雖然通常被視為常規(guī)操作，但勤于維護才能發(fā)揮其重要性。SKF潤滑管理開發(fā)經(jīng)理 Alain Noordover強調(diào)了潤滑在大幅提升效率方面的關鍵作用，并分享了他豐富的經(jīng)驗。
Lubrication, though often viewed as routine, gains importance with diligence. Alain Noordover, SKF lubrication management development manager, stresses its pivotal role for substantial efficiency gains, sharing insights from his extensive experience.
潤滑對制造業(yè)至關重要，但它卻常常被忽視——如此基礎的事情似乎不值得任何人花時間去關注。盡管人們都知道，如果沒有潤滑，機器幾乎會完全停止運轉(zhuǎn)。不良的潤滑操作和污染約占所有滾動軸承過早失效的一半，如果考慮到工業(yè)鏈條等設備，這一比例甚至更高。隨著時間的推移，情況幾乎沒有改變。雖然出現(xiàn)了新的潤滑劑、工具，甚至一些潤滑管理軟件工具，但這種輕視的態(tài)度依然存在。
在環(huán)境問題（例如二氧化碳排放）成為一切的核心的今天，不適當?shù)臐櫥瑫斐删薮蟮睦速M，包括資金、資源、人力和環(huán)境方面的浪費。
《摩擦》雜志2017年的一項研究估計，全球20%的能源用于克服摩擦損失。雖然這在一定程度上是不可避免的——人們并非生活在一個沒有摩擦的世界——但想象一下，如果使用更有效的潤滑，這個數(shù)字可能會大大降低。因此，任何國家每年都會有一部分GDP用于更換磨損部件。
顯然，采取有針對性的潤滑管理方法有助于提高效率。正確的做法可以將潤滑從目前的負債狀態(tài)轉(zhuǎn)變?yōu)檎嬲馁Y產(chǎn)。
Lubrication is critical to manufacturing, yet it is often treated as an afterthought – something so basic that it seems unworthy of anybody’s time. This is despite knowing that without lubrication, machinery can quite literally grind to a halt. Poor lubrication practices and contamination account for around half of all premature rolling bearing failures, and even more if we consider equipment such as industrial chains. Over time, very little has changed. While there are new lubricants, tools and even some lubrication management software tools, this dismissive approach remains.
Inappropriate lubrication can lead to huge waste, in terms of both capital and resources and humans and the environment, at a time when environmental concerns (such as CO2 emissions) are at the core of everything.
A study from 2017 in the journal Friction estimated that 20 percent of the world’s energy is used to overcome friction losses. While partly inevitable – we don’t live in a frictionless world – imagine how this figure might be reduced with more effective lubrication. It follows that every year a portion of any country’s GDP will be expended on replacing worn parts.
It is clear that a targeted approach in the form of lubrication management can help raise efficiency. By doing this correctly, lubrication can be transformed from its current status as a kind of liability into a true asset.
連接的單點潤滑器TLDD（The connected single-point lubricator TLDD.）
績效不佳
Poor performance
正確潤滑雖然有諸多潛在優(yōu)勢，但仍然值得思考為什么潤滑管理如此糟糕。
? 這是一項臟活累活，而且并不好玩。潤滑劑并非易事，涂抹潤滑劑需要大量的步行和日?；顒?。
? 潤滑在公司維護預算中只占很小一部分（通常約為10%），因此往往被忽視，或被視為成本而非機遇。
? 無論是運營層面還是管理層，都需要掌握更多潤滑方面的知識和技能。
? 每個潤滑點都涉及無數(shù)任務，所有這些任務都需要技能和最佳實踐才能完成。
潤滑仍然績效不佳的最可能原因是上述所有因素都發(fā)揮了作用，但程度因公司而異。雖然許多人認同正確潤滑的重要性，但執(zhí)行力度往往不足。潤滑不應被視為一組獨立的任務，而應被視為一種生命過程，并應這樣對待。
With all these potential upsides to correct lubrication, it is worth considering some of the reasons why it is widely managed so poorly.
? It’s a dirty job that’s not much fun. Lubricants are not the nicest materials to handle, and applying them involves lots of walking and routine activities.
? Lubrication forms a small part (usually around 10 percent) of a firm’s maintenance budget so it tends to be neglected or seen as a cost rather than an opportunity.
? There is a need for more knowledge and skills, at both the operational and management levels, when it comes to lubrication.
? It involves countless tasks at each lubrication point, which all need skills and best practices to be accomplished.
The most likely reason why lubrication is still performed poorly is that all the above play a role, in degrees that vary from company to company. While many would agree on the significance of proper lubrication, the execution often falls short. Lubrication should not be seen as a set of dissociated tasks but more as a kind of living process, and it should be treated as such.
出現(xiàn)問題
When things go wrong
展示潤滑不良影響的最佳方式是結合實際案例。
在一個水泥行業(yè)的案例中，最終用戶發(fā)現(xiàn)昂貴的調(diào)心滾子軸承 (SRB) 反復出現(xiàn)故障。深入研究后發(fā)現(xiàn)，潤滑管理方案的不同部分使用了四種不同的潤滑劑。錯誤的潤滑劑（粘度僅為所需粘度的二十分之一）被添加到軸承中。金屬與金屬之間的接觸導致了軸承過早失效?？偠灾?，潤滑管理中各個環(huán)節(jié)的不當處理導致了災難性的故障。
第二個例子涉及食品和飲料 (F&B) 行業(yè)的壓鹽機。在這里，一個老式的潤滑系統(tǒng)將潤滑脂分配到中大型SRB中，然后潤滑脂泄漏到最終產(chǎn)品中。該潤滑脂本應獲得食品和飲料 (F&B) 認證，但實際上并未獲得認證。此外，軸承還受到了鹽分的侵蝕，因此必須每兩周清潔一次。
以上只是兩個例子，但還有很多，可能在網(wǎng)站上也有類似的案例。他們表明，“小”潤滑問題可能會導致高成本、生產(chǎn)損失和額外工作，所有這些都會影響任何公司的收入和利潤。
The best way to show the effects of poor lubrication is with actual examples.
In one case, in the cement industry, the end user saw repeated failure of expensive spherical roller bearings (SRBs). Looking deeper, four different lubricant names were attributed to the different parts of the lubrication management programme. The wrong lubricant, with one-twentieth the necessary viscosity, was being added to the bearing. Metal-to-metal contact then led to premature failure. Overall, different aspects of lubrication management that were not addressed properly led to catastrophic failure.
A second example involved a salt press in the food and beverage (F&B) industry. Here, a vintage lubrication system dispensed grease into medium-large SRBs and this then leaked into the final product. The grease should have been F&B approved, but it was not. There was also salt ingress into the bearings, so they had to be cleaned every two weeks.
These are two examples, but there are many more, possibly on your own site. They show that “small” lubrication issues can lead to high costs, lost production and extra work, all of which affect the top and bottom lines of any company.
從手動工具到自動潤滑系統(tǒng)的潤滑劑應用
（Lubricant application from manual tools to automatic lubrication systems.）
潤滑管理
Lubrication management
潤滑管理可以最大限度地減少資金、資源和時間的浪費，改善健康狀況，并通過降低二氧化碳排放和材料釋放來減少對環(huán)境的影響。潤滑管理也有正式的定義：
“合理組織資源，有效提高可靠性，減少低效和成本，并提高安全性和環(huán)保合規(guī)性?！?/p>
SKF潤滑劑生命周期模型可用于幫助直觀地了解潤滑管理的七個不同部分：
? 選擇：選擇合適的產(chǎn)品。這可能是一個微妙的過程，但像 SKF LubeSelect這樣的工具可以通過結合真實的軸承性能來提供幫助。
? 采購：選擇少數(shù)幾家提供穩(wěn)定產(chǎn)品質(zhì)量的可靠供應商。
? 儲存：將不太可能立即使用的潤滑劑儲存在合適的溫度和濕度下，并避免其暴露于污染物中。
? 轉(zhuǎn)移：對工具和潤滑點進行顏色編碼，以避免交叉污染等因素。當然，擁有清潔的工具也很重要。
? 應用：定期檢查潤滑劑的用量和補充潤滑間隔，無論潤滑劑是手動涂抹還是通過自動化系統(tǒng)涂抹。
? 監(jiān)控：分析油或潤滑劑的使用情況，以了解潤滑劑是否發(fā)揮應有的作用。
? 修復/處置：正確處置潤滑劑。像SKF RecondOil這樣的系統(tǒng)允許油循環(huán)，但潤滑劑通常會被更換，因此需要處置。
此后，循環(huán)閉合，又回到了潤滑劑的選擇問題。
水泥廠和鹽壓機的案例都通過應用潤滑管理得到了解決。在水泥廠，答案是常識性的。通過記錄流程，克服了系統(tǒng)中的主要故障——潤滑劑使用不當。對于鹽壓機，正確的潤滑劑選擇和使用、適當?shù)拿芊庖约巴ㄟ^振動和油脂分析對資產(chǎn)的監(jiān)控有助于解決問題。
Lubrication management can minimize the waste of capital, resources and time, improve health and reduce environmental impact through lower CO2 emissions and material release. There is also a formal definition of lubrication management:
“The proper organization of resources to effectively and efficiently improve reliability, reduce inefficiencies and costs and increase safety and environmental compliance.”
The SKF lubricant life-cycle model can be used to help visualize the seven different parts of lubrication management:
? Selection: choosing the right product. This can be a delicate process, but tools such as SKF’s LubeSelect can help by incorporating real bearing performance.
? Purchase: choosing a small number of reliable vendors that offer consistent product quality.
? Storage: storing lubricants that are not likely to be used immediately at the right temperature and humidity, and avoiding exposing them to contaminants.
? Transfer: colour-coding tools and lubrication points, to avoid factors such as cross-contamination. Having clean tools is of course also important.
? Application: checking quantities and relubrication intervals regularly, whether the lubricant is applied to assets manually or via an automated system.
? Monitoring: analysing oil or lubricant use to understand if a lubricant is performing as it should.
? Recondition/disposal: disposing of lubricant correctly. A system such as SKF RecondOil allows recirculation of oil, but lubricant is typically replaced, and thus disposal is necessary.
After this, the loop is closed and we are back at lubricant selection.
Both the cement works and the salt press cases were solved by applying lubrication management. At the cement works, the answer was common sense. By documenting the process we overcame the main failure in the system, that of using the wrong lubricant. For the salt press, correct lubricant selection and application, proper sealing and monitoring of the asset via vibration and grease analysis helped to solve the problem.
SKF潤滑管理模型。（The SKF Lubrication Management Model.）
全局規(guī)劃
Fuller picture
這描述了潤滑劑的生命周期，但完整的潤滑管理模型包含四個更關鍵的部分：規(guī)劃與調(diào)度、流程、培訓與個人發(fā)展以及管理和關鍵績效指標 (KPI)。將這些部分結合起來，可以更全面地了解潤滑管理。
規(guī)劃與調(diào)度
工廠中必須完成許多任務。首先，必須確定任務是否設計正確：是否在正確的時間以正確的方式將正確的潤滑劑、正確的用量、正確的方法輸送到正確的潤滑點？如果沒有，是否可以移除或更換？其次，如何安排任務以使工作量保持可控？專用潤滑管理軟件可以提供幫助。
流程
為了確保工作的一致性，必須制定流程并向所有人開放。數(shù)字文檔易于更新，并且可以遠程訪問。通常，技術人員會根據(jù)自己的知識開展工作，無論這種做法是好是壞。另一個問題是，當熟練的技術人員退休或離職時，信息會丟失。
培訓與個人發(fā)展
如果不關注潤滑人員，前面幾點就毫無意義。潤滑工作應被視為一項技術性工作，并應予以重視，并制定培訓和發(fā)展計劃。用積極主動、解決問題的工作取代日?，嵤?，能讓工作更具挑戰(zhàn)性。有時，將潤滑任務外包也是可行的。
管理與關鍵績效指標 (KPI)
最后，必須衡量哪些指標才能確定是否朝著正確的方向前進？為此，必須設定周到且務實的關鍵績效指標 (KPI)。潤滑管理軟件可以幫助監(jiān)控和可視化關鍵信息。典型的目標可能是提高潤滑執(zhí)行效率、減少計劃外任務的數(shù)量或在不損壞機器的情況下降低油耗。所有這些都可以跟蹤和衡量。
This describes the lubricant life cycle, but the full lubrication management model has four more crucial parts: planning & scheduling, procedures, training and personal development, and management and KPIs. Putting these together provides a fuller picture of lubrication management.
Planning & scheduling
Many tasks must be accomplished in a plant. First we must ascertain whether the right tasks are designed: do we have the right lubricant, in the right amount, using the right method, at the right time, to the right lubrication point? If not, could they be removed or replaced? Second, how do we schedule tasks so the workload stays manageable? Dedicated lubrication management software can help here.
Procedures
To ensure job consistency, procedures must be developed and made available to all. Digital documentation is easy to update and is accessible remotely. Usually, technicians carry out activities based on their own knowledge, whether this is good or bad. Another issue is loss of information when skilled technicians retire or leave.
Training & personal development
The earlier points mean little without looking at the people who carry out lubrication. It should be seen as a skilled job and treated as such, with training and development plans. Replacing routine, mundane tasks with proactive, problem-solving work makes a job more stimulating. Sometimes, outsourcing lubrication tasks can be appropriate.
Management & KPIs
Lastly, what must we measure to know we are heading in the right direction? For this, we must set up thoughtful and pragmatic KPIs. Lubrication management software can help monitor and visualize critical information. Typical goals might be to improve efficiency of lubrication execution, to reduce the number of unplanned tasks or to cut oil consumption without hurting the machine. All of these can be tracked and measured.
參考模型
Using the model
潤滑管理包含諸多要素，涵蓋摩擦學、過濾、油液分析和管理，看似復雜，實則令人望而生畏。然而，通過以下簡單實用的措施，只需循序漸進，即可取得顯著成效。
? 評估現(xiàn)狀
工廠表現(xiàn)如何？如果需要采取行動，潤滑審計可以提供幫助，例如使用SKF客戶需求分析等工具，評估并設定有效潤滑管理的基準?；蛘?，個人也可以使用在線自我評估工具，例如 SKF QLR（快速潤滑評估），來評估自身的潤滑實踐。
? 構建商業(yè)案例
利用已知問題并嘗試為其定價。使用文獻或潤滑審計結果來評估正確潤滑的積極影響。
? 培養(yǎng)員工技能
引導員工從“推油”轉(zhuǎn)向主動解決問題。如果實現(xiàn)潤滑自動化，技術人員就可以將更多時間用于檢查機器。
? 遵循最佳實踐
將此應用于潤滑劑管理的各個環(huán)節(jié)，并制定切實可行的活動計劃。這聽起來令人望而生畏，但不妨將其想象成烹飪一頓家庭大餐。目標是在做出各種選擇、采購和其他決策之后，最終將一頓豐盛的晚餐擺上餐桌。
? 設定目標
一個可能的目標是將與潤滑相關的軸承故障減少一定數(shù)量。巧妙的潤滑管理也會產(chǎn)生連鎖反應：潤滑劑通常占維護預算的2%到3%，但潤滑錯誤可能會影響 40% 的預算（例如備件和人工）。
Lubrication management comprises many elements, encompassing tribology, filtration, oil analysis and management, and it may appear overwhelming. However, significant improvements can be made in small steps with simple, pragmatic actions such as the ones below.
? Assess the situation
How does your plant measure up? If action is required, a lubrication audit can help by employing tools, such as the SKF Client Needs Analysis, that and set benchmarks for effective lubrication management. Alternatively, individuals can use online self-assessment tools, such as the SKF QLR (Quick Lubrication Review), to their own lubrication practices.
? Build a business case
Use known issues and try to put a price tag on them. Use literature or the results from a lubrication audit to estimate the positive impact of proper lubrication.
? Develop people’s skills
Move people away from “pushing grease” and towards proactive, problem-solving tasks. If relubrication is automated, technicians can spend more time inspecting machines.
? Follow best practice
Apply this in all parts of lubricant management and devise a pragmatic activity plan. It sounds daunting, but think of it like cooking a family meal. The aim is to end up with a meal on the table, having made various selections, purchases and other decisions.
? Set targets
One possible target might be to cut lubrication-related bearing failures by a set amount. Clever lubrication management can also have knock-on effects: Lubricants are often 2 to 3 percent of a maintenance budget, but lubrication errors can influence 40 percent of the budget (such as spare parts and labour).
結論
Conclusion
實現(xiàn)這些改變需要轉(zhuǎn)變態(tài)度，并樹立潤滑管理的理念——承認行動是提高效率的必要條件。
第一步，也是最重要的一步，是提高認識。這可以通過開展宣傳活動、走訪或培訓來實現(xiàn)。這樣，每個人都能相互理解，并進行平等溝通。下一步是清理混亂局面，但目前為止，這個問題已經(jīng)得到承認并可以采取行動。首先要解決一些顯而易見的問題，例如儲藏室，因為這能表明問題正在得到重視。
潤滑需要進入一個新時代，而這要歸功于行業(yè)知識、新設備、數(shù)字化、人工智能和再循環(huán)技術。最終，潤滑管理將有助于減少資源和能源的消耗，同時保持生活水平。
沒有神奇的解決方案，也不會一蹴而就，但承認問題并致力于解決它是每個人都可以做到的。
Making these changes requires a change of attitude and adopting a lubrication management mindset – accepting that action is needed in order to raise efficiency.
The first step, and the most important one, is awareness. This can be achieved with an awareness campaign, a visit or training. Everybody gains mutual understanding and can communicate equally. The next step is to clean up the mess, but by now it has been acknowledged and can be acted on. Start by addressing visible problems, such as the storage room, as this sends a signal that the problem is being taken seriously.
Lubrication needs to enter a new era, and it can do this thanks to industry knowledge, new devices, digitalization, artificial intelligence and reconditioning. Ultimately, lubrication management will help reduce consumption of resources and energy while maintaining our standard of living.
There is no magic solution, and it will not be solved overnight, but accepting the problem and making a commitment to solve it is within everybody’s reach.
什么是潤滑？它是如何工作的？
What is lubrication – and how does it work?
簡而言之，潤滑通過在表面之間注入潤滑劑來避免金屬間的接觸，從而減少表面的摩擦和磨損。潤滑劑可以是固體（例如石墨）、液體（油）、半固體（油脂）或氣體（空氣）。每種潤滑劑都有特定的粘度（流動阻力），結合配合表面的相對速度、載荷以及由部件幾何形狀產(chǎn)生的楔形，會形成一層薄薄的潤滑膜。
潤滑膜通常為微米或亞微米級，人眼通常無法察覺。油和脂是當今最重要的潤滑劑?？梢蕴砑犹砑觿﹣碓黾踊驕p少某些特性，例如極壓、抗磨損和抗氧化。對于脂，增稠劑可以使油保持粘稠，并賦予潤滑劑一定的稠度，使其能夠保持在原位。
從火車到吸塵器，社會中移動的大多數(shù)東西，都是依靠軸承、鏈條和其他機器部件之間的微米厚的潤滑膜才能運行的。
In simple terms, lubrication reduces friction and wear of surfaces by avoiding metal-to-metal contact by placing lubricant between the surfaces. A lubricant can be solid (such as graphite), liquid (oil), semi-solid (grease) or gas (air). Each has a specific viscosity (resistance to flow) that, combined with the relative speed of the mating surfaces, the load and the wedge created by the geometry of the components, will create a thin lubricant film.
The lubricant film is typically in the order of microns or sub-microns that the human eye cannot usually detect. Oils and greases are the most important lubricants used today. Additives can be incorporated into them to add, or remove, certain properties, such as extreme pressure, anti-wear and anti-oxidant. For greases, a thickening agent holds the oil together and gives the lubricant a consistency that enables it to stay in place.
Most things that move within our society, from trains to vacuum cleaners, only operate thanks to a micron-thick lubricant film between bearings, chains and other machine components.
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