润滑系统的维护与管理：提高性能的方法（中英文）

润滑虽然通常被视为常规操作，但勤于维护才能发挥其重要性。SKF润滑管理开发经理 Alain Noordover强调了润滑在大幅提升效率方面的关键作用，并分享了他丰富的经验。

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.

润滑对制造业至关重要，但它却常常被忽视——如此基础的事情似乎不值得任何人花时间去关注。尽管人们都知道，如果没有润滑，机器几乎会完全停止运转。不良的润滑操作和污染约占所有滚动轴承过早失效的一半，如果考虑到工业链条等设备，这一比例甚至更高。随着时间的推移，情况几乎没有改变。虽然出现了新的润滑剂、工具，甚至一些润滑管理软件工具，但这种轻视的态度依然存在。

在环境问题（例如二氧化碳排放）成为一切的核心的今天，不适当的润滑会造成巨大的浪费，包括资金、资源、人力和环境方面的浪费。

《摩擦》杂志2017年的一项研究估计，全球20%的能源用于克服摩擦损失。虽然这在一定程度上是不可避免的——人们并非生活在一个没有摩擦的世界——但想象一下，如果使用更有效的润滑，这个数字可能会大大降低。因此，任何国家每年都会有一部分GDP用于更换磨损部件。

显然，采取有针对性的润滑管理方法有助于提高效率。正确的做法可以将润滑从目前的负债状态转变为真正的资产。

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.

连接的单点润滑器TLDD（The connected single-point lubricator TLDD.）

绩效不佳

Poor performance

正确润滑虽然有诸多潜在优势，但仍然值得思考为什么润滑管理如此糟糕。

• 这是一项脏活累活，而且并不好玩。润滑剂并非易事，涂抹润滑剂需要大量的步行和日常活动。

• 润滑在公司维护预算中只占很小一部分（通常约为10%），因此往往被忽视，或被视为成本而非机遇。

• 无论是运营层面还是管理层，都需要掌握更多润滑方面的知识和技能。

• 每个润滑点都涉及无数任务，所有这些任务都需要技能和最佳实践才能完成。

润滑仍然绩效不佳的最可能原因是上述所有因素都发挥了作用，但程度因公司而异。虽然许多人认同正确润滑的重要性，但执行力度往往不足。润滑不应被视为一组独立的任务，而应被视为一种生命过程，并应这样对待。

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.

出现问题

When things go wrong

展示润滑不良影响的最佳方式是结合实际案例。

在一个水泥行业的案例中，最终用户发现昂贵的调心滚子轴承 (SRB) 反复出现故障。深入研究后发现，润滑管理方案的不同部分使用了四种不同的润滑剂。错误的润滑剂（粘度仅为所需粘度的二十分之一）被添加到轴承中。金属与金属之间的接触导致了轴承过早失效。总而言之，润滑管理中各个环节的不当处理导致了灾难性的故障。

第二个例子涉及食品和饮料 (F&B) 行业的压盐机。在这里，一个老式的润滑系统将润滑脂分配到中大型SRB中，然后润滑脂泄漏到最终产品中。该润滑脂本应获得食品和饮料 (F&B) 认证，但实际上并未获得认证。此外，轴承还受到了盐分的侵蚀，因此必须每两周清洁一次。

以上只是两个例子，但还有很多，可能在网站上也有类似的案例。他们表明，“小”润滑问题可能会导致高成本、生产损失和额外工作，所有这些都会影响任何公司的收入和利润。

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.

从手动工具到自动润滑系统的润滑剂应用

（Lubricant application from manual tools to automatic lubrication systems.）

润滑管理

Lubrication management

润滑管理可以最大限度地减少资金、资源和时间的浪费，改善健康状况，并通过降低二氧化碳排放和材料释放来减少对环境的影响。润滑管理也有正式的定义：

“合理组织资源，有效提高可靠性，减少低效和成本，并提高安全性和环保合规性。”

SKF润滑剂生命周期模型可用于帮助直观地了解润滑管理的七个不同部分：

• 选择：选择合适的产品。这可能是一个微妙的过程，但像 SKF LubeSelect这样的工具可以通过结合真实的轴承性能来提供帮助。

• 采购：选择少数几家提供稳定产品质量的可靠供应商。

• 储存：将不太可能立即使用的润滑剂储存在合适的温度和湿度下，并避免其暴露于污染物中。

• 转移：对工具和润滑点进行颜色编码，以避免交叉污染等因素。当然，拥有清洁的工具也很重要。

• 应用：定期检查润滑剂的用量和补充润滑间隔，无论润滑剂是手动涂抹还是通过自动化系统涂抹。

• 监控：分析油或润滑剂的使用情况，以了解润滑剂是否发挥应有的作用。

• 修复/处置：正确处置润滑剂。像SKF RecondOil这样的系统允许油循环，但润滑剂通常会被更换，因此需要处置。

此后，循环闭合，又回到了润滑剂的选择问题。

水泥厂和盐压机的案例都通过应用润滑管理得到了解决。在水泥厂，答案是常识性的。通过记录流程，克服了系统中的主要故障——润滑剂使用不当。对于盐压机，正确的润滑剂选择和使用、适当的密封以及通过振动和油脂分析对资产的监控有助于解决问题。

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润滑管理模型。（The SKF Lubrication Management Model.）

全局规划

Fuller picture

这描述了润滑剂的生命周期，但完整的润滑管理模型包含四个更关键的部分：规划与调度、流程、培训与个人发展以及管理和关键绩效指标 (KPI)。将这些部分结合起来，可以更全面地了解润滑管理。

规划与调度

工厂中必须完成许多任务。首先，必须确定任务是否设计正确：是否在正确的时间以正确的方式将正确的润滑剂、正确的用量、正确的方法输送到正确的润滑点？如果没有，是否可以移除或更换？其次，如何安排任务以使工作量保持可控？专用润滑管理软件可以提供帮助。

流程

为了确保工作的一致性，必须制定流程并向所有人开放。数字文档易于更新，并且可以远程访问。通常，技术人员会根据自己的知识开展工作，无论这种做法是好是坏。另一个问题是，当熟练的技术人员退休或离职时，信息会丢失。

培训与个人发展

如果不关注润滑人员，前面几点就毫无意义。润滑工作应被视为一项技术性工作，并应予以重视，并制定培训和发展计划。用积极主动、解决问题的工作取代日常琐事，能让工作更具挑战性。有时，将润滑任务外包也是可行的。

管理与关键绩效指标 (KPI)

最后，必须衡量哪些指标才能确定是否朝着正确的方向前进？为此，必须设定周到且务实的关键绩效指标 (KPI)。润滑管理软件可以帮助监控和可视化关键信息。典型的目标可能是提高润滑执行效率、减少计划外任务的数量或在不损坏机器的情况下降低油耗。所有这些都可以跟踪和衡量。

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.

参考模型

Using the model

润滑管理包含诸多要素，涵盖摩擦学、过滤、油液分析和管理，看似复杂，实则令人望而生畏。然而，通过以下简单实用的措施，只需循序渐进，即可取得显著成效。

• 评估现状

工厂表现如何？如果需要采取行动，润滑审计可以提供帮助，例如使用SKF客户需求分析等工具，评估并设定有效润滑管理的基准。或者，个人也可以使用在线自我评估工具，例如 SKF QLR（快速润滑评估），来评估自身的润滑实践。

• 构建商业案例

利用已知问题并尝试为其定价。使用文献或润滑审计结果来评估正确润滑的积极影响。

• 培养员工技能

引导员工从“推油”转向主动解决问题。如果实现润滑自动化，技术人员就可以将更多时间用于检查机器。

• 遵循最佳实践

将此应用于润滑剂管理的各个环节，并制定切实可行的活动计划。这听起来令人望而生畏，但不妨将其想象成烹饪一顿家庭大餐。目标是在做出各种选择、采购和其他决策之后，最终将一顿丰盛的晚餐摆上餐桌。

• 设定目标

一个可能的目标是将与润滑相关的轴承故障减少一定数量。巧妙的润滑管理也会产生连锁反应：润滑剂通常占维护预算的2%到3%，但润滑错误可能会影响 40% 的预算（例如备件和人工）。

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).

结论

Conclusion

实现这些改变需要转变态度，并树立润滑管理的理念——承认行动是提高效率的必要条件。

第一步，也是最重要的一步，是提高认识。这可以通过开展宣传活动、走访或培训来实现。这样，每个人都能相互理解，并进行平等沟通。下一步是清理混乱局面，但目前为止，这个问题已经得到承认并可以采取行动。首先要解决一些显而易见的问题，例如储藏室，因为这能表明问题正在得到重视。

润滑需要进入一个新时代，而这要归功于行业知识、新设备、数字化、人工智能和再循环技术。最终，润滑管理将有助于减少资源和能源的消耗，同时保持生活水平。

没有神奇的解决方案，也不会一蹴而就，但承认问题并致力于解决它是每个人都可以做到的。

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.

什么是润滑？它是如何工作的？

What is lubrication – and how does it work?

简而言之，润滑通过在表面之间注入润滑剂来避免金属间的接触，从而减少表面的摩擦和磨损。润滑剂可以是固体（例如石墨）、液体（油）、半固体（油脂）或气体（空气）。每种润滑剂都有特定的粘度（流动阻力），结合配合表面的相对速度、载荷以及由部件几何形状产生的楔形，会形成一层薄薄的润滑膜。

润滑膜通常为微米或亚微米级，人眼通常无法察觉。油和脂是当今最重要的润滑剂。可以添加添加剂来增加或减少某些特性，例如极压、抗磨损和抗氧化。对于脂，增稠剂可以使油保持粘稠，并赋予润滑剂一定的稠度，使其能够保持在原位。

从火车到吸尘器，社会中移动的大多数东西，都是依靠轴承、链条和其他机器部件之间的微米厚的润滑膜才能运行的。

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.