World economic development is inseparable from industrial manufacturing, manufacturing cost control is difficult due to the increasingly competitive business environment. Multinational corporations moved their production bases gradually to the underdeveloped areas, it is difficult to sustain the cost reduction on the labor and raw material costs. Modern enterprises get more profit from the management and integrated utilization.
For businesses, the most important task is to smooth production process and decrease the overall costs. Industrial Maintenance has markedly effective performance in factory production especially the manufacturing plants depend on the production output rate as their profit base. Shutdown and production overload is the production life security line which cannot be underestimated.
· Lubrication maintenance · Anti-corrosion and Anti-rust · Cleaning maintenance · Adhesive maintenance · Sealing Maintenance
· Gear · Bearing · Chain · Bolt · Rope
What might happen to the gear?
Broken teeth, missing teeth
Unqualified materials or long-term wear of the gear might cause cracking of the tooth surface, and sudden overload may cause the gear to break and fail.
Tooth surface pitting, missing
The initial sign of pitting is fatigue cracking. As these cracks expand and connect, eventually the tooth surface metal material will fall off, forming initial pitting corrosion, and it may continue to develop into expanding pitting, chipping or flaking.
Gearbox greasy dirt, acidification
The long-term high temperature in the gear box causes coking and accumulation of metal wear debris on the tooth surface and bearings, and the erosion of water and oxygen causes lubricant acidification and fouling in the gear box.
Gear deformation, irregular vibration
The plastic deformation of the gear teeth is a deformation that cannot be recovered after the applied load is removed, and this is due to the overload on the gear teeth.
What will happen to the bearings?
Rolling element pitting, missing
Due to long-term inactivity and wear-caused fatigue, rolling elements start to have pitting, material flaking and material missing.
Broken bearing might be caused by substandard materials, low temperature embrittlement or heavy load.
Poor lubrication, burnout
In the case of poor or no lubrication, a small load or speed can cause the bearing to burn out.
Outer ring wear, abnormal noise
Poor installation, excessive load, improper clearance, or poor lubrication may cause wear of the outer ring and create abnormal noises during operation.
What will happen to the chain?
Wear, chain break
In addition to wear and poor design and installation, the other reason is that the improper lubricant causes the chain to have a large operation resistance, and even causes the chain to get stuck and cause stress fracture.
Poor lubrication, pitting
In the case of insufficient or inappropriate lubricants, it is difficult to form a complete lubricant film between the contact surface of the pin and the sleeve when high speeds or heavy loads occur, and direct contact between metals causes pitting or binding.
Rusting, sprocket wear
External rusting and corrosion are also important reasons for chain damage.
Broken teeth on the sprocket
The plastic deformation of the gear teeth is a deformation that cannot be recovered after the applied load is removed, and this is caused by the overload on the gear teeth.
What will happen to the bolts?
Stuck and interlocking bolts
High temperature, heavy load or other severe working conditions will cause the screw pair to interlock, and they cannot be loosened due to tight fitting with each other.
Rusting and reduced strength
Water leaching, oxidation and chemical environment will constantly rust the bolts and the loosening and falling-off of the surface material will reduce the fastening strength.
Breakage during fastening or loosening
When the bolts are in low quality, and the breakage might occur due to excessive preload during fastening and loosening. In fact, more fractures are caused by excessive torque after the bolts become loose.
Insufficient strength, frequent loosening, abrasion, and poor thread accuracy can cause bolts to slip and lose tightness, leaving hidden safety hazards and requiring immediate replacement.
What will happen to the wire rope?
Corrosion, reduced strength
Corrosion can be caused by lack of lubricant, high temperature, weather erosion or other external damages which resulted in a reduced rupture force of the wire rope. It’s also difficult to determine how big the rupture force is.
Deformed hemp core, formation of a so-called “bird cage”
This deformation occurs when the outer strands become disjointed or become longer than the inner strands. Distorted wire ropes should be discarded immediately.
Twisted, fold-led broken
Kinking is a kind of deformation caused by the steel wire rope being tightened in a loop without being able to rotate around its axis. As a result, uneven lay length occurs, and extra wear is caused. In severe cases, the wire rope is twisted. Severely kinked wire ropes should be discarded immediately.
Broken strands, broken wires
A small number of broken wires at the end of the rope or its attachment indicates a high stress at that location. When the number of broken wires exceeds a certain level, change them. If the entire strand breaks, the rope should be scrapped.