Analysis of Common Misunderstandings in Lubrication of Mining Machinery and Suggestions for Avoidance

The lubrication management of mining machinery is of vital importance for equipment lifespan, operational efficiency, and safe production. However, in actual operations, improper lubrication often occurs due to cognitive biases, leading to equipment failures. The following, based on the special working conditions of mining machinery, discusses the key misunderstandings in lubrication and the scientific solutions to them.

I.Misunderstandings about the Purpose and Foundation of Lubrication

Misunderstanding 1: Lubrication is only for improving equipment operating speed

The core purpose of lubrication is to reduce friction and wear, cool down, absorb vibration and shock, and prevent rust and seal, rather than simply pursuing "faster operation". According to statistics, one-third of the world's energy consumption comes from friction loss. Reasonable lubrication can significantly extend equipment lifespan and reduce energy consumption.

Misunderstanding 2: All lubricants can be used interchangeably

Mining machinery operates under harsh conditions ,such as high dust, large temperature differences, and heavy loads, and requires strict lubricant performance standards ,such as heat stability, oxidation resistance, anti-emulsification, and fire resistance (for underground equipment, anti-fire fluids must be used). Random mixing or substitution will lead to lubrication failure and even safety accidents.

II.Misunderstandings in Lubricant Selection and Dosage Control

Misunderstanding 3: More lubricant is always better

Excessive lubrication can backfire: excessive grease lubrication causes increased resistance in bearings, overheating, and oil leakage; in oil lubrication, the depth of immersion of the high-speed gears in the gearbox should be 1-2 teeth high, and the filling amount of rolling bearing lubricating grease should not exceed one-third to one-half of the void space, otherwise, due to increased stirring resistance, the oil temperature will rise and energy consumption will increase.

Misunderstanding 4: The higher the viscosity, the better the lubrication effect

Viscosity needs to match the equipment working conditions: high-viscosity oil has a thick oil film but poor low-temperature fluidity and high power loss; low-viscosity oil can reduce energy consumption (a 1 mm²/s reduction in viscosity can save 15% fuel). Mining machinery needs to balance high and low temperature stability to avoid lubrication film failure or startup difficulties due to inappropriate viscosity.

Misunderstanding 5: Strictly follow the oil usage instructions and no need for adjustment

The oil usage instructions are only for "general conditions". The actual environment of mining ,such as dust, temperature differences, heavy loads, may require adjustments: for example, open-air equipment requires higher temperature-resistant oil, and corrosive environments require enhanced anti-rust additives in the lubricating oil.

III.Misunderstandings in Lubricant Replacement and Maintenance

Misunderstanding 6: Once the lubricating oil turns black, it needs to be replaced

The blackening of lubricant with anti-foaming and dispersing agents is usually normal (forming a dark protective oil film), and it should be determined whether it has deteriorated through oil sample testing ,such as viscosity, moisture, and impurity content, rather than just relying on appearance.

Misunderstanding 7: Waste oil must be directly discarded

Except for spoiled and deteriorated waste oil, only impure waste oil can be filtered and reused; heavily contaminated oil can be treated and used for rust prevention or lubrication of low-demand equipment; waste oil that is difficult to regenerate can be recycled as fuel oil to avoid resource waste.

 IV. Key Points of Lubrication in Special Working Conditions of Mining Machinery

Environmental adaptability: Select lubricants with anti-pollution,anti-emulsification, and strong rust prevention properties to cope with dust, moisture, and corrosive media.

Component differentiation: Gearboxes, bearings, and hydraulic systems require dedicated oils ,such as gear oil for extreme pressure and anti-wear properties, and hydraulic oil for viscosity stability, and they must not be mixed.

Regular monitoring: Through oil analysis (ferrography, spectroscopy testing), monitor the oil quality in real time to avoid lubrication failure due to long-term non-replacement.

Summary
Lubrication of mining machinery should avoid operating solely based on experience and should be scientifically selected, controlled, and maintained based on working conditions. Through standardized management, achieve the goal of "cost reduction and efficiency increase, extended lifespan". Regular lubrication training and the establishment of oil monitoring mechanisms are key to avoiding misunderstandings and ensuring the safe operation of equipment.