# Research on the Design of an On-Line Lubrication System for Wire Ropes

## TL;DR

This paper introduces an intelligent lubrication system for wire ropes that improves lubrication efficiency and reduces maintenance costs using advanced grease and control technologies.

## Contribution

The novel system combines high-adhesion grease with real-time feedback and adaptive control for improved wire rope lubrication.

## Key findings

- The specialty grease reduced friction by 46.7% and wear by 33.3% compared to conventional lubricants.
- The system achieved full lubrication coverage on a 20 m wire rope in 60 seconds with a uniform layer of 0.3–1.0 mm thickness.
- Optimal heating at 50 °C and dual closed-loop control improved system performance and reliability.

## Abstract

This study presents an on-line intelligent lubrication system utilizing specialty grease to address lubricant loss and uneven coating issues in traditional methods. Characterized by scanning electron microscopy (SEM) and Fourier transform infrared spectroscopy (FT-IR), the specialty grease demonstrates superior tribological performance, achieving a 46.7% reduction in the average friction coefficient and 33.3% smaller wear scar diameter under a 392 N load compared to conventional lubricants. The system features an automatic control vehicle design integrating heating, grease supply, lubrication-scraping mechanisms, and a dual closed-loop intelligent control system combining PID-based temperature regulation with machine vision. Experiments identified 50 °C as the optimal heating temperature. Kinematic modeling and grease consumption analysis guided greasing parameters optimization, validated through simulations and practical tests. Evaluated on a 20 m long, 36.5 mm diameter wire rope, the system achieved full coverage within 60 s, forming a uniform lubricant layer of 0.3–1.0 mm thickness (±0.15 mm deviation). It realizes the innovative application of high-adhesion lubricating grease, adaptive process control, and real-time thickness feedback technology, significantly improving the lubrication effect, reducing maintenance costs, and extending the lifespan of the wire rope. This provides intelligent lubrication technology support for the reliable operation of wire ropes in industrial fields.