In a large-scale road project in Qatar, I witnessed an astonishing contrast: using the same brand of diamond blades, the blade life of my cutting machine reached 3,100 meters, while that of the competitor's equipment was only 900 meters. This 3.4-fold difference was not accidental; it was the direct result of my meticulous maintenance management of the entire cutting system.
The precision control of my blade installation started with the tightening torque. I used German-made torque wrenches and strictly followed the graded tightening method: first pre-tightening with 50Nm, then final tightening with 120Nm, and finally verifying with 150Nm. I had seen too many blades due to improper installation causing deflection, which was an invisible 0.1 millimeter deviation that would shorten the blade life by 60%. I designed a special flange with scale indication to ensure the blade was absolutely perpendicular to the main shaft.
The scientific management of cooling water is the key to extending the blade life. I insisted on using softened water with a hardness of less than 50 ppm. On the desert construction site in Egypt, the local water hardness exceeded 400 ppm. I configured a mobile water treatment equipment. I also strictly controlled the water temperature, maintaining it between 15-25 degrees through a circulating cooling system. My intelligent system could automatically adjust the water flow based on the cutting depth and material hardness, increasing it to 20 liters per minute when cutting reinforced concrete and reducing it to 12 liters when cutting asphalt. This precise control kept the blade temperature always within the optimal working range.
The dynamic optimization of cutting parameters is based on my big data system. I collected cutting data from over 3,000 engineering cases worldwide and established a corresponding model of material - parameters - lifespan. When the operator inputs the type of pavement material and the cutting depth, the system would automatically recommend the optimal rotational speed and feed rate. In the expansion of the highway in South Korea, this system increased the blade life from an average of 1,500 meters to 2,800 meters, saving 40% on blade costs alone.
My preventive maintenance system has strict time nodes. Every 50 hours of work, I checked the straightness of the guide rails and the pressure of the hydraulic system; every 200 hours, I replaced the hydraulic oil filter and cleaned the radiator; every 500 hours, I checked the wear of the transmission gears. For this, I developed an AR-assisted maintenance system. Maintenance personnel could see three-dimensional disassembly guidance and standard operation videos through smart glasses. In the mines in Australia, this system reduced the average maintenance time by 65% and the standardization level of maintenance quality reached 95%.
The blade refurbishment service is my special value-added service. When the blade reaches its lifespan, customers can send it back to my factory for professional refurbishment. I replace the diamond blade head using laser welding technology, with the refurbishment cost being only 35% of a new blade, but the performance can reach 85% of a new blade. In Brazil, my blade refurbishment service saved over $2 million in material costs for the customers.
True maintenance is not waiting for the equipment to break down and then repairing it; it is through meticulous management to keep the equipment in the best condition all the time. I developed an IoT monitoring system that can monitor the operating status of the equipment in real time and predict maintenance needs. In the five-year road project in Saudi Arabia, my predictive maintenance system reduced unplanned downtime by 92%, and the utilization rate of the equipment reached 1.8 times the industry average.
