The real-time lubrication data of large units in the petrochemical industry is the key information for online equipment monitoring,intelligent diagnosis and early warning.In order to realize on-line monitoring,intelligent diagnosis and early warning of lubrication status of large units in petrochemical industry,an oil on-line safety monitoring and intelligent early warning system based on the integration of mechatronics and hydraulics was designed by integrating sensor technology,network communication,big data and fault diagnosis technology.Using the real-time data such as lubricating oil temperature,moisture,viscosity,dielectric constant and pollution level collected by multi-sensors,the on-line monitoring,intelligent diagnosis and early warning of the lubrication system were realized,and a distributed remote on-line monitoring system was constructed.The expert diagnosis system establishes a lubricant deterioration model based on the autoregressive moving average model,combined with the equipment status and the deterioration mechanism of lubricant performance indicators,and derives the remaining life before the lubricant performance degradation until failure,and realizes the function of predicting the lubricant wear status of the equipment.The practical engineering application shows that the prediction results of the system are consistent with the off-line detection results,which shows that the system can accurately warn the potential failure risk of the lubrication system and provide a scientific basis for making equipment maintenance plan.