What spare parts are needed and how to set up a guaranteed stock for a fully automatic rotor precision turning vision machine for electric motors?
First, the type of spare parts
1、Machinery
Cutting tools: Cutting tools are constantly worn out during the turning process, and they are highly consumed spare parts. For example, carbide cutting tools, in the processing of different materials of the motor rotor, due to the cutting force, temperature and other factors, the knife edge will gradually wear blunt, and need to be replaced regularly to ensure the machining accuracy and surface quality. Different specifications, shape of the tool, such as cylindrical turning tool, hole turning tool, cut off the knife, etc., according to the equipment processing process demand reserves.
Guideway slider: When the equipment is running, the guideway slider is subjected to frequent reciprocating motion, which is prone to wear and deformation over a long period of time, affecting the precision of the equipment movement. Such as linear guide slider, its ball wear or track strain, will lead to table movement jam, positioning is not allowed, so need to prepare the appropriate type of guide slider as spare parts.
Screw nut vice: Screw nut is responsible for converting rotary motion into linear motion, and it bears a large load in the fine-turning process. After long-term operation, the threads and nuts of the screws may wear out, resulting in increased transmission gap and affecting the positioning accuracy and repeatability of the equipment. Therefore, stock the corresponding specifications of the screw nut vice.
Belt and Chain: In the motor transmission system, belt and chain are used to transmit power. During operation, the belt will slacken or break due to friction and stretching, and the links of the chain may wear out and fall off. For example, synchronous belt, triangle belt and transmission chain should be stocked as spare parts to ensure the stability of power transmission of equipment.
2、Electrical
Servo motor: as the power source of equipment movement, servo motor frequent start and stop, forward and reverse, work intensity, prone to failure, such as winding short circuit, circuit breaker, bearing wear and so on. Once the servo motor failure, the equipment will not be able to run normally, so at least one common type of servo motor should be stocked.
Driver: The driver controls the servo motor operation and plays a key role in the motion accuracy and response speed of the equipment. Because of its internal electronic components, temperature, humidity, electromagnetic interference and other factors, may be damaged components, control signal abnormalities and other issues. Therefore, it is necessary to prepare the drive supporting the servo motor as a spare part.
Sensors: The equipment is equipped with a variety of sensors, such as position sensors for detecting the position of the table to ensure machining accuracy; pressure sensors to monitor the cutting force to prevent overload damage to the tool and workpiece; vision sensors are responsible for identifying the characteristics of the rotor, positioning and so on. The long-term use of these sensors may be degraded accuracy, signal transmission abnormalities, etc., the need to reserve the corresponding types and specifications of sensors, such as photoelectric sensors, pressure transmitters, industrial cameras, etc..
Contactors and relays: In the electrical control system, contactors and relays are used to control the on-off of circuits, and their frequent actions make their contacts prone to erosion and sticking, leading to circuit failures. Different specifications, models of contactors and relays, such as the control of the main circuit of the large-capacity contactors, control signal circuit of small relays, should be stocked in appropriate quantities.
3、Optics (for vision system)
Camera lens: the camera lens of the vision system is prone to dust and oil, which affects the imaging quality and leads to a decrease in the precision of visual recognition. And in some unexpected circumstances, the lens may be damaged by collision. Therefore, it is necessary to reserve lenses that are suitable for the camera model, such as fixed focal length lens and zoom lens.
Light source: The light source provides illumination for the visual system to ensure that the rotor imaging is clear. After long-term use of the light source, the brightness may decay, uneven light emission, affecting the visual recognition effect. Different types of light sources, such as ring light source, strip light source, backlight, etc., need to be based on the needs of the equipment vision system reserve spares.
Second, to protect the inventory setup method
1、Analysis of historical data
Review the operation and maintenance records of the equipment for the past year or more, and count the replacement frequency of each spare part. For example, in the past year, a certain type of tool replacement every 20 working days on average, based on this data, a preliminary estimate of future use. At the same time, analyze the seasonal occurrence of failures, changes in production tasks and other factors on the frequency of spare parts replacement. If the equipment is used frequently during the peak season, the replacement cycle of certain spare parts may be shortened.
2, consider the supply cycle
Understand the procurement and supply cycle of each spare part, including the time from order to receipt of goods. For domestic procurement and stable supply channels for spare parts, such as common contactors, relays, the supply cycle may be shorter, set to 1 - 2 weeks; for imported special servo motors or customized optical lenses, the supply cycle may be as long as 2 - 3 months or even longer. Supply cycle of long spare parts, protection of inventory should be set relatively high, in order to avoid out-of-stock resulting in equipment downtime for a long time.
3. Evaluate the degree of equipment criticality
Spare parts are categorized according to the degree of criticality to the operation of the equipment. Such as servo motors, drives, etc., once the failure of the equipment will be completely stopped, belonging to the key spare parts, need to set up a higher protection stock, can ensure that meet the use of 3 - 6 months; and some non-critical but commonly used spare parts, such as ordinary contactors, relays, the protection of stock can be set to meet the use of 1 - 2 months.
4、Combined with the production plan
According to the enterprise's future production plan, the estimated equipment running time and processing tasks. If the next large-scale motor rotor production orders, equipment running time will increase significantly, accordingly, the demand for spare parts will also increase. At this time, the production plan should be adjusted in advance according to the production plan to protect the inventory, increase the reserve of wearing parts.
5、Regular review and adjustment
Quarterly or half-yearly review of all the guaranteed inventory. Compare the actual use with the estimated amount, analyze the reasons for the difference. If the actual usage is much lower than the set value of guaranteed inventory, the inventory level can be appropriately lowered to reduce the use of funds; if the actual usage exceeds the expected amount, it should be analyzed whether it is caused by aging of equipment, changes in production process or other reasons, and adjust the guaranteed inventory accordingly to ensure that it meets the maintenance needs of the equipment and does not result in too much inventory backlog.
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