What spare parts are needed for a brushless motor motor automatic rotor loading machine and how to set up a guaranteed stock?
I. Spare parts
1、Mechanical parts
Conveyor belt and chain: conveyor belt and chain is the main transmission parts of the feeding machine, due to long-term use will produce wear and tear, elongation or breakage and other problems, so you need to reserve a certain number of spare conveyor belt and chain. According to the frequency of use and load of the equipment, you can consider preparing 1-2 complete sets of conveyor belts and appropriate amount of chain links as spare parts.
Loading Jaws and Suction Cups: If the loader uses loading jaws or suction cups for rotor gripping, these parts will wear out or be damaged by frequent operation, so it is necessary to have a certain number of loading jaws and suction cups. Usually 3-5 loading claws and 2-3 suction cups can be stocked, the specific quantity can be determined according to the loading frequency of the equipment and the service life of the components.
Bearings: Motors, transmission parts, etc. need bearings to support and rotate, and bearings are wearing parts that may be damaged due to wear, overheating, or poor lubrication. According to the different specifications and quantity of bearings in the equipment, 2-5 bearings of each specification can be prepared as spare parts.
Silo parts: For the silo, such as silo gate, vibrator spring, motor and other parts, you can prepare 1-2 sets of spare gate parts and a few spare springs and vibrator motors, in order to prevent the silo parts from failing to affect the material.
2、Electrical parts
Sensors: position sensors, counting sensors and proximity sensors are the key components for automatic control of the feeder. Since the sensors may fail due to environmental influences or aging, it is necessary to reserve various types of sensors. Each type of sensor can be prepared 2-3, to ensure that the sensor failure can be replaced in a timely manner.
Motor: Brushless motor is the core component of the loader. Although it is highly reliable, it may be damaged due to long-term use, overload or electrical failure. You can prepare 1-2 spare brushless motors, and also need to prepare some motor accessories, such as motor driver, motor fan, motor junction box and so on.
Relay and contactor: These control components play an important role in the control circuit to connect and disconnect the circuit, and are easy to fail due to contact erosion, spring aging and other reasons. You can prepare 5-10 common specifications of relays and contactors to ensure that the control circuit can work properly.
PLC module: If the equipment is controlled by PLC, you may need to prepare some PLC input and output modules, according to the use of PLC, you can prepare 1-2 spare input and output modules, in case the module fails to affect the control logic of the equipment.
Fuses and circuit breakers: they are important components to protect the circuit safeguard, in the event of overload or short circuit will fuse or trip, need to reserve different rated current fuses and circuit breakers, each specification can be prepared 5-10.
3、Other Components
Circuit boards and chips: for some key control circuit boards and chips, although their probability of failure is relatively low, but once damaged may lead to equipment downtime for a long time, according to the complexity of the equipment and the importance of the circuit board, reserve 1-2 key circuit boards and some important chips.
Indicator lights and buttons: the indicator lights and buttons on the operation panel may also be damaged, you can prepare a certain number of indicator lights of different colors and buttons of different functions, such as start, stop, reset buttons, etc., each of which can be prepared 3-5.
Second, to protect the stock settings
1. Determine the consumption rate:
Through the use of equipment records and maintenance records, statistics for each spare parts in a certain period of time (such as a month or a quarter) within the average consumption. For example, in the past year, a certain specification of conveyor belts are replaced every three months on average, then it can be roughly determined that its monthly consumption rate of 1/3 of the article. For different spare parts, to count their consumption rate separately.
2. Consider the procurement cycle:
Understand the procurement cycle of each spare part, i.e., the time required from placing an order for procurement to actually receiving the goods. If the procurement cycle of a particular spare part is long, it is necessary to appropriately increase the number of guaranteed stock. For example, some special specifications of the sensor procurement cycle may take two months, then you need to consider stocking enough for two months of use of the sensor as a guarantee stock.
3, set the level of guaranteed stock:
Base stock level: According to the consumption rate and procurement cycle, the basic amount of guaranteed stock is calculated. Calculation formula can be: guaranteed stock = average consumption rate × procurement cycle. For example, a certain type of relay monthly consumption of 2, the procurement cycle for 1 month, then its guaranteed stock can be set to 2.
Consideration of contingencies: In the base inventory level, it is also necessary to consider some unforeseen circumstances, such as a sudden increase in the frequency of use of the equipment, delayed delivery by the supplier, quality problems with parts and components, and so on. A certain margin can be added to the base stock, usually an additional 20%-50% of the margin can be added as the back of the guaranteed stock. For critical spare parts, the margin can be increased appropriately, such as for brushless motors, an additional 50% of the margin to ensure that the equipment can still operate normally in the event of an accident.
4、Inventory monitoring and updating:
Establish an inventory management system to regularly inventory and monitor the stock of spare parts to ensure that the stock quantity is accurate. When the inventory quantity is lower than the guaranteed inventory, trigger the procurement process in time. At the same time, according to the use of equipment and the frequency of failures, adjust the quantity of guaranteed stock and spare parts types at the right time to meet the needs of equipment maintenance and production.
5. Supplier management:
Establish long-term and stable cooperative relationships with several reliable suppliers to ensure the supply stability of spare parts. For some critical spare parts, an emergency supply agreement can be signed with the supplier to ensure that the required spare parts can be obtained quickly in case of emergency. At the same time, we should pay attention to the quality of the supplier's products and after-sales service to ensure that the quality of the purchased spare parts is reliable.
In short, a reasonable spare parts reserve and guarantee inventory settings can ensure that the brushless motor motor automatic rotor loading machine in the event of failure can be timely maintenance and replacement parts, reduce downtime, improve equipment reliability and productivity. In actual operation, according to the specific conditions of the equipment and the production needs of the enterprise, flexible adjustment of spare parts reserves and guarantee inventory level.
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