What are the spare parts required for a fully automatic load tester for brushless motors and how to set up a guaranteed stock?
The spare parts and guarantee stock of brushless motor motor automatic load tester are as follows:
I. Common spare parts
1、Sensors
Current sensor: used to measure the working current of the brushless motor, the precision may be decreased or damaged due to overloading and aging in long-term use, a certain amount of spare parts are required.
Voltage sensor: It monitors the voltage of the tester to ensure the stability of the voltage and prevent over-voltage or under-voltage from damaging the tester and the motor under test, it is a fragile part and should be kept as spare parts.
Temperature sensor: Brushless motor will generate heat during load test, the temperature sensor is used to monitor the temperature in real time to prevent overheating, it may fail due to high temperature environment and other factors, it is necessary to prepare spare parts.
2、Electrical components
Relay: It plays the role of switch in the circuit control of the tester, and its frequent action may lead to contact wear and tear, sticking and other problems, so it is a spare part that needs to be replaced frequently.
Contactor: control the main circuit of the tester, long time use may appear contact erosion, coil failure, etc., should reserve a certain number.
Fuse: overload or short-circuit protection in the circuit occurs, after the fuse needs to be replaced in a timely manner, different specifications of the fuse should be used as spare parts.
Capacitors: used for filtering, energy storage, etc., may be damaged due to voltage shock, aging, etc., common capacity of capacitors should be used as spare parts.
3、Mechanical components
Motor bearings: the drive motor bearings of the tester will be worn out in long-term operation, affecting the performance of the motor, different types of motor bearings should be used as spare parts.
Belts and pulleys: belts will be worn and stretched during transmission, and pulleys may be worn or damaged, so different specifications of belts and pulleys need to be prepared.
Fixture accessories: the fixture of the tester is used to fix the brushless motor, and its accessories such as jaws, springs, bolts, etc. may be damaged due to frequent use, so it is necessary to reserve corresponding spare parts.
4、Other accessories
Power Cord and Plug: Long-term use may lead to skin breakage, internal wire breakage, etc. Some power cords and plugs of different lengths and specifications should be prepared.
Display: the display of the tester may show abnormalities, backlight damage and other problems, according to the model number of the tester should be prepared for the corresponding display as spare parts.
Second, to protect the inventory setup method
1、Historical data analysis method
Collect the replacement records of each spare part of the testing machine in the past period of time, including the time of replacement, the reason for replacement, the number of replacement and other information.
Analyze the data to find out the use of more frequent spare parts, according to its average replacement cycle and the number of each replacement, to determine the level of guaranteed inventory. For example, a certain type of current sensor has been replaced once every 3 months in the past year, and 2 units are replaced each time, so we can consider setting 6 units as the guaranteed stock.
2, failure mode and impact analysis (FMEA) method
FMEA analysis of the test machine to assess the degree of impact of each component failure on the overall operation of the test machine and the probability of occurrence.
For components with high impact degree and higher probability of occurrence, appropriately increase the guaranteed stock. Such as contactor failure may lead to the test machine can not be started normally, and according to experience its failure probability is relatively high, should increase the contactor security inventory.
3, the supplier delivery method
Understand the spare parts supplier's delivery period, for the longer delivery period of spare parts, the need to set a higher guarantee stock, in order to prevent the normal use of the test machine due to stock-outs.
For example, a special specification of capacitors supplier delivery period of 2 weeks, then at least 2 weeks should be prepared to meet the amount of guaranteed inventory.
4, cost-benefit analysis
Consider the procurement cost of spare parts, storage costs and stock-out costs. Procurement costs are low, storage costs are not high, but out of stock will cause large losses of spare parts, should be appropriately increased to ensure inventory.
If the tester can not run due to the lack of a small accessory, resulting in a delay in the test task, resulting in a large economic loss, then even if the procurement cost of the accessory is low, a certain amount of guaranteed inventory should be ensured.
5, regular assessment and adjustment
Safeguard inventory is not fixed, should be regularly assessed and adjusted to protect the inventory.
With the increase in the use of the tester, changes in testing tasks, equipment technology transformation, etc., the use of spare parts may change, the need to adjust the level of guaranteed inventory according to the actual situation, to ensure that not only meet the maintenance needs, but also will not cause excessive inventory backlog.
※ If you need help, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for assistance.
