What are the spare parts required for a fully automatic rotor-to-magnet machine for brushless motors and how to set up a guaranteed stock?
Below is the information about the spare parts needed for the automatic rotor-to-magnetization of brushless motor motors and how to set up a guaranteed stock:
I. Spare parts
1、Machine parts spare parts:
Magnetizing tools (e.g. magnet clamps, press-fit heads):
Since the magnetizing tools are easy to be worn and damaged in frequent use, 3-5 sets of spare magnetizing tools of different specifications should be prepared to ensure that they can meet the requirements of magnetizing operation for different sizes and types of magnets.
For small, fragile magnetizing tools, such as the jaws of fixtures and the ends of press-fit heads, an appropriate number of spare parts, generally 10-20, should be prepared, depending on the rate of wear and frequency of damage.
Transmission parts:
Conveyor belts and chains:
Prepare 1-2 sets of spare conveyor belts to ensure timely replacement of conveyor belts in case of damage, based on the expected service life of the belts and the operating intensity of the equipment.
For chains, have an appropriate number of spare links, typically 20-30, and 1-2 sets of spare chains in case of severe damage or deterioration.
Gears (if any):
Prepare 2-3 sets of spare gears of different specifications, taking into account the wear and tear of gears and possible damage, especially the gears in the key transmission position, to ensure the normal transmission of the equipment.
Guide rails and slides:
Prepare 2-3 sets of spare guide rails and slider assemblies, as they are moving parts that are prone to wear and affect the accuracy of the movement of the incoming magnetizer.
Bin Components:
Prepare 1-2 sets of spare bin gates and discharge mechanisms (e.g., cylinders, electric actuators) in case of failure of the bin discharge mechanism.
For the structural parts of the silo, such as side plate and bottom plate, prepare 1-2 spare parts to prevent deformation or damage caused by material impact or long-term use.
2、Electrical parts spare parts:
Motor and its accessories:
Prepare 1-2 spare brushless motors to cope with motor failure, such as winding damage, bearing failure or motor driver failure.
At the same time, prepare some motor accessories, such as motor fan, motor driver, motor junction box, etc. Prepare 2-3 of each kind of accessories to ensure the normal operation of the motor.
Sensors:
For all types of sensors such as position sensors, proximity sensors, counting sensors, etc., prepare 2-3 spares of each type to cope with damage or degradation of sensor performance.
Relays and Contactors:
Prepare 5-10 relays and contactors of different sizes as they are critical components in control circuits and are prone to contact erosion, spring deterioration, etc. due to frequent on-off operations.
Fuses and Circuit Breakers:
Prepare 5-10 fuses and circuit breakers for each specification, as they are the key components in the protection circuit safeguard and need to be replaced in time when there is overload or short circuit.
3、Control unit spare parts:
PLC module:
Prepare 1-2 spare PLC input modules and output modules to cope with module failures, such as damage to input and output points or internal circuit failures.
Controller Components:
For the controller of the equipment, prepare some key parts, such as the controller's power supply module, display module, operation buttons, etc. Prepare 1-2 of each kind of parts.
Second, safeguard the inventory settings
1. Determine the consumption rate:
Record the operation log and maintenance records of the equipment, and count the average consumption of each spare part in a certain period of time (e.g., one month or one quarter). For example, if it is known through the records of the past six months that a fuse is consumed every two months on average, then the monthly consumption rate of the fuse is 0.5. For each spare part, the rate of consumption should be carefully counted.
2. Consider the procurement cycle:
Communicate with the supplier to clarify the procurement cycle of each spare part, i.e., the time required from placing an order for procurement to receiving the goods. For the procurement cycle of longer spare parts, it is necessary to appropriately increase the guaranteed inventory. For example, some special specifications of the sensor procurement cycle may be as long as 3 months, we must reserve enough 3 months of the sensor as a guarantee stock.
3, set the level of guaranteed inventory:
Basic guaranteed stock:
Based on the consumption rate and procurement cycle to calculate the base guarantee stock, the formula is: guarantee stock = average consumption rate × procurement cycle. For example, a certain model into the magnet steel tool monthly consumption of 1 set, the procurement cycle for 1 month, then its basic guaranteed stock can be set to 1 set.
Consider the contingency factor:
On the basis of the basic guaranteed stock, consider unforeseen circumstances, such as a sudden increase in the intensity of equipment use, fluctuations in the frequency of equipment failures, and delayed delivery by suppliers. For critical spare parts, an additional 30%-50% margin can be added as the back guarantee stock. For example, for brushless motors, a 50% margin can be added on top of the basic guarantee stock to ensure that the equipment can operate normally in case of emergency.
4、Inventory monitoring and adjustment:
Establish an inventory management system to regularly inventory and monitor the inventory of spare parts to ensure the accuracy of the inventory quantity. When the stock quantity is lower than the guaranteed stock, trigger the procurement process in time.
According to the use of equipment, equipment replacement and changes in the frequency of failures, adjust the quantity of guaranteed stock and the types of spare parts in due course to meet the maintenance and production needs of the equipment.
5、Vendor management:
Establish long-term and stable cooperative relationship with several reliable suppliers to ensure quick procurement of spare parts when they are needed. For important spare parts, an emergency supply agreement can be signed with the supplier to ensure that the supply can be prioritized in case of emergency. At the same time, we regularly evaluate the quality and service level of the suppliers to ensure that the purchased spare parts are of reliable quality and reasonable price.
By reasonably stockpiling spare parts and setting up a guarantee stock, we can effectively reduce equipment downtime, improve the reliability and production efficiency of the brushless motor motor fully automatic rotor into the magnet steel machine, and guarantee the smooth progress of production. In actual operation, according to the specific conditions of the equipment and changes in the production environment, the level of spare parts reserves and guarantee inventory should be flexibly adjusted.
※ If you need help, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for assistance.
