What are the spare parts required for a manual duplex external coil winder for brushless motor motors and how to set up a guaranteed stock?
Spare parts and guarantee stock setting for brushless motor motor manual duplex external coil winder:
I. Spare parts list
1、Mechanical parts
Transmission parts
Belt and pulley (if belt drive):
Belt will be worn, elongated or broken due to long-term use, and the pulley will also be worn due to friction, which will affect the transmission efficiency and precision. Therefore, it is necessary to stock spare belts and pulleys of different specifications.
Chain and sprocket (in case of chain drive):
The chain may elongate, the links may wear out or even break, and the sprocket teeth may wear out or be damaged, so it is necessary to prepare an appropriate amount of spare chains and sprockets.
Gears:
Gears may have tooth wear and tooth breakage during operation, so it is necessary to reserve spare gears with different modulus, number of teeth and accuracy level to meet the different transmission requirements of the winding machine.
Bearings:
Spools, motors and transmission parts etc. need bearings to support them, and the bearings will be damaged due to long-term operation, poor lubrication or overloading, all kinds of bearings of common specifications should be stocked, such as deep groove ball bearings, cylindrical roller bearings etc.
Winding parts
Winding head components:
Components of winding head such as guide pin and crimping device will be worn out or damaged during frequent winding operation, and it is necessary to stock up perishable parts such as guide pin and crimping device of winding head.
Bobbin:
Spools may affect winding due to deformation, wear or damage, a certain number of spare spools can be stocked, including different sizes and types, to meet different winding tasks.
Clamps and Accessories:
The clamping jaws, grooves, locating pins and fastening bolts of the fixture will be worn, deformed or loosened due to long-term use, so stock up on the appropriate fixture fittings to ensure the reliability and stability of the fixture.
2、Electrical parts
Motor parts
Motor brushes (if brush motor):
Brushes will gradually wear out with the operation of the motor, and it is necessary to reserve brushes matched with the motor to ensure the normal operation of the motor.
Motor Windings:
Motor windings may be damaged due to overheating, overloading or aging of insulation. Reserve a small number of motor windings so that they can be replaced in time to shorten the repair time when they are damaged.
Motor Bearings:
Motor bearings will wear out due to long-term operation, reserve motor-specific bearings to ensure the performance and life of the motor.
Sensors
Position Sensors:
Position sensors (such as photoelectric sensors, Hall sensors, etc.) may be damaged due to environmental factors, collision or component aging, reserve the appropriate position sensors to ensure that the winding machine can accurately control the winding position.
Tension Sensor:
Tension sensors are essential to ensure the quality of winding, its strain gauges, pressure sensitive components, etc. may be damaged, should be stocked with the same type of tension sensor.
Speed Sensors:
Speed sensors (e.g. encoders) may fail due to wear, component failure or external interference and should be stocked with the appropriate speed sensor.
Counting Sensors:
Counting sensors (e.g., photoelectric counters, proximity switches, etc.) may fail due to component damage or sensing failures; stock up on a certain number of counting sensors.
Circuit Board Components
Resistors, capacitors, inductors:
These components on circuit boards can be damaged by over-voltage, over-current, long-term use, or environmental factors. Reserve resistors, capacitors, and inductors with commonly used resistance, capacitance, and inductance values to ensure that circuit board failures can be repaired quickly.
Integrated circuit chips (e.g., controller chips, driver chips, etc.):
Chips are the core components of control units and driver units and may be damaged by static electricity, power surges, long-term use or overheating. Reserve key integrated circuit chips to reduce repair waiting time.
Relays and fuses:
Relays are used to control the on-off of circuits, and fuses are used to protect circuits, they are perishable parts, a certain number of relays and fuses need to be stocked.
Second, to protect the inventory setup method
1、Statistical analysis based on the frequency of use and failure rate
Record equipment usage and failure information:
Record in detail the frequency of use of the winding machine, the time and work intensity of each use, as well as the name of the part that fails each time, the time of the failure, the phenomenon of the failure and the repair situation.
For example, record the replacement cycles of winding head components and count their average service life to provide data support for determining the guaranteed inventory.
Calculate the failure rate and mean time between failures (MTBF):
For each spare part, calculate its failure rate based on the failure record with the formula: failure rate = number of failures / total usage time.
The Mean Time Between Failures (MTBF) is also calculated using the formula: MTBF = Total Use Time / Number of Failures. For example, if a particular model of position sensor has had 5 failures in the last 1000 hours of use, the failure rate is 0.005 failures/hour and the MTBF is 200 hours.
Determine guaranteed stock levels:
Based on the failure rate and MTBF, determine the guaranteed stock level in relation to the importance of the equipment and the repair response time. For components with high failure rate and short MTBF, a higher guaranteed stock should be set.
For example, for the above position sensor, if the maintenance response time is 24 hours, in order to ensure the normal operation of the equipment during the maintenance response time, consider reserving 3 - 4 as a guaranteed stock.
2. Consider the cost of equipment downtime and the degree of criticality
Evaluate the cost of equipment downtime:
Consider the impact of winding machine downtime on production, such as delays in order delivery, affecting product quality and production schedule, etc., according to the cost of downtime to determine the level of guaranteed inventory of critical components.
If one hour of winding machine downtime results in high economic losses, the guaranteed inventory for critical components (e.g., motors, critical sensors, etc.) can be increased appropriately.
Evaluate component criticality:
Evaluate the criticality of each component of the winding machine, and classify the components that directly affect the core functions of the winding machine (e.g., motor drive, winding position control, and tension control) as critical components, and increase their guaranteed inventory.
For the auxiliary function parts (such as indicator lights, non-critical display components, etc.), the guaranteed inventory can be appropriately reduced.
3, combined with the supplier delivery cycle
Understand the supplier delivery time:
Communicate with spare parts suppliers to obtain the normal delivery cycle of each spare part, taking into account factors such as the supplier's production capacity, transportation distance and inventory.
For example, some special specifications of the integrated circuit chips may need to be purchased from abroad, the delivery cycle is longer, while the delivery cycle of ordinary mechanical parts is relatively short.
Determine the quantity of guaranteed stock:
Adjust the guaranteed inventory according to the supplier's lead time. For the long delivery cycle of the components, in order to ensure the normal operation of the equipment, the need to reserve enough to use a certain period of time (such as the delivery cycle 2 times the time) of the spare parts.
Such as an integrated circuit chip delivery cycle of 4 weeks, you can reserve enough to use 8 weeks of the chip as a guarantee stock.
4、Dynamic adjustment to protect the inventory
Regularly review and update the inventory strategy:
Establish a regular inventory checking mechanism, such as quarterly or semi-annual review and adjustment of the guaranteed inventory of spare parts.
Consider factors such as equipment upgrades, changes in frequency of use, changes in failure rates and changes in supplier conditions to adjust the quantity and type of guaranteed inventory in a timely manner.
Adjust inventory according to equipment upgrading:
When a winding machine is technically upgraded or remodeled, new parts will be used or part specifications will be changed, and the safeguarded inventory should be adjusted accordingly to increase the spares for the new parts and to reduce or eliminate the inventory of the old parts.
※ If you need help, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for assistance.
