What spare parts are needed for DC motor motor automatic carbon brush cover assembly machine and how to set up guarantee stock?
I. Spare parts list
1、Mechanical parts
Transmission parts:
Belt and chain: according to the machine model and specifications, stock the appropriate amount of spare belts and chains. For example, for commonly used synchronous belts, reserve 2-3 belts for each specification (differentiated by width, number of teeth, etc.); for chains, reserve 1-2 sets of each according to the number and size of links. These parts are prone to wear and tear and may break during long periods of operation or in the event of an accident.
Gears: Prepare spare parts for some key gears, such as main drive gears and indexing gears. Due to the long manufacturing cycle of gears and specific models, 1 - 2 sets of each kind of important gears are stocked so that the gears can be replaced in time when there is serious wear or damage to the tooth surface.
Bearings: Bearings are the key support for rotating parts and are prone to wear and damage. Stock various types of bearings, such as deep groove ball bearings, tapered roller bearings, etc. The number of bearings depends on the number of different bearings used in the machine and the degree of fragility, generally 3 - 5 of each type of bearing.
Fixture and arm parts:
Fixtures: For fixture holders, locating pins, and other parts that are prone to wear, stock 5 - 10 of each. These parts are in direct contact with the workpiece and are prone to wear after frequent use, affecting clamping accuracy.
Mechanical arm: the key parts of mechanical arm such as joint bearing and connecting rod should be stocked, 3-5 joint bearings for each kind of stock, 1-2 connecting rods for each kind of stock according to the structure and fragility of mechanical arm.
2、Electrical components
Motor: Although the motor is generally more durable, but taking into account the possible failures, you can reserve 1 - 2 sets of spare motors, especially for some special specifications or customized motors, the procurement cycle is long, it should be prepared in advance.
Sensors:
Photoelectric sensors: As they are more sensitive to the working environment and prone to failure, reserve 2 - 3 photoelectric sensors for each model.
Proximity sensors, pressure sensors, etc.: Proximity sensors and pressure sensors according to the number of their use in the machine and the importance of each reserve 2 - 3, in order to deal with sensor damage caused by the failure of the detection function.
Controller Components:
PLC Input/Output (I/O) Modules: Stock some commonly used I/O modules such as digital input and output modules and analog input and output modules. Reserve 1 - 2 of each type of module, so that when the module fails, it can be replaced in time to ensure the normal operation of the control system.
Relays and contactors: These components play a key role in circuit control and are prone to problems such as contact wear. Depending on the type and number of models used in the machine, stock 3 - 5 of each type of relay and contactor.
Electrical components: including fuses, capacitors, resistors, etc. These small components are easily damaged and should be stocked with a certain number of components of various specifications according to the circuit diagram of the machine and the use of the components, such as 10 - 20 for each specification of fuses and 5 - 10 for each specification of capacitors and resistors.
3、Software related components
Storage devices: Prepare some spare hard disks or solid state disks for backup and recovery of the software system. The quantity can be 1 - 2 according to the storage requirement of the machine and the importance of data.
Software license key backup: Ensure that there is a backup of the software license key stored in the safeguarded place so that it can be used without any problem when the software needs to be reinstalled.
Second, the method of setting up the safeguarded inventory
1、Frequency of use and failure rate assessment
For parts with high usage frequency, such as fixture chucks, belts, etc., a higher guaranteed inventory should be set. Through the collection of machine operation data, statistics on the frequency of replacement of these parts, for example, a certain type of fixture collet average monthly replacement of 2 times, can be set to meet the number of guaranteed stock 3 - 6 months of use.
Analyze the failure rate of components, based on historical failure records and product reliability data provided by the supplier, to determine the parts that are prone to failure, and set the corresponding guaranteed inventory. For example, a certain photoelectric sensor failure rate of 10% per year, taking into account the procurement cycle and maintenance time, can be set to protect the stock to meet the number of normal operation of the machine 3 - 4 weeks required.
2. Consideration of procurement cycle
Investigate the procurement cycle of spare parts, including the supplier's production cycle, transportation time and so on. For parts with a long procurement cycle, such as customized gears, special specification motors, etc., should increase the guaranteed inventory. If the procurement cycle of a component is 3 months, the guaranteed stock should be able to meet at least the quantity required for the normal operation of the machine within these 3 months, and then consider a certain margin, such as 10% - 20%.
3、Cost and storage space balance
Consider the cost of spare parts to avoid overstocking expensive parts. At the same time, also consider the cost of storage and storage space limitations. For high-cost, large parts, such as motors, large gears, etc., you can ensure a certain degree of timely maintenance under the premise of appropriately reducing the guaranteed inventory, through the establishment of a rapid response with the supplier to make up for possible shortages.
According to the actual space size of the warehouse, rationally plan the storage location and method of spare parts. Adopt scientific inventory management methods, such as the ABC classification method (spare parts are classified into three categories, A, B and C, according to their importance and capital consumption, with emphasis on management of category A, general management of category B, and simple management of category C), to optimize the setup of guaranteed inventory.
※ If you need any help, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
