What spare parts do I need for my DC motor tester and how do I set up a guaranteed stock?
DC motor motor automatic tester spare parts and guarantee stock setting:
I. Spare parts list
1、Electrical components
l Motor brushes and commutator
During long-term operation of the motor, the brushes will gradually wear out, and the surface of the commutator may also be worn or oxidized. This can lead to problems such as reduced motor performance and sparking. Therefore, stock an appropriate amount of brushes and spare commutators.
l Sensors
RPM Sensor: The RPM sensor is the key component of the tester to obtain the motor's RPM, and its performance directly affects the accuracy of the RPM measurement. Since the sensor may be damaged by environmental factors (such as temperature changes, vibration, electromagnetic interference) or long-term use, it is necessary to reserve the same type of speed sensor.
Temperature Sensor: Used to monitor the temperature of the motor to prevent it from overheating. The thermal element of the temperature sensor may fail, so keep a spare temperature sensor on hand.
Torque Sensor (if available): The torque sensor is an important component for equipment that can test the torque of the motor. It may be damaged by overload, fatigue, or other factors, and spares should be stocked accordingly.
l Capacitors and resistors
In the electrical control circuit of the tester, capacitors and resistors play the roles of filtering, voltage dividing and current limiting. These components may be damaged due to over-voltage, over-current, aging and other reasons, so you need to stock common specifications of capacitors and resistors.
l Fuses and Relays
Fuses are used to protect circuits from overload currents, and relays are used to control the on-off of circuits. They are wearing parts in the electrical system, easy to fuse or damage due to current impact and other reasons, should be used as a permanent spare parts.
Integrated circuit chips (such as controller chips, signal processing chips, etc.)
These chips are the core components of the tester's control unit and signal processing unit. Although they are relatively stable, they can be damaged by static electricity, power surges, long-term use, etc. Reserve some key integrated circuit chips can be replaced in time when the chip is damaged, shortening the equipment maintenance time.
2、Mechanical components
l Drive components
Belt and pulley (if it is a belt drive): The belt will be worn, aged and elongated after long-term use, resulting in reduced transmission efficiency or slippage. The pulleys may also wear out and affect the transmission accuracy, so stock up on the right type of belts and pulleys.
Chains and sprockets (in case of chain drives): Chains may elongate and break, and the teeth of sprockets may wear out. Spare chains and sprockets should be kept on hand to ensure proper operation of the drive system.
Gears: Gears are key components in the transmission system and are prone to tooth wear and tooth breakage. For gears of different specifications and uses, a certain number of spare parts should be stocked.
l Bearing
The mechanical transmission parts of motors and testers cannot be separated from the support of bearings. Bearings may be damaged during long-term operation due to wear, poor lubrication, and overload. It is necessary to stock various specifications of motor bearings and mechanical transmission bearings.
l Clamps and fixture accessories
Fixture is used to fix the motor for testing, and the fixture's jaws, positioning pins, fastening bolts and other accessories may be worn, deformed or lost. Stocking some fixture accessories, such as spare clamping jaws, positioning pins and bolts, can easily replace damaged parts and ensure the normal use of the fixture.
Second, to protect the inventory setup method
1、Statistical analysis based on equipment failure rate
l Collect failure data
Make a detailed record of the failure history of the testing machine, including the number of failures of each component, the time between failures, the cause of failure and other information. For example, record the average service life of motor brushes, and calculate the approximate replacement cycle through previous replacement records.
Calculate failure rate and mean time between failures (MTBF)
Based on the collected data, calculate the failure rate of each spare part. The failure rate can be expressed as the number of failures per unit of time. Also, calculate the Mean Time Between Failures, i.e. MTBF = Total Operating Time / Number of Failures. For example, if a certain model of speed sensor had 5 failures in the past 1000 hours of operation, then its failure rate is 5/1000 = 0.005 times/hour, and the MTBF is 1000/5 = 200 hours.
l Determine the quantity of guaranteed stock
Based on the failure rate and MTBF, combine the importance of the equipment and the maintenance response time to determine the number of guaranteed stock. Generally speaking, for parts with high failure rate and short MTBF, a higher guaranteed stock should be maintained. For example, if the MTBF of a component is 100 hours, the maintenance response time is 24 hours, in order to ensure that the equipment can operate normally during the maintenance response time, it may be necessary to reserve at least 3 - 4 of the component as a guaranteed inventory.
2. Consider the cost and importance of equipment downtime
l Assessment of equipment downtime costs
If the tester is in a critical position in the production or testing process, downtime will cause greater economic losses, such as delays in product delivery, affecting the production schedule and so on. For such cases, the guaranteed inventory of critical spare parts should be increased to minimize downtime. For example, for a production line that relies on the tester for motor quality inspection, if one day's downtime of the tester will result in a loss of 10,000 yuan, then in order to avoid downtime due to the lack of spare parts, the level of spare parts inventory should be increased appropriately.
l Determine the degree of equipment criticality
Evaluate the criticality of each component of the tester. For those parts that directly affect the core functions of the tester (such as motor drive, test data acquisition) should be given a higher inventory priority. For example, the motor drive chip and the main sensor is more critical than some auxiliary components such as indicators, should be stocked more related spare parts.
3, the supplier delivery cycle factors
l Understand the supplier delivery time
Communicate with the supplier of spare parts to obtain the normal delivery cycle of each spare part. Delivery cycle may be affected by a variety of factors, such as the supplier's production capacity, transportation distance, inventory levels. For example, some IC chips with special specifications may need to be purchased from foreign suppliers, and the lead time may be weeks or even months.
l Combined with the delivery cycle to determine the inventory
Adjust the quantity of guaranteed stock according to the delivery cycle of the supplier. For spare parts with long lead times, the guaranteed stock should be increased to cope with possible supply delays. For example, if a part of the supplier's delivery cycle is 4 weeks, and the equipment demand for the part is more stable, in order to ensure the normal operation of the equipment in the delivery cycle, may need to reserve enough to use 4 - 6 weeks of the part as a guarantee stock.
4、Dynamic adjustment of the guaranteed inventory
l Regular review and update inventory strategy
Establish a regular inventory review mechanism, such as quarterly or semi-annual review of spare parts to ensure that the inventory strategy. Dynamically adjust the quantity and types of guaranteed inventory according to factors such as equipment upgrades, changes in frequency of use, changes in failure rates, and changes in supplier conditions.
l Consider the impact of new technologies and components
As technology continues to advance, testers may undergo technological upgrades and adopt new components or technologies. In this case, the guaranteed inventory should be adjusted in a timely manner to increase the spares of new components while reducing the inventory of old components that are no longer in use. For example, if the tester is upgraded with new sensor technology, it is necessary to stock spares for the new sensors and dispose of the stock of old sensors.
※ If you need help, please contact Xinhui Mechatronics Equipment Co., Ltd. technical specialists for assistance via the page chat tool.
