What spare parts do I need and how do I set up a guaranteed stock for my fully automated rotor test vision machine for electric motors?
The normal operation of a fully automated rotor test vision machine is critical to production. Preparing the right spare parts and setting up a guaranteed stock can effectively reduce equipment downtime. The following are the required spare parts and how to set up the guarantee stock:
I. Required Spare Parts
1、Electrical
Sensors: including position sensors, photoelectric sensors, pressure sensors, temperature sensors and so on. Sensors may fail in long-term use due to aging, environmental factors, etc., affecting the equipment to accurately detect the rotor position, status and other information.
Drives: such as motor drives, which control the operation of the motor. Once the driver is faulty, the motor may not work properly, leading to interruption of the test process.
Power Module: Provides a stable power supply to the device. Failure of the power module can cause the entire device to lose power and fail to operate.
Control boards: including PLC (Programmable Logic Controller), industrial computer boards, etc., are responsible for the logic control and data processing of the equipment. Damage to the board will cause confusion in the control of the equipment and abnormal test functions.
2、Mechanical
Fixture accessories: such as clamping jaws, positioning blocks, etc., used to fix the rotor.The fixture will be worn out in frequent use, which will affect the clamping accuracy of the rotor, and then affect the test results.
Transmission parts: such as belts, chains, gears, etc., used to transfer power and movement. These parts can be damaged during operation due to friction, fatigue, etc., resulting in poor movement of the equipment.
Guide rails and screws: are the guiding and transmission elements for the moving parts of the equipment.Wear and tear of the guide rail and screw will affect the precision and stability of the movement of the equipment.
Bearings: support rotating parts and reduce friction.Damage to the bearings will lead to abnormal noise and vibration when the parts are running, or even can not rotate normally.
3、Optics
Industrial camera: It is the core component of the vision system and is used to collect image information of the rotor. Failure of the camera will make the visual inspection function invalid, unable to accurately obtain the appearance of the rotor, size and other information.
Lens: used with the camera, affecting the clarity of the image and the range of vision. Damaged lenses or optical problems will lead to image quality degradation, affecting the detection accuracy.
Light source: provides suitable light conditions for visual inspection. Unstable brightness or damage to the light source will affect the camera imaging effect, resulting in inaccurate detection results.
Second, to protect the inventory setup method
1, historical data analysis method
Collect the replacement records of each spare part in the past period of time (e.g., 1 - 2 years) of the equipment, including the replacement time, the number of replacements and so on.
Analyze these data to calculate the average replacement cycle and replacement quantity of each spare part. For example, a certain type of sensor is replaced once every 6 months on average, and 1 sensor is replaced each time.
According to the equipment utilization plan and production schedule, predict the number of spare parts required in the coming period. Adjust the forecast value appropriately by combining the operating time and usage frequency of the equipment.
Considering the uncertainty of the supply cycle, on the basis of the forecasted demand quantity, add a certain guarantee margin to determine the guarantee stock level. Generally speaking, the guarantee margin can be determined according to the fluctuation range of the supply cycle and the degree of dependence of the equipment on the spare parts, such as fluctuations in the supply cycle or the equipment is very critical to the spare parts, the guarantee margin can be set higher.
2、Supplier evaluation method
Spare parts supplier assessment, to understand its supply capacity, supply stability, delivery and so on. For example, some suppliers have limited production capacity, there may be supply delays.
Based on the results of supplier evaluation, the guaranteed stock levels of spare parts of different suppliers are determined. For suppliers with unstable supply and long delivery period, the guaranteed inventory is appropriately increased; for suppliers with stable supply and short delivery period, the guaranteed inventory can be reduced.
Establish a good cooperative relationship with suppliers and sign long-term supply agreements to ensure that spare parts can be obtained in time when needed. At the same time, pay attention to the supplier's production plan and inventory, and prepare for replenishment in advance.
3、Equipment failure impact assessment method
Evaluate the impact of each spare parts failure on equipment operation, divided into three levels: critical, important and general. Critical spare parts failure will lead to complete equipment shutdown, important spare parts failure will affect some of the functions of the equipment, general spare parts failure on the operation of the equipment has less impact.
For critical spare parts, a higher guaranteed inventory is set to ensure that they can be replaced quickly in the event of a failure, reducing downtime. For example, motor drives are critical spares and the guaranteed stock can be set at 2 - 3.
The guaranteed stock of important spare parts can be determined according to their impact on the function of the equipment and the repair time, and is generally set at 1 - 2. General spare parts of the guaranteed inventory can be relatively low, such as 0 - 1.
4、Dynamic adjustment method
Regular evaluation and adjustment of the guarantee stock. With the use of equipment and maintenance changes, the demand for spare parts will also change. For example, after the equipment has undergone technical transformation, the frequency of use of certain spare parts may be reduced.
Pay attention to market dynamics and industry information, such as suppliers' product updates and price fluctuations. If new substitutes appear or the price of spare parts fluctuates significantly, the guaranteed stock can be adjusted according to the actual situation.
Adjust the guaranteed inventory in time according to the operating conditions and maintenance records of the equipment. If a spare part is frequently replaced over a period of time, this indicates that there may be a problem with the reliability of the spare part, and that it is necessary to increase the safeguarded inventory and conduct an in-depth analysis and improvement of the spare part.
※ If you need any help, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. via the page chat tool for assistance.
