What spare parts do I need for my motor motor rotor automatic meshing machine and how do I set up a guaranteed stock?
I. Spare parts list
(I) Mechanical parts
Transmission parts
Belt and chain: this is the key part of the equipment transmission system, which is easy to wear out. According to the frequency of use and load of the equipment, regular replacement is necessary. For example, for a high load, continuously running meson machine, it may be necessary to have a spare set of belts or chains every 3 - 6 months.
Gears: Gears may wear and spall on the tooth surfaces over a long period of mesh operation. Especially for high-speed transmission gears, gears of different sizes and modules should be available, such as small-module precision gears (module 0.5 - 2) for precision transmission and large-module power gears (module 3 - 5) for transmitting larger torque.
Couplings: are used to connect motors and other drive components, to cushion and compensate for axial, radial and angular misalignments. Since they are easily damaged during frequent starts and stops and load changes, it is necessary to have some common types of flexible or rigid couplings as spare parts.
Positioning and clamping components
Locating pins and blocks: The locating pins are used to determine the precise position of the rotor in the equipment, while the blocks assist in locating the rotor and withstand certain impact forces. These components may be worn or deformed after a long period of use, affecting the positioning accuracy, so it is important to have a wide range of locating pins (ranging from 3 - 10mm in diameter) and blocks available.
Clamps and jaws: The clamps and jaws of the clamping mechanism are responsible for fixing the rotor and keeping it stable during the installation of the meson. They are susceptible to wear and fatigue damage due to frequent clamping and unclamping actions. It is necessary to stock a certain number of spare clamp jaws and clamp assemblies according to the type and size of clamps used on the equipment.
Mounting Tool Heads
Press-fit head and screwing head: Used to install the meson onto the rotor, such as the punch head for press-fitting the meson and the screwing head for tightening the meson nut. These tool heads are prone to wear and deformation under long-term high pressure or high torque working environment. Tool heads of different sizes and shapes should be prepared to meet the installation requirements of various mesons.
(ii) Electrical components
Sensor
Photoelectric sensor: used to detect the position and motion status of the rotor, its light emitting diode and photosensitive element may be damaged. Keep the same type of photoelectric sensors as in the equipment, including sensors with different detection distances (e.g. 5 - 50mm) and sensing methods (diffuse reflection, counter-reflective).
Hall sensors: are mainly used to detect magnetic field signals to determine parameters such as rotor speed. Due to magnetic field interference, electrical aging and other factors, it may fail, so it is necessary to reserve a certain number of Hall sensors, and pay attention to its model and equipment motor matching.
Proximity sensors: useful in detecting the proximity of dielectrics or other components whose sensing surfaces and internal electronic components may be damaged. Prepare proximity sensors of different types (inductive, capacitive) and detection ranges (e.g. 2 - 10 mm) as spare parts.
Motors and drives
Motors: The power source of the equipment, e.g. motors that drive the rotation of the rotor and motors that control the movement of the mounting tool. Considering the possibility of motor failures such as short-circuited windings, broken circuits, worn brushes (for brushed motors), motors with the same specifications (parameters such as power, speed, torque, etc.) as those in the equipment should be stocked.
Motor driver: Used to control parameters such as speed, steering and torque of the motor. Because the electronic components inside the driver are complex and susceptible to damage from voltage fluctuations, overloads, and other factors, it is important to have some commonly used models of motor drivers as spare parts.
Control Unit
PLC Module (Programmable Logic Controller): As the core control component of the equipment, the input/output interface, power supply module, and communication module of the PLC module may fail. It is important to stock up on key modules such as input modules with high-speed counting functions (for receiving sensor signals) and relay output modules (for controlling actuators).
Touch panel: The touch panel of the operation interface may be subject to malfunctions such as touch failure and display abnormality. Prepare touch screens of the same model as the equipment, including spare parts for touch screens of different sizes and resolutions (e.g., 800 × 480, 1024 × 600).
(iii) Other parts
Seals and gaskets
Oil seals and O-rings: Used to prevent lubricant leakage and dust from entering critical parts of the equipment, such as motor shaft ends and connections of hydraulic or pneumatic systems. Due to long-term friction and aging, seals are easily damaged, to prepare a variety of specifications (ID, OD and thickness) of the oil seal and O-ring.
Sealing gaskets: Used in equipment connection flanges, valves, etc. to prevent fluid or gas leakage. Stock sealing washers in different materials (rubber, metal, etc.) and sizes to meet equipment maintenance needs.
Fasteners and Connectors
Screws, nuts and bolts: There are a large number of fasteners in the equipment, which may be lost or damaged during routine maintenance and part replacement. It is important to stock a variety of screws, nuts and bolts in various sizes (length, diameter, tooth spacing), including high-strength alloy steel screws and locknuts.
Terminals and plugs and sockets: Terminals and plugs and sockets in the electrical connection section are prone to loosening, oxidization and other problems. Prepare terminals of different specifications (current capacity, number of pins) and plugs and sockets matching the equipment as spare parts.
Second, the protection of inventory setting method
(i) Inventory setting based on the probability of equipment failure
Collection of failure data: through the equipment's maintenance records, failure reports and other information, statistics on the frequency of failure of each component. For example, after a year of statistics, it is found that the belt fails once every 4 months on average, and the sensor fails once every 6 months.
Calculate the quantity of guaranteed stock: Determine the quantity of guaranteed stock based on the failure frequency of components and the importance of the equipment. In general, for parts that fail frequently, the guaranteed stock quantity can be set at 1.5 - 2 times the number of replacements required in the average time between failures. For example, if a certain type of belt needs to be replaced every 4 months on average, and continuous operation of the equipment is critical, then the guaranteed stock can be set to 3 - 4 items.
(ii) Inventory setup considering the procurement cycle
Determine the procurement cycle: Understand the procurement cycle of each spare part, including the supplier's production cycle, transportation time. For example, for a special specification motor drive, the production cycle of the supplier is 3 weeks, and the transportation time is 1 week, so the procurement cycle is 4 weeks.
Setting inventory in conjunction with usage demand: Set up guaranteed inventory based on the intensity of equipment usage and possible demand during the procurement cycle. If it is expected that the equipment will need to replace 2 motor drives during the procurement cycle, the guaranteed stock can be set to 3 - 4 to prevent unforeseen circumstances.
(iii) Balance inventory according to importance and cost
Evaluate the importance of components: categorize spare parts into critical, important and general parts. Critical components, such as PLC modules, once damaged will lead to equipment downtime for a long time, should maintain a higher guaranteed inventory; important components, such as sensors, whose failure will affect the performance of the equipment, to maintain a certain level of inventory; general components, such as sealing gaskets, can be set up according to the actual situation of a lower inventory.
Consider the cost factor: for expensive parts, such as motors and drives, under the premise of ensuring the normal operation of the equipment, try to set up a reasonable inventory to avoid the accumulation of inventory funds. Inventory costs can be reduced by negotiating emergency purchasing terms with suppliers and sharing inventory. At the same time, for lower-priced but easily damaged parts, such as seals and fasteners, you can appropriately increase the guaranteed inventory to minimize the workload of frequent purchases.
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