What spare parts are required for manual 3-in-1 servo presses with electric motors and how should I set up a safeguard stock?
Spare parts and safeguard stock setup for motor-manual 3-in-1 servo presses need to be planned in conjunction with the operating characteristics of the equipment, the frequency of maintenance and the supplier's delivery cycle. The following are specific recommendations:
I. Key spare parts list
1. wearing parts
Seals: hydraulic cylinder seals, O-rings, dust rings (easy to age or wear resulting in leakage).
Transmission components: screws, guide rails, synchronous belts (wear and tear of long-term high-frequency use).
Electrical components: contactors, relays, fuses (easy to start and stop frequently burned).
Sensors: pressure sensors, displacement sensors (accuracy critical, high risk of accidental damage).
2. Consumables
Lubricating oil / grease: special lubricating oil for guide rail, screw grease (daily consumption).
Hydraulic oil: special oil for the hydraulic system of the equipment (need to be replaced regularly).
Filter element: hydraulic oil filter element, air filter element (high risk of clogging, need to be replaced regularly).
3. Key mechanical components
Bearings: spindle bearings, slide guide bearings (high load and easy to damage).
Fasteners: high-strength bolts, gaskets (easy to loosen by vibration, need to be replaced periodically).
Mold parts: mold positioning pins, buffer pads (direct contact with the workpiece, easy to wear and tear).
4. Electrical system spare parts
Servo drive module: the core control components, failure and downtime impact.
Encoder: the key component of position feedback, with strong dependence on accuracy.
Power supply module: unstable voltage may lead to damage.
5. Emergency tools
Special wrenches/tools: Special tools for equipment disassembly (to avoid inoperable during downtime).
Calibration instruments: pressure gauges, micrometers (required for periodic calibration of equipment accuracy).
II. Safeguard inventory setup method
1. Core principles
Consumption frequency: high-frequency replacement of spare parts (such as cartridges, lubricants) inventory should cover 1-2 months of consumption.
Supply cycle: imported or customized spare parts (such as servo drives) need to be prepared according to the “supplier delivery cycle + buffer” stock (for example: supply takes 2 weeks, the inventory should be prepared at least 3 weeks).
Equipment criticality: Core components that directly affect the production line (e.g. pressure sensors) need to be doubly stocked.
Historical data: According to the spare parts replacement records in the past year, statistical failure rate, dynamic adjustment of inventory. 2.
2. Classification management (ABC method)
Class A (critical spare parts): high unit price, long supply cycle, large impact of downtime (such as servo motors, controllers), inventory according to the “maximum expected failure cycle + 20% redundancy” stock.
Class B (regular spare parts): medium frequency replacement parts (such as seals, filter elements), the stock is 1.5 times the average monthly consumption.
Category C (low value consumables): bolts, lubricants, etc., can be purchased in bulk (3-6 months consumption).
3. Inventory monitoring
Minimum stock warning: set the lower limit of stock (e.g. replenishment is triggered when 10 cartridges are left).
Regular Inventory: Monthly inventory check and elimination of expired items (e.g. grease has a shelf life of 6 months after opening).
Supplier agreement: sign an emergency supply agreement with the supplier (e.g. response within 48 hours) to reduce the pressure on the inventory of long-cycle spare parts.
Notes
Spare parts compatibility: Record spare parts model / specification (eg: servo motor model Σ-7 series) to avoid mis-purchase.
Environmental storage: Precision spare parts (e.g. sensors) need to be protected from moisture and dust; avoid high temperature storage of lubricants.
Replacement program: Identify general-purpose parts that can be temporarily replaced (e.g., common relays instead of prototype emergency).
Failure records: Establish a spare parts replacement account and analyze the pattern (e.g., screws need to be replaced every 12 months).
Through scientific stocking and dynamic adjustment, the risk of downtime can be minimized, while avoiding excessive capital consumption.
※ If you need help, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. via the page chat tool for assistance.
