What spare parts are needed for a brushless motor motor automatic rotor magnetizer and how to set up a safeguard stock?
Brushless motor motor automatic rotor magnetizer in the process of operation may be damaged parts, in order to ensure that the equipment can resume operation in a timely manner to reduce the loss of downtime, you need to reserve some spare parts and set up a reasonable protection stock. The following is a detailed introduction:
I. Spare parts needed
1、Electrical
Power module: In the process of magnetization, the power module undertakes the important task of converting electric energy into high energy pulse suitable for magnetization. After a long time of use, the power module may be damaged due to overheating, overcurrent and other reasons, so it needs to be stocked.
Control board: The control board is the control core of the magnetizer, which is responsible for coordinating the work of various components and accurately controlling the time, intensity and other parameters of the magnetization. Once the control board fails, the magnetizer will not be able to operate normally, so it should be stocked.
Sensors: including temperature sensors, current sensors, position sensors, etc.. Temperature sensors are used to monitor temperature changes during the magnetization process to prevent the equipment from overheating; current sensors are used to accurately measure the magnetizing current; and position sensors ensure that the rotor is in the correct position during magnetization. The accuracy of these sensors is critical to the effectiveness of the magnetization process and they are prone to failure and need to be stocked.
Fuse: The fuse is a safeguard protection device in the circuit. When an overload or short circuit occurs in the circuit, the fuse will automatically fuse to cut off the circuit and protect other electrical components. It is a wearing parts, need to reserve different specifications.
Relay: Relay is used to control the on-off of the circuit and plays an important role in the electrical control system of the magnetizer. Due to frequent action, the contacts of the relay are easy to wear and need to be stocked.
2、Mechanical
Rotor Fixture: The rotor fixture is used to fix the rotor to ensure the accurate position of the rotor during the magnetizing process. After long-term use, the fixture may affect the positioning accuracy due to wear and deformation, and it is necessary to reserve fixtures of different specifications to adapt to different rotors.
Transmission Belt: The transmission belt is used to transmit power and make the various mechanical parts of the magnetizer work together. In the process of operation, the belt will be worn, slack and so on, resulting in a decline in transmission efficiency, so it is necessary to stock.
Bearings: Bearings support the rotation of the rotor and other rotating parts and are subject to high pressure and friction. After a long time of operation, the bearings are easy to wear, affecting the stability and accuracy of the equipment, need to reserve the right type of bearings.
Guideway slider: The guideway slider provides precise guidance for the movement of the rotor and ensures the accuracy of the magnetizing position. If the guide rail slider is worn or damaged, it will lead to poor rotor movement and affect the magnetizing effect, so it should be stocked.
3、Other consumables
Capacitor: Capacitor is used to store and release energy in the magnetizer, and is a key component in the magnetizing process. With the increase of using time, the performance of capacitor may decline, so you need to reserve a certain number of capacitors.
Resistors: Resistors are used to regulate the current and voltage in the circuit to ensure the stable operation of the circuit. Resistors of different specifications play different roles in the electrical system of the magnetizer, and it is necessary to reserve some common specifications of resistors.
Second, the method of setting the protection stock
1、According to the historical failure data
Collect the failure records of the magnetizer in the past period of time (e.g. one year or several years), and count the replacement frequency and quantity of each spare part. For example, if the power module has been replaced 3 times in the past year, with 1 unit replaced each time, the guaranteed inventory level of the power module can be initially determined based on this data.
Analyze the pattern and trend of failures, and consider whether there are seasonal and cyclical factors that affect the occurrence of failures. If a certain type of spare parts in a particular season or time period of high replacement frequency, should be appropriate to increase the time period of the guaranteed inventory.
2、Consider the supplier supply cycle
Communicate with the supplier of spare parts to understand their supply cycle. If the supplier's supply cycle is long, for example, it takes 30 days to arrive, then in order to avoid the lack of stock caused by equipment downtime for a long time, it is necessary to set a higher protection of inventory.
Evaluate the reliability of the supplier, including the quality of their products, on-time delivery and so on. For the lower reliability of the supplier, should be appropriate to increase the guaranteed inventory, in order to cope with possible supply delays.
3. Combine the importance of the equipment and production plan
If the magnetizer is a key piece of equipment in the production line, which will have a serious impact on the whole production if it is shut down, then it is necessary to set a higher guaranteed inventory to ensure that the equipment can be repaired in time to reduce the impact on production.
According to the production schedule, predict the frequency of use and running time of the equipment. If the recent heavy production tasks, the equipment needs to run continuously for a long time, then you can appropriately increase the guarantee stock of spare parts.
4, the use of mathematical models
You can use some classic inventory management models, such as the economic order quantity model (EOQ), guarantee inventory model. These models take into account the uncertainty of demand, ordering costs, holding costs and other factors, through the calculation of the very best guaranteed inventory level.
For example, the guaranteed inventory formula:, where is the guaranteed inventory, is a coefficient related to the service level (e.g., about 1.65 for a service level of 95%), and is the standard deviation of demand in the lead time. By counting the historical demand data and calculating the standard deviation of the demand during the lead time, combined with the desired service level, the guaranteed stock can be calculated.
※ If you need help, please contact the technical specialist of Xinhui Mechatronics Equipment Co., Ltd. via the page chat tool for assistance.
