What spare parts are needed for the fully automatic terminal press with series excitation motor motor and how to set up the guarantee stock?
I. Spare parts list
1、Mechanical parts
Molds and cutting tools: these are the parts that directly act on the terminal crimping, which are easy to be worn or damaged due to the frequent stamping action. Different specifications of terminal crimping molds and cutting tools should be used as standing spare parts, such as European terminal molds, American terminal molds.
Transmission belts and chains: used to transmit power, if slack, worn or broken, it will affect the normal operation of the equipment. According to the transmission mode of the equipment, prepare the corresponding type of belt (such as V-belt, synchronous belt) and chain.
Gears and Drive Shafts: In mechanical drive systems, gear teeth may wear out and drive shafts may become bent or worn. For gears and drive shafts in critical areas, a certain number of spare parts need to be stocked.
Bearings: Bearings are used in many places such as motors and transmission parts, and long-term operation may lead to bearing wear, ball damage, etc. Spare parts for bearings of different specifications should be prepared.
Screws, nuts and washers: Although these small parts do not seem to be important individually, the screws may loosen and be lost during the operation of the equipment, so it is necessary to reserve a variety of commonly used specifications of screws, nuts and washers to facilitate timely replacement.
2、Electrical components
Motor: as the power source of the equipment, the motor may be damaged due to overload, short circuit, insulation aging and other reasons. It is important to stock the same type of motor as the original motor of the equipment, or at least a motor that is compatible.
Sensors: such as pressure sensors, position sensors, etc., are used to detect and provide feedback on the operating status of the equipment. Sensors may lose accuracy or be damaged due to environmental factors, long-term use, and spare sensors should be prepared.
Relays and contactors: In electrical control systems, they are used to control the on-off of circuits. Frequent actions may cause the contacts to wear out and stick, so it is necessary to stock some common types of relays and contactors.
Fuses and circuit breakers: they are used to protect circuits from damage caused by overloads and short circuits. Fuses need to be replaced promptly when they blow, and circuit breakers may fail, so stock up on fuses and circuit breakers of appropriate sizes.
Wires and cables: Wires may be damaged due to aging, wear and tear, short circuits, etc. Wires and cables of different specifications need to be prepared for repair and replacement.
3、Other Components
Seals and gaskets: Some parts of the equipment need to be sealed, such as hydraulic systems (if any), control cabinets, etc. Aging or damage to seals and gaskets can lead to leaks and other problems, so stock up on a variety of seals and gaskets.
Lubricating grease and lubricating oil: Used for lubrication and maintenance of equipment to ensure the smooth operation of mechanical parts. According to the lubrication requirements of the equipment, reserve the appropriate grease and lubricating oil.
Operation panel and buttons: the operation panel may appear key failure, display damage, etc., buttons may also be damaged due to frequent use, to prepare spare operation panel and buttons.
Second, to protect the inventory setup method
1、Based on equipment failure rate statistics
Record the equipment in the past period of time (for example, a year) the failure frequency of each component. For frequent failure of components, such as molds, tools, fuses, etc., set a higher guarantee stock. For example, if a certain model of terminal crimping molds need to be replaced every three months on average, then the guaranteed inventory can be set to at least meet the number of half a year's use.
2, consider the procurement cycle
Understand the procurement cycle of each spare part, including the supplier's production time, transportation time, etc.. For the procurement cycle of long parts, such as certain special specifications of the motor, customized gears, etc., to appropriately increase the guaranteed inventory. Assuming that the procurement cycle of a certain foreign imported sensor is three months, then the guaranteed stock should guarantee the quantity required for normal maintenance of the equipment within these three months.
According to the importance of components and the degree of impact on production
For those parts that are critical to the normal operation of the equipment and production, such as motors, key sensors, etc., even if the procurement cycle is short, should set up enough to protect the inventory. Because once these parts are damaged, the equipment will not work properly, which will lead to production stagnation. For some of the smaller impact on production components, such as individual buttons on the operating panel, you can set a relatively low guarantee inventory.
3, combined with the cost and capital utilization
Under the premise of ensuring equipment maintenance and normal production, the cost of spare parts should be considered. For expensive parts, such as high-precision molds, imported motors, etc., can be negotiated with the supplier of emergency supply, appropriate lower guarantee stock, but to ensure that it can be obtained in a timely manner in case of emergency. For inexpensive but easily damaged parts, such as screws, washers, etc., you can appropriately increase the guaranteed inventory to reduce the workload and cost of frequent procurement.
4, regular assessment and adjustment
Safeguard inventory is not static, the need for regular (for example, every six months) inventory and assessment of inventory. The quantity and type of safeguarded inventory is adjusted in a timely manner based on factors such as the renewal of equipment (e.g., certain parts are no longer used after equipment upgrades), changes in the frequency of replacement of parts (e.g., the failure rate of certain parts is reduced through equipment maintenance and improvement), and changes in suppliers (e.g., shorter or longer delivery times from suppliers).
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