What spare parts are needed for a series excitation motor motor stator press end plate machine and how should I set up a guaranteed stock?
I. Spare parts list
1、Mechanical parts
Press head: This is the part that directly contacts with the end plate for press fitting, which is easy to wear. According to the frequency of use of the equipment and the size of the pressure of the press fitting, the degree of wear will vary. Under high load working conditions, the press head may need to be replaced in a few months.
Bearings: Used to support the rotating shaft of the motor and drive components, they may wear and fatigue and spall over long periods of operation. Generally, they may need to be replaced every 1 - 2 years, depending on the operating hours and load conditions of the equipment.
Transmission Belt / Chain (if any): During the power transmission process, the belt or chain will gradually wear and stretch. If it is a belt drive, it may need to be replaced in half a year to a year; chain drive may have a slightly longer service life, but it may also have problems such as skipped teeth due to wear.
Guide slide: ensure the accuracy of up and down movement of the press head, due to frequent friction, it is easy to wear and affect the precision of press fitting. Its service life may be about 1 - 3 years, depending on the intensity of use of the equipment.
2、Electrical components
Motor brushes (for series-excited motors): as the key components of series-excited motors, brushes contact with the commutator during motor operation and are easily worn. Depending on the running time and load of the motor, they may need to be replaced in 3 - 6 months.
Contactors and relays: In control circuits, they open and close frequently, and their contacts are prone to oxidation and burnout. Service life may be around 1 - 2 years, depending on the number of operations.
Fuses: are used to protect circuits from overloads and short-circuit currents. They will blow in the event of an abnormal circuit condition and need to be replaced in a timely manner. Fuses can be stocked in various sizes, depending on the circuit layout of the equipment and the amount of current.
Sensors (e.g., pressure sensors, position sensors): These sensors may be affected by vibration, oil, electromagnetic interference and other factors in the working environment and fail. Generally 2 - 3 years may need to be replaced, but if the working environment is harsh, it may be damaged earlier.
3、Seals and gaskets
Oil seals: used to prevent lubricant leakage and dust into the motor and transmission components, long-term use will be aging, wear. General 1 - 2 years may need to be replaced.
Sealing washers: used in the connection parts of the equipment to prevent liquid or gas leakage, the material may be damaged due to temperature, pressure and chemical substances, according to the actual situation, may need to be replaced in about 1 - 3 years.
4、Other consumables
Lubricating oil and grease: used for lubrication of the equipment to ensure the smooth operation of mechanical parts. According to the number of lubrication points and lubrication cycle of the equipment, regularly replenish or replace.
Cleaning supplies: such as cleaning brushes, wiping cloths, detergents, etc., are used for the daily cleaning of the equipment to ensure the cleanliness of the surface and interior of the equipment and to prevent the accumulation of dust and impurities.
Second, safeguard inventory setting method
1、Based on equipment operation data
Historical failure data collection: Collect the past failure records of the equipment, including information on faulty parts, the time interval between failures, and the frequency of maintenance and replacement. For example, if the past records show that the indenter needs to be replaced once every 8 months on average, then the number of indenters in the safeguard stock can be stocked in accordance with the number that ensures the normal operation of the equipment in 10 - 12 months.
Runtime and Load Analysis: Consider the impact of equipment runtime and load conditions on component life. For equipment that operates continuously and under high loads, parts will wear out at a faster rate and, accordingly, the quantity of guaranteed stock should be increased. For example, a press-end plate machine that operates continuously 24 hours a day should have more bearings in its guaranteed inventory than one that operates 8 hours a day.
Consider procurement lead times and suppliers
Purchasing lead time determination: Know the purchasing lead time for each type of spare part, i.e., the time it takes from the time an order is placed to the time the goods are received. If the lead time is long, such as 3 - 4 weeks for some specialized sensors, then the guaranteed stock level should be able to cover the number of spares required for the normal operation of the equipment during the lead time.
Supplier assessment: assess the reliability of the supplier, including the timeliness of delivery, product quality and stability. If the supplier is prone to delivery delays, product quality instability, etc., the need to appropriately increase the guaranteed inventory. At the same time, with multiple suppliers to establish a cooperative relationship can reduce the supply risk, to ensure that in a supplier can not be timely delivery, from other suppliers to obtain the required spare parts.
2, cost and risk balance
High-value spare parts considerations: for expensive spare parts, such as motors, high-precision sensors, etc., can not be too much reserve, so as not to take up too much money. Can be based on the criticality of the equipment and the probability of failure to determine a reasonable amount of inventory. For example, for series excitation motors, if the probability of failure is low, but once damaged will lead to a long production stoppage, then 1 - 2 units can be stocked as a guarantee stock.
Failure Impact Assessment: Consider the extent to which an equipment failure will affect production. If the equipment failure will cause serious production delays, huge economic losses or safeguard risks, then the related spare parts should be set up a higher guarantee stock. For example, in an automated production line with a press-end board machine, if the quality of the product goes out of control due to a failure of the pressure sensor, a large number of products will be scrapped, so the guaranteed stock of the pressure sensor should be sufficient to cope with any unexpected situation that may arise.
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