What spare parts are needed for a series excitation motor stator winding machine and how should I set up a guaranteed stock?
I. Spare parts list
l Mechanical components
Winding mold: The winding mold is the key component of the winding machine, which directly affects the shape and dimensional accuracy of the winding. Due to long time use or improper operation, the molds may be worn and deformed, and need to be replaced regularly. For example, if the winding specifications are changed frequently, the mold will wear out faster and may need to be replaced once every 1 - 2 years depending on the frequency of use.
Line-up gears and screws: The gears and screws of the line-up mechanism are responsible for accurate line-up. The gears may have worn or broken teeth, and the screws may be bent or worn, affecting the accuracy of the alignment. Typically, they may become defective after about 1 - 3 years of high load operation and need to be replaced.
Tension Wheel: The tension wheel is used to regulate the winding tension and its surface is prone to wear, resulting in unstable tension control. Depending on the material and tension of the wire, it may need to be replaced in 6 - 12 months.
Drive Belt / Chain (if belt or chain drive): The drive components will wear out, stretch, slip or skip teeth with use. Belts may need to be replaced in 6 months - 1 year, chains last a little longer but may need maintenance or replacement in about 1 - 2 years.
Bearings: Used to support rotating parts such as bobbin winder and cable arrester, they are subject to wear and fatigue spalling over a long period of time. Under normal working environment, they may need to be replaced in 2 - 3 years, but the replacement cycle will be shortened if the equipment is under high load or harsh environment.
l Electrical Components
Motor brushes (for series-excited motors): brushes are in contact with the commutator and are prone to wear and tear, and may need to be replaced in 3 - 6 months, depending on the motor's operating time and load.
Contactors and relays: Frequent opening and closing in the control circuit, contacts are prone to oxidation and corrosion. The service life may be around 1 - 2 years, depending on the number of operations.
Fuses: Used to protect circuits from overload and short-circuit currents. It is necessary to stock various sizes of fuses according to the circuit layout of the equipment and the amount of current so that they can be replaced in time after the fuse is blown.
Sensors (e.g., tension sensors, position sensors, speed sensors): These sensors may be affected by vibration, oil, electromagnetic interference, etc. and fail. Generally 2 - 3 years may need to be replaced, but if the working environment is harsh, it may be damaged earlier.
l Other parts
Wool felts, wire nozzles, and other wire crossing parts: Wool felts are used to clean and lubricate the wire, and wire nozzles guide the winding of the wire, and these parts are prone to wear or clogging. Wool felts may need to be replaced in 3 - 6 months and wire nozzles may need to be replaced in 1 - 2 years depending on wear.
Lubricating oil and grease: Used to lubricate the equipment and ensure the smooth operation of mechanical parts. They should be replenished or replaced periodically, depending on the number of lubrication points and lubrication intervals of the equipment.
Seals (e.g. oil seals): used to prevent lubricant leakage and dust from entering the motor and transmission parts, which will deteriorate and wear out after long-term use. Generally 1 - 2 years may need to be replaced.
Second, the protection of inventory setting method
l Based on equipment operation data
Historical failure data collection: Collect the past failure records of the equipment, including information on the failed parts, the time interval between failures, and the frequency of repair and replacement. For example, if the past records show that tension wheels need to be replaced every 8 months on average, then the number of tension wheels in the guarantee stock can be stocked in accordance with the number that ensures the normal operation of the equipment within 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 faster and the guaranteed stock level should be increased accordingly. For example, a winding machine that runs continuously 24 hours a day should have more bearings in its guaranteed inventory than one that runs 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 the event that a supplier is unable to deliver in a timely manner, you can obtain the required spare parts from other suppliers.
l Balancing cost and risk
Consideration of high-value spare parts: For expensive spare parts, such as motors and high-precision sensors, it is important not to stock too many of them, so as not to take up too much money. A reasonable amount of stock can be determined according to the criticality of the equipment and the probability of failure. 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 for a higher guarantee stock. For example, in the case of a winding machine on an automated production line, if the quality of the winding is out of control due to a faulty position sensor, a large number of products will be scrapped, so the guaranteed stock of position sensors should be sufficient to cope with any unexpected situations that may arise.
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