What spare parts are needed for an automatic single-station fine-turning machine for motor rotors and how to set up a guaranteed stock?
Motor motor rotor automatic double-station precision turning machine spare parts and set up to protect the stock:
I. Spare parts for mechanical parts
l Cutting tools
Spare parts: various sizes of turning tools (such as external turning tools, internal hole turning tools), milling cutters (if there is a milling function), drills and so on are essential. Prepare tools of different materials (e.g., carbide, high-speed steel) and edge types according to the common materials and shapes of the machined rotors.
Guaranteed stock setup: Considering the frequency of machining tasks and the service life of the tools, generally maintain a guaranteed stock of at least 5 - 10 pieces of each commonly used tool. For special specifications or customized tools, as their procurement cycle may be longer, the stock can be increased to 3 - 5 pieces, and the stock quantity and quality of tools can be checked regularly.
l Clamps and positioning elements
Spare parts: spare fixture clamping blocks, locating pins, locating bushings, etc. These components are prone to wear after long-term use. These components are prone to wear and tear after long-term use, affecting machining accuracy.
Guaranteed stock setting: According to the complexity and fragility of the fixture, keep 3 - 5 sets of guaranteed stock for each specification of clamping blocks and positioning elements. For frequent change of workpiece types, increase the stock of positioning elements to cope with the positioning needs of different sizes and shapes of workpieces.
l Drive components
Spare parts: belts, chains, sprockets, gears, screws, guide slides, etc.. These components may wear out, break, etc. during long-term operation.
Setting up of stock for protection: For belts and chains, prepare at least 2 - 3 sets according to the frequency of use and load of the equipment. For sprockets and gears, prepare 1 - 2 sets, and for screws and guide slides, 1 - 2 sets of each specification. Regularly check the wear and tear of these transmission parts, and adjust the guarantee stock with the procurement cycle and replacement frequency.
Second, electrical parts spare parts
l Sensor
Spare parts: displacement sensors, speed sensors, pressure sensors and so on. Failure of sensors may lead to loss of machining accuracy or equipment abnormality.
Safeguard stock setting: Keep 2 - 3 pieces of each type of sensors as safeguard stock. Since the accuracy and type of sensors are strictly required to be compatible with the control system of the equipment, make sure that the specifications of the spare parts are consistent with the original equipment and that they are calibrated and tested regularly.
l Motors and Drives
Spare parts: spindle motors, feed motors, motor drives, etc. Motor failure will directly affect the normal operation of the equipment, and driver failure may result in the motor not being controlled properly.
Safeguard stock setup: Prepare at least 1 - 2 sets of each size of motor and drive. Considering the high price of motors and drives, the inventory can be reasonably set up by combining the historical failure data and maintenance cycle of the equipment. At the same time, pay attention to the storage environment of spare parts to avoid moisture, electromagnetic interference and other conditions.
l Electrical control components
Spare parts: relays, contactors, fuses, switching power supply, PLC input and output modules, etc. These components play a role in the electrical control system. These components play a key role in the electrical control system and are prone to failure.
The guaranteed stock setting: 5 - 10 pieces of relays and contactors for each specification, 10 - 20 pieces of fuses according to different current specifications, 1 - 2 pieces of switching power supply, 1 - 2 sets of PLC input/output modules according to the actual configuration of the equipment and the probability of failure. Regularly test the function of these spare parts to ensure good performance.
Other spare parts
l Lubrication and cooling system components
Spare parts: lubricating oil, grease, oil pump, cooling pump, coolant filter and so on. The lubrication and cooling system is crucial to the normal operation and service life of the equipment.
Safeguard stock setting: Lubricating oil and grease are kept in stock in sufficient quantity for one month's use according to the lubrication cycle and usage of the equipment. Prepare 1 - 2 oil pumps and cooling pumps of each kind, and 3 - 5 coolant filters according to the replacement cycle.
l Seals and protective parts
Spare parts: all kinds of seals, gaskets, protective door switches, protective cover and so on. Damage to seals may lead to leakage of coolant or entry of dust into the equipment, and damage to protective parts may affect the security of the equipment.
Safeguard stock setup: 10-20 seals and gaskets of each type depending on the quantity and specifications used on the equipment. Protective door switches and shields are prepared 1 - 2 each.
Fourth, the protection of inventory management methods
l Inventory list management
Establish a detailed inventory list of spare parts, including the name of spare parts, specifications, quantity, storage location, procurement cycle, supplier information and so on. Use spreadsheets or professional inventory management software to record and manage for easy inquiry and update.
Regular Inventory and Update
Regularly (e.g. monthly or quarterly) inventory of spare parts stock to ensure that the actual stock quantity is consistent with the inventory list. At the same time, the quantity and types of the safeguarded inventory are updated in a timely manner according to the use of the equipment, the frequency of failures and maintenance records.
l Quality Inspection and Maintenance
Conduct regular quality inspection on the spare parts in stock, such as checking the performance of electrical components and the dimensional accuracy of mechanical parts. For spare parts stored for a long period of time, pay attention to their preservation environment and shelf life to avoid performance degradation or damage due to long storage time.
l Purchasing Plan Development
Based on the very low stock level of guaranteed stock and the procurement cycle, a reasonable procurement plan is formulated. Before the stock quantity is lower than the lower limit of guaranteed stock, place orders with suppliers in time to ensure the supply continuity of spare parts. At the same time, we establish a good relationship with multiple suppliers so that we can quickly obtain the required spare parts in case of emergency.
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