What spare parts are needed for motor motor rotor automatic air blades machine and how to set up guarantee stock?
First, the type of spare parts
1、Mechanical parts
l Motor bearing
Motor bearings are the key wearing parts. Due to the continuous operation of the motor, the bearings are subjected to large radial and axial forces, and are prone to wear and fatigue and other problems. The specifications of bearings are different for different types of motors, and they should be stocked according to the motor type of the equipment.
For example, for commonly used small and medium-sized motor motor rotor automatic air blade machine, deep groove ball bearings are the more common type. Their service life is related to the operating conditions of the motor. Under normal load and speed, they may need to be replaced in 2 - 3 years in general.
l Wind Blade
Wind blades may be damaged during long-term operation due to impact by foreign objects, material aging, unbalanced wear and other reasons. Damaged air blades will lead to increased vibration, insufficient airflow and other problems.
The wind blade is made of various materials, such as plastic, aluminum alloy and so on. Plastic wind blade is relatively brittle, easy to rupture in harsh environments; aluminum alloy wind blade is stronger, but may be deformed. According to the use environment of the equipment and the service life of the wind blades, generally every 3 - 5 years may need to be replaced, to reserve the same type and specifications of spare parts with the original equipment wind blades.
l Drive belt (if any)
The belt is an important transmission component in motor-motor rotor automatic air blades machines that utilize a belt drive. Belts are subject to wear, slack, etc. as they are used over time.
Types of belts include delta belts, synchronous belts, etc. The service life of a V-belt is generally around 1 - 2 years, while a synchronous belt may have a slightly longer service life of around 2 - 3 years. It is important to stock suitable spare parts according to the transmission requirements of the equipment and the type of belt.
l Couplings (if any)
Couplings are used to connect the motor shaft to the fan blade shaft to transmit torque. The coupling is susceptible to wear, deformation, and damage to the keyway when it is frequently started, stopped, or subjected to shock loads.
Depending on the material of the coupling (e.g., flexible coupling, rigid coupling) and the operating conditions of the equipment, their service life varies. The elastic elements in flexible couplings may need to be replaced in 1 - 2 years, while rigid couplings are relatively durable, but may need to be replaced as a whole in the event of a failure, and stockpiling of spare parts is generally considered every 3 - 5 years.
2. Electrical components
l Motor Winding
Although motor windings are relatively durable, they may be damaged under over-voltage, overload, short-circuit and moisture conditions. For some equipment with harsh working environment (such as humidity, dusty, frequent starting and stopping), the probability of motor winding damage will increase.
Motor windings are customized according to the motor's power, number of poles and other parameters, and when stocking them, make sure that they match exactly with the equipment's motor model. As motor windings are more costly and complicated to replace, they can be appropriately stocked according to the importance of the equipment and the probability of failure, and generally may need to be replaced every 5 - 10 years (under normal operating conditions).
l Capacitors (if any)
Capacitors play a role in improving the power factor and providing starting torque in the starting and running circuits of motors. Capacitors can be damaged by aging, overvoltage, overcurrent, etc. The service life is generally 3 - 5 years.
Their service life is generally around 3 - 5 years. When stocking capacitors, it is important to note that their withstand voltage value, capacity and other parameters are consistent with the requirements of the equipment.
l Fuses and Circuit Breakers
Fuses and circuit breakers are used to protect circuits from overloads and short circuits. Fuses are single-use components that need to be replaced each time they blow; circuit breakers can be reset after tripping, but may need to be replaced if they operate frequently.
Stock different sizes of fuses and circuit breakers, depending on the current level of the equipment and circuit protection requirements. Due to the relatively low price of these components, and the probability of failure is relatively high, you can appropriately reserve more, such as in accordance with the number of equipment 10% - 20% of the reserve.
l Sensors (e.g. temperature, vibration, speed sensors)
Temperature sensors are used to monitor the temperature of the motor and equipment to prevent overheating; vibration sensors can detect the vibration of the equipment, timely detection of imbalance, bearing damage and other issues; speed sensors are used to monitor the rotational speed of the wind blades and motor.
These sensors may fail due to environmental factors (e.g., temperature, humidity, dust), aging of components due to long-term use, etc. The sensors are designed for use in a variety of applications. Their service life is generally about 3 - 5 years, reserve to ensure that the model and parameters of the sensor is compatible with the control system of the equipment.
3、Sealing and fastening components
l sealing gasket
Sealing gaskets are used to seal the motor and the shell of the equipment to prevent dust, moisture and so on into the equipment. With the passage of time, the sealing washer will be aging, deformation, resulting in reduced sealing effect.
Generally, they need to be replaced every 2-3 years. Stock sealing washers that match the size and material of the equipment sealing part.
l Tighten bolts and nuts
The bolts and nuts in the equipment may loosen, lose or be damaged during long-term vibration. Different parts of the bolts and nuts of different specifications, to reserve with the equipment connection parts to match the various specifications of the fastening parts, especially the wind blade fixing bolts, motor mounting bolts and other key parts of the components.
Second, safeguard inventory setting method
1、Method based on historical data
l Collect failure data
Record data on the number of failures and the time between failures for each type of spare part in the past period of time (e.g., 1 - 3 years). For example, the number of failures of motor bearings in the past 3 years is 6, and the average time between failures is 18 months.
l Calculate the guaranteed stock level
Calculate the guaranteed stock level according to the number of equipments, operation time and procurement cycle. Assuming that there are 20 pieces of equipment and the procurement cycle is 3 months, taking motor bearings as an example, the expected number of failures in 3 months is, and the guaranteed stock can be set to 4 after rounding upwards.
2、Method of considering risk factors
l Supplier risk
Evaluate the reliability of the supplier, including delivery time, product quality and so on. If the supplier's delivery time is not stable, the procurement cycle may be extended. For example, the supplier's average delivery time is 1 month, but the long delivery time has reached 3 months, and there is a 10% probability of such a situation, then this risk should be considered when calculating the guaranteed stock.
l Equipment Importance Risk
For critical production equipment, the loss caused by downtime is huge. For example, one hour's downtime of a motor rotor automatic air blower in a production line can result in a production loss of 100,000 yen. In this case, in order to minimize downtime, it is necessary to set a high level of guaranteed inventory even if some spare parts are expensive. Reasonable guaranteed stock can be calculated according to the downtime loss and spare parts replacement time. For example, if it is expected to take 1 hour to replace a motor bearing, 6 - 8 bearings may be set up as guaranteed stock in order to avoid downtime loss due to out-of-stock bearings.
3、Dynamic adjustment strategy
l Regular assessment
Periodically (e.g. quarterly or annually) evaluate the guaranteed stock. Check whether the quantity of stock meets the actual demand and whether the quality of spare parts still meets the requirements. For example, if some sealing washers are found to have deteriorated due to long storage time during inventory, they should be handled and replenished with new washers in time.
l Adjustment according to equipment changes
When the equipment for upgrading, replacement of new parts or change the operating conditions, to adjust the protection of inventory. For example, if the equipment is replaced with a new model of motor, and the bearing specifications of the motor and the parameters of other parts have changed, the list of spare parts and the quantity of safeguarded inventory should be updated.
※ If you need any help, please contact the Technical Specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool for assistance.
