What are the spare parts needed for motor motor rotor double station spot welder and how to set up guarantee stock?
A list of spare parts for motor motor rotor duplex spot welder:
(A) mechanical parts
l electrode-related spare parts
Electrode head: Since the electrode head will be worn out continuously during the welding process, it is one of the parts that should be replaced frequently. Various sizes of electrode heads should be stocked according to the specifications and models of electrode heads used in the welding machine to suit different welding needs. For example, for copper alloy electrode head, different diameters (such as 3mm, 4mm, 5mm, etc.) should be stocked.
Electrode holders: Electrode holders are used to fix the electrode head, which may be worn and deformed after long-term use. Prepare the appropriate amount of spare parts for the electrode holder to ensure that it matches the connection between the electrode head and the body of the welder.
Electrode Clamps: The function of electrode clamps is to clamp the electrode to prevent the electrode from loosening during the welding process. Stock up some electrode clamps, especially the spring-type electrode clamps which are easy to be damaged, to ensure that the electrode is stable.
l Spare parts for pressurizing mechanism
Pneumatic or hydraulic cylinder parts (if applicable): For pneumatic or hydraulic pressurized welders, pistons, piston rods, seals, etc. are critical spare parts. Pistons and rods can wear out and seals are prone to deterioration leading to leaks, so stock up on the appropriate parts. For example, prepare seals such as piston rings and O-rings according to the type of cylinder used in the welder.
Springs (if mechanically pressurized): In a mechanically pressurized mechanism, springs provide pressure. Springs may lose their elasticity after a long period of compression and relaxation. Stock different sizes of springs, including different coefficients of elasticity and sizes, to meet the pressure requirements of the welder.
Connecting rods and cams (if available): These parts are used to transmit pressure and motion and are susceptible to wear or distortion. Stock up some connecting rods and cams to ensure that their dimensions and materials are the same as the original parts of the welding machine.
l Fixture spare parts
Collets: The collets of the fixture are in direct contact with the motor rotor, and frequent clamping and unclamping motions may lead to collet wear. According to the type and size of the fixture, stock a variety of collets, such as flush collets and V-shaped collets, to adapt to different shapes and sizes of the rotor.
Locating pins and blocks: Used to locate the motor rotor and ensure accurate welding position. Positioning pins and blocks may wear out or be damaged, so it is necessary to stock a certain number of spare parts and ensure that their accuracy meets the requirements.
Fixture transmission parts (e.g., gears, screws, etc.): If the fixture is mechanically driven, gears, screws, and other parts may wear out or break. Stock these parts and pay attention to their accuracy and installation when replacing them.
(ii) Electrical parts
l Welding transformer spare parts
Winding coils: Although welding transformers are relatively stable, prolonged high load operation may cause damage to the winding coils. Stock winding coils that match the transformer, including primary and secondary windings. Pay attention to the number of turns, wire diameter, insulation grade and other parameters that are consistent with the original transformer.
Insulating materials: The insulating materials of the transformer (such as insulating paper, insulating paint, etc.) are crucial to ensure the normal operation of the transformer. Stock a certain amount of insulating materials for the repair and maintenance of the transformer to prevent short circuit between windings.
Iron core (optional): In rare cases, the transformer core may become magnetically saturated or damaged. If the conditions permit, you can reserve some iron core spare parts, but due to the high cost of iron core and the relative complexity of replacement, you can decide the quantity of reserve according to the actual situation.
l Controller and circuit board spare parts
Programmable Logic Controller (PLC) module (if applicable): PLC is the core component of welder control, reserve some key PLC modules, such as CPU module, input and output modules. Make sure the model and program compatibility of the spare parts are consistent with the original PLC.
Control circuit boards: including power supply boards, drive boards and other circuit boards. The electronic components on these boards (e.g. capacitors, resistors, chips, etc.) may be damaged. Stock up some common control circuit boards and understand their circuit principles and repair methods.
Relays and contactors: Used to control the on/off of circuits, the contacts are prone to ablation. Reserve a variety of specifications of relays and contactors, including different rated current and voltage levels to meet the control needs of the welder.
l Sensor spare parts
Pressure sensor: pressure sensor is very important for controlling electrode pressure. Stock up spares of the same type as the original pressure sensor of the welder and pay attention to its range, accuracy and other parameters. After replacement, calibration may be required.
Temperature sensor (if any): Used to monitor the temperature of the weld joint to ensure the quality of the weld. Stock temperature sensors with performance indicators such as response time and measuring range that match the original sensor.
Displacement Sensor (if available): In some welding machines that require precise control of electrode displacement, the displacement sensor is a key component. Stock the displacement sensor and consider its linearity, resolution and other parameters consistent with the original equipment.
l Electrical Connection Components
Power and signal cables: Power and signal cables may be broken and aged due to long-term use. Reserve wires of different specifications, including wire diameter, insulation material, shielding performance and other parameters to meet the requirements of the welding machine. At the same time, prepare some wire connectors, such as plugs, sockets, terminals and so on.
Fuse: Fuse is the protection device of the circuit, it will fuse when the circuit is overloaded or short-circuited. Stock a variety of fuses with rated currents, whose size and fusing characteristics should match the circuit of the welder.
(iii) Other components
l Cooling system components
Cooling fan: If the welder is cooled by air-cooling, the cooling fan may fail. Stock the cooling fan with the same model as the original fan, including its size, airflow, speed and other parameters to be consistent.
Heat sink (if applicable): For some high power welders, a heat sink is used to dissipate heat. Stock up on radiators and pay attention to their heat dissipation performance, connection with other components, etc.
Coolant (if water-cooled system): Water-cooled system needs coolant, stock up enough coolant and change it regularly according to the requirement of the equipment.
l Lubrication and protection parts
Lubricating oils and greases: These are used to lubricate mechanical parts, such as electrode holders, fixture drive parts, etc. Stock different types of lubricants and greases, such as high temperature lubricants, extreme pressure greases, etc., to meet the lubrication needs of different parts.
Protective gloves and goggles: These are the operator's protective gears and are easily damaged or soiled. Stock a sufficient number of protective gloves and goggles to ensure their quality meets safeguard standards.
II. Methods for setting up safeguard stock
(i) Based on equipment failure frequency and maintenance cycle
l Failure frequency statistics
Collect records of past failures of the welding machine, including information on the type of failure, time of failure, and spare parts required for repair. Through the analysis of these records, determine the failure frequency of each spare part. For example, statistics reveal that electrode heads need to be replaced on average every two weeks, while transformer winding coils may fail only once every two years.
The frequency of failures is used to determine the basic guaranteed stock levels. For high frequency failure parts, such as electrode head, should maintain a relatively large inventory, such as stocking enough to use a month's quantity; for low frequency failure parts, such as transformer core, you can stock 1 - 2 as a spare.
l Maintenance cycle consideration
Consider the maintenance cycle and maintenance ability of maintenance personnel. If the maintenance personnel can quickly repair the equipment failure, and spare parts supply in time, then the guaranteed stock can be appropriately reduced. However, if the repair cycle is longer, or if you need to wait for spare parts from external suppliers, then the guaranteed stock should be increased accordingly. For example, for some special spare parts that need to be purchased from abroad, considering the longer procurement cycle, sufficient quantity should be stocked to cope with the possible long waiting time.
(ii) Combination of equipment running time and production tasks
l Estimation of equipment running time
Based on the estimated annual running time of the welding machine and the service life of each component, the replacement cycle of the component is calculated. For example, if it is known that the welder operates for 2000 hours per year and the electrode holder has a service life of 10,000 hours, then the electrode holder will need to be replaced approximately every five years. Based on this replacement cycle, determine the amount of guaranteed stock to ensure that parts are available when they need to be replaced.
Consider the effect of the intensity of the equipment's operation on component life. If the welder is operated under high load and frequency, the wear and tear of the parts will be accelerated, and the guaranteed stock will need to be increased. For example, for a production line with continuous welding operations, the guaranteed inventory of electrode-related parts is greater than for a welder used intermittently.
l Production Task Prioritization
Adjust the guaranteed stock according to the priority of production tasks. If a welding machine is critical to the task of producing a critical product, then the safeguarded inventory of spare parts for that welding machine should be increased appropriately. For example, for a welding machine producing rotors for aerospace motors, in order to avoid production stoppage due to equipment failure, ensure that there are sufficient spare parts, even if the frequency of failure of certain parts is low, and the stock can be increased.
(iii) Consideration of supplier factors
l Supplier delivery time and reliability
Understand the supplier delivery time for each type of spare part, including normal delivery time and possible delays. For parts with long lead times, increase the safeguard stock. For example, some customized sensors may have a lead time of up to three months, so stock sufficient quantities to cover possible failures during that time.
Evaluate supplier reliability, including the supplier's reputation, product quality, and supply stability. If the supplier's reliability is low, to minimize the risk of supply interruptions, it is necessary to increase the guaranteed inventory or find alternate suppliers. Partnerships can be established with multiple suppliers to obtain spare parts from other suppliers in case one supplier is unable to deliver on time.
l Low order quantities and procurement costs
Consider suppliers' low MOQ requirements. Some suppliers may require certain low MOQs, which may affect the setup of guaranteed stock. If the low MOQ is large and the equipment's need for the part is relatively small, it may be appropriate to increase the safeguarded inventory, but balancing the cost of the inventory.
Analyze the impact of procurement costs on guaranteed inventory. For higher-priced spare parts, under the premise of ensuring the normal operation of the equipment, it is prudent to set the guaranteed inventory quantity to avoid excessive inventory to occupy funds. However, for lower-priced parts, such as fuses and screws, the inventory can be appropriately increased to reduce the workload of frequent procurement.
※ If the above ways and means still can not solve the equipment failure, please contact the technical specialist of Xinhui Electromechanical Equipment Co., Ltd. through the page chat tool to seek help.
