What spare parts are needed for motor motor rotor duplex tester and how to set up guarantee stock?
A list of spare parts for motor motor rotor duplex tester:
(I) Mechanical parts
l Clamp related spare parts
Collet: The collet is the part that directly contacts with the motor rotor and fixes the rotor, which is easy to wear out. According to the models and specifications of the tester fixture, stock a variety of sizes and types (e.g., flush collets, V-shaped collets) of collets to adapt to different shapes and sizes of motor rotors.
Positioning pins and blocks: Used to determine the position of the motor rotor to ensure test accuracy. Due to frequent positioning operations, the locating pins and blocks may wear out or be damaged, so it is important to stock a sufficient number of spares and their accuracy should meet the requirements of the tester.
Fixture springs and screws: springs provide clamping force and may lose their elasticity after long-term use; screws are used to fix various parts of the fixture and may become loose or damaged. Stock different sizes of springs and screws to ensure that they match the fixture model.
l Drive train spare parts
Belts and chains (if applicable): If the tester is driven by belts or chains, stock a quantity of spare belts and chains. Consider different lengths and types in case of wear or breakage. Also, have the appropriate pulleys and sprockets on hand, as they too may be subject to wear.
Gears: Gear drives are more common in testers, and the teeth of gears are prone to wear. Stock up on gears of various sizes, including modulus, number of teeth and other parameters to be consistent with the drive system of the tester. For high-precision testers, the precision grade of the gears also needs to be considered.
Screws and guide rails (if applicable): In some testers that utilize screw and guide rail drives, wear and tear on the screws and guide rails can affect motion accuracy. Keep a stock of spare silk rods and guide rails and note that their pitch, diameter, accuracy and other parameters are the same as those of the original parts. At the same time, prepare supporting parts such as nuts for the screws and sliders for the guide rails.
l Workbench spare parts
Workbench table (optional): If the workbench table is seriously deformed, damaged beyond repair, it may be necessary to replace the entire table. According to the size and material of the tester's table, stock the appropriate table top spare parts.
Bench support feet and adjusting screws: The support feet are used to support the bench and the adjusting screws are used to adjust the leveling of the bench. These parts may be damaged or lost, reserve a certain number of support feet and adjusting screws to ensure the stability of the table.
(ii) Electrical parts
l Sensor spare parts
Displacement sensor: according to the type of displacement sensor used in the test machine (such as scale, magnetic scale, inductive sensors, etc.), reserve the same type of sensor. Displacement sensors are very important for measuring the position and size changes of the motor rotor, to ensure that the accuracy of the spare parts, range and other parameters consistent with the original sensor.
Speed sensors: Speed sensors (such as photoelectric encoders, Hall sensors, etc.) are used to measure the rotational speed of the motor rotor. When stocking speed sensors, it is important to note that their resolution, response frequency and other performance indicators are the same as those of the original sensor to ensure the accuracy of speed measurement.
Pressure sensors and temperature sensors (if applicable): If the tester involves pressure and temperature testing, stock the appropriate pressure sensors and temperature sensors. Pressure sensors should be considered for their range, accuracy and interface type; temperature sensors should be noted for their measuring range, accuracy and mounting method.
l Controller and circuit board spare parts
Programmable Logic Controller (PLC) module: PLC is the core component of the tester control, reserve key PLC modules, such as CPU module, input and output modules. Ensure that the model and program compatibility of the spare parts are consistent with the original PLC, and understand how to backup and restore the program.
Control circuit boards: These include power supply boards, driver boards, signal processing boards, and various other circuit boards. The electronic components (such as capacitors, resistors, chips, etc.) on these boards may be damaged. Stock up on some common control circuit boards and be familiar with 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 test machine. Also, prepare some contact assemblies for replacement in case of minor contact ablation.
l Electrical Connection Components
Power and signal cables: Reserve power and signal cables of different specifications, including wire diameter, insulation materials, shielding performance and other parameters to meet the requirements of the test machine. At the same time, prepare all kinds of wire connectors, such as plugs, sockets, terminals, etc., in order to cope with the damage of the line or the need to extend the line.
Fuses and Circuit Breakers: Fuses and circuit breakers are protection devices for circuits that will act when there is an overload or short circuit in the circuit. Stock fuses and circuit breakers in a variety of current ratings, with sizes and fusing characteristics that match the circuitry of the tester. And check the condition of the fuses and circuit breakers periodically to ensure that they are working properly.
(iii) Other components
l Cooling system components (if any)
Cooling fan: If the tester uses air-cooling to cool electrical components or motors, 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 should be the same. Also, prepare accessories such as mounting screws and connecting wires for the fan.
Heat sink (if applicable): For some high-power electrical components or motors, a heat sink is used to dissipate heat. Stock heat sinks and pay attention to their heat dissipation performance, how they are connected to other components, and so on. If the heat sink is connected to the heat generating element through thermally conductive silicone grease, also stock an appropriate amount of thermally conductive silicone grease.
Coolant (if water-cooled system): Water-cooled system needs coolant, reserve enough coolant and replace it regularly according to the requirements of the equipment. At the same time, prepare spares of pipes, joints and other components of the water-cooled system to prevent leakage and other situations.
l Lubrication and protection parts
Lubricating oil and grease: Used for the lubrication of mechanical parts, such as movable joints of fixtures, gears and screws of transmission mechanism. Stock different types of lubricants and greases, such as high temperature lubricants, extreme pressure greases, etc., to meet the lubrication needs of different parts. At the same time, prepare some lubrication tools, such as grease guns, oil jugs, etc.
Protective gloves and goggles: These are the operator's protective equipment and are easily damaged or soiled. Stock a sufficient number of protective gloves and goggles to ensure that their quality meets the relevant standards. And we should regularly check the status of protective equipment and replace damaged gloves and goggles in time.
Second, the method of setting up the protection stock
(i) Based on equipment failure frequency and maintenance cycle
l Failure frequency statistics
Collect the past failure records of the testing machine, including the type of failure, the time of failure, the spare parts required for maintenance and other information. By analyzing these records, determine the failure frequency of each spare part. For example, it was found that collets need to be replaced every two months on average, while PLC modules may fail only once every two years.
The frequency of failures is used to determine the basic guaranteed stock levels. For components with high frequency of failure, such as collets, a relatively large stock should be maintained, such as stocking a quantity sufficient for three months of use; for components with low frequency of failure, such as table tops, 1 - 2 can be stocked 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 the supply of spare parts in a timely manner, 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 testing machine and the service life of each component, the replacement cycle of the component is calculated. For example, if it is known that the tester will run for 3000 hours per year and the belt will have a service life of 10,000 hours, then the belt will need to be replaced approximately every three 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 tester is operated at high loads and frequencies, the wear on the parts will be accelerated, and additional safeguard stock will be required at this time. For example, for a production line that performs a large number of motor rotor tests on a continuous basis, the guaranteed inventory of fixture-related parts is greater than for a tester that is used intermittently.
l Production Task Prioritization
Adjust the guaranteed inventory according to the priority of production tasks. If a tester is critical to the task of producing a key product, then the spare parts safeguard inventory for that tester should be increased. For example, for a tester producing aerospace motor rotors, 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 increase the inventory.
(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 Small order quantities and procurement costs
Consider suppliers' MOQ requirements. Some suppliers may require a certain MOQ, which may affect the setup of a guaranteed inventory. If the MOQ is large and the equipment demand for the part is relatively small, the guaranteed stock can be increased appropriately, but balanced against the inventory cost.
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 necessary to cautiously set the number of guaranteed inventory to avoid excessive inventory to occupy funds. However, for lower-priced parts, such as screws and fuses, the inventory can be increased appropriately to reduce the workload of frequent procurement.
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