What spare parts are needed for motor and motor rotor automatic balancing machine and how to set up the guarantee stock?
I. Types of spare parts
1、Wearable mechanical parts
Bearings: The support and rotation of the motor rotor depends on the bearings, which are easy to wear parts. According to the model and specification of balancing machine, stock different types of bearings, including deep groove ball bearings, cylindrical roller bearings and so on. For example, for small motor motor rotor automatic balancing machine, commonly used 6204, 6305 and other types of bearings should be stocked in appropriate amount.
Belt and transmission belt: If the balancing machine adopts the belt transmission method, the belt will be worn, aged and stretched due to long time use. Spare belts of the same type should be prepared, such as synchronous belts and V-belts. Meanwhile, for the part that uses chain drive, the corresponding chain and sprocket should also be stocked.
Rollers and support blocks: During the placement and rotation of the rotor, the rollers and support blocks are subject to friction and pressure and are prone to wear. Reserve rollers and support blocks of appropriate size and material to ensure that their surface accuracy and hardness meet the requirements of the balancing machine.
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2、Electrical components
Sensors: Displacement sensors, speed sensors and vibration sensors are the key components of the balancing machine to obtain rotor information. These sensors may be damaged due to environmental factors, electrical interference or long-term use, and it is necessary to stock spare sensors, such as eddy current displacement sensors and photoelectric speed sensors.
Motors and Drives: The drive motors of balancing machines and their drives can also fail. According to the power, voltage, speed and other parameters of the motor, reserve the same type of motor and matching driver for timely replacement.
Circuit boards and chips: Electronic components on the control circuit boards, such as capacitors, resistors, integrated circuit chips, etc., may be short-circuited, disconnected, or have degraded performance. Reserve commonly used circuit boards and key chips, such as control chips, signal processing chips, etc., for replacing damaged parts.
3、Other Consumables
Grease and lubricant: Used for the lubrication of mechanical parts to ensure the smooth operation of the machine. Reserve the right amount of high temperature grease and mechanical lubricant, etc., and determine the amount to be reserved according to the lubrication requirements and frequency of use of the equipment.
Cleaning supplies: such as anhydrous ethanol, cleaning cloths, brushes, etc., used to clean sensors, mechanical parts and electrical equipment to maintain the good performance of the equipment.
Second, to protect the inventory setup method
1、Consumption forecast
Historical data analysis: Review the balancing machine's maintenance records and parts replacement frequency, and analyze the average consumption rate of each spare part. For example, through the past year's maintenance data, found that bearings need to be replaced every three months on average, it is used as a basis to predict future consumption.
Equipment operating hours and load estimation: Consider the effect of balancing machine operating hours and load intensity on component life. If the balancing machine is in continuous operation 24 hours a day and handles large, heavy rotors, the parts will wear out more quickly, and the stock of spare parts will have to be increased accordingly. According to the operation plan and working tasks of the equipment, estimate the service life of each component under different working conditions, so as to determine the basic quantity of guaranteed stock.
2、Supplier factors to consider
Supply cycle assessment: understand the spare parts supplier's supply cycle, including normal delivery time and possible delays. If the supplier's delivery period is longer, such as some special specifications of the sensor needs to be imported from abroad, the delivery period of 3 - 6 months, then you need to increase the protection of inventory to cope with the demand during this period.
Supplier Reliability: Evaluate the supplier's reputation and reliability, such as whether there is a record of on-time delivery, product quality is stable. For suppliers with low reliability, it is appropriate to increase the guaranteed stock to reduce the risk of supply interruption.
Guarantee Factor Setting
According to the degree of impact of failure: Set a higher guarantee coefficient for key components that, if damaged, will lead to a long downtime of the balancing machine and affect the production schedule, such as control circuit boards, motors, and so on. For example, set the guaranteed stock of these parts at 1.5 - 2 times the expected consumption quantity. For parts that have less impact on the operation of the equipment and are easy to replace, such as cleaning supplies, you can set a lower guarantee coefficient, such as 1.2 - 1.3 times.
Considering the importance of the equipment and the urgency of the production task: If the balancing machine is the key equipment in the production line, and the production task is urgent, which does not allow the equipment to be shut down for a long time for maintenance, then the overall spare parts coverage factor should be increased accordingly to ensure that the equipment can be restored to operation in time.
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