7、What spare parts are needed for motor motor rotor automatic spring clamping machine and how to set up guarantee stock?
I. Spare parts list
l Mechanical components
Perishable transmission parts: belts, chains, gears are common perishable transmission parts in automatic spring clamping machine. These parts are prone to wear and tear, breakage and so on due to friction and force in the process of long-term mechanical movement. For example, the belt may deteriorate and crack due to long time tension; the links of the chain may wear out, resulting in chain elongation; the teeth of the gears may be smoothed out, affecting the transmission accuracy.
Clamps and mounting tools: The clamping jaws of the clamps and the clamp spring mounting tools (such as the clamp spring pliers) are also easily damaged parts. The contact surface of the clamping jaws may wear out during frequent clamping and releasing of the motor rotor, affecting the stability of the clamping; the jaws of the circlip pliers may deform or wear out after long-term use, resulting in inaccurate installation of the circlip.
Guide rails and screws: These two components are critical to the accuracy of the machine. The guide rail may wear out due to the erosion of dust and oil as well as the frequent movement of the slider, affecting the movement accuracy of the rotor and other components; the silk rod may have problems such as increased pitch error and worn out threads during prolonged rotation and axial force.
l Electrical components
Sensors: position sensors, photoelectric sensors, etc. in the working environment may be affected by dust, oil, vibration and electromagnetic interference and other factors and damage. For example, the light-emitting element and photosensitive element of the photoelectric sensor may fail, resulting in the inability to detect the position of the object properly; the position sensor may have abnormal signals due to mechanical collision or aging of the internal components.
Motors and drives: The brushes (in the case of brushed motors), bearings, and windings of motors are the parts that are more prone to failure. The brushes will wear out during long time friction and need to be replaced regularly; the bearings may be damaged due to poor lubrication or long time high speed operation; the windings may be short-circuited or disconnected due to overheating, overloading or aging of insulation. The electronic components of the drive may be damaged due to power fluctuation, overload and other factors.
Controller components: such as capacitors, resistors, chips and other components on the circuit board may be damaged due to prolonged operation, power surges and other reasons. Capacitors may leak, bulge, etc.; resistors may change resistance value due to overheating; chips may have program errors or hardware damage.
Second, the method of safeguarding inventory setting
l Based on the frequency of equipment use and failure rate
Statistical historical data: collect data on the frequency of use and the number of failures of each component of the automatic card spring machine in the past period of time (e.g., one year). For example, equipment maintenance records and production logs are used to determine how often each component is replaced. If a part has been replaced 5 times in the past year, and the equipment operates for 2,000 hours per year, then it can be roughly calculated that the part needs to be replaced every 400 hours.
Consider Changes in Equipment Intensity of Use: Predict future changes in equipment intensity of use. If it is expected that equipment will be used for longer periods of time due to increased orders in the future, the corresponding parts will be used more frequently, and the warranty stock will need to be increased appropriately. For example, if the equipment originally operated for 8 hours per day and is expected to operate for 12 hours per day in the future, the frequency of replacement of each part may increase by 1.5 times, and the guaranteed inventory should be adjusted accordingly.
l Based on procurement cycle and supply stability
Determine the procurement cycle: Understand the procurement cycle of each spare part, including the supplier's production cycle, transportation time and so on. For example, for a particular gear, the production cycle of the supplier is 2 weeks and the transportation time is 1 week, so the total procurement cycle is 3 weeks.
Evaluate supply stability: Evaluate the supplier's supply stability. If the supplier is susceptible to interruptions in supply due to factors such as raw material supply, natural disasters, or business conditions, it is necessary to increase the guaranteed inventory. For example, if the supplier is located in a region where natural disasters frequently occur, causing transportation disruptions, it is necessary to consider increasing the guaranteed inventory of key components to cope with possible supply delays.
l Calculating guaranteed inventory quantities
Formula for minimum guaranteed inventory: Minimum guaranteed inventory = (Estimated maximum daily usage - Average daily usage) x Purchasing cycle. For example, if the average daily usage of a certain type of belt is 1, the expected maximum daily usage is 2 when the equipment is running at full capacity, and the procurement cycle is 7 days, then the minimum guaranteed stock = (2 - 1) x 7 = 7 items.
Consideration of guarantee coefficient: Consider adding a guarantee coefficient based on the importance of the part, supply risk, and other factors. For critical parts with unstable supply, the protection factor can be set to 1.5 - 2. For example, if the belt mentioned above is a critical part and the supply from the supplier is not stable, the protection factor is set to 2, then the actual guaranteed stock should be 7 x 2 = 14 items.
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