What spare parts are needed and how should I set up a guaranteed stock for my DC motor motor fully automated rear end dielectric assembly machine?
I. Spare parts list
1、Mechanical parts
l Transmission parts
Belt and chain: According to the transmission mode of the equipment, reserve appropriate amount of spare belt and chain. Their specifications should be exactly the same as the original equipment, including model, size (length, width, etc.) and material. Generally each specification can reserve 2 - 3 sets, because they are easy to wear and elongation in long-term use.
Gears (including worm gears and worm wheels): Since gears are the key part of the transmission system, stock gears with different modulus, number of teeth, pressure angle, and other parameters that match the original equipment. For worm gears and worm wheels that are easy to wear, stock at least 1 - 2 of each; for other common gears, stock the appropriate quantity according to their importance and fragility.
Shafts and bearings:
Shafts: Spare shafts should be prepared for critical drive shafts, with dimensions (diameter, length, shoulder, etc.), accuracy class and material identical to those of the original shafts. Considering the relatively low damage probability of shafts, 1 - 2 pcs of each key shaft can be stocked.
Bearings: Different types of bearings are used in different locations, so reserve enough deep groove ball bearings, tapered roller bearings and other types of bearings. Bearings are wearing parts, so stock 3 - 5 sets of each type to cope with wear and damage.
Fixtures and positioning devices:
Fixture: Stock fixture collets, locating pins, and other wear parts. The shape, size and material of the collets should match the original fixtures. 5 - 10 collets and locating pins of each specification can be stocked as they are prone to wear and deformation during frequent clamping and unclamping operations.
Positioning block and seat: the accuracy of positioning block and seat is crucial to the meson assembly, reserve the same specifications as the original equipment positioning block and seat, each of which can be reserved for 2 - 3 pcs.
l Electrical Components
Motors and drives:
DC motor: reserve 1 - 2 sets of spare DC motor, motor power, speed, torque and other parameters should be the same as the original motor, to ensure that it can directly replace the faulty motor.
Motor Driver: The driver is the key equipment to control the operation of the motor, and its parameters should be matched with the motor. Reserve 1 - 2 drives for timely replacement in case of drive failure.
Sensors:
Photoelectric sensors and proximity sensors: These two sensors are used to detect the position and status of the dielectric and 2 - 3 of each model are stocked. They are susceptible to failure due to environmental factors (e.g. dust, oil).
Encoders: If the equipment uses encoders to measure the position and speed of motors or robotic arms, stock 1 - 2 encoders with resolution, accuracy and other parameters consistent with the original encoder.
Controllers and relays:
Programmable Logic Controller (PLC) Modules: Depending on the complexity of the control system, stock up on some commonly used PLC Input/Output (I/O) modules, such as Digital I/O Modules and Analog I/O Modules, and stock up on 1 - 2 of each.
Relays and contactors: These components play a key role in circuit control and are prone to problems such as contact wear. Reserve 3 - 5 relays and contactors of each type, and their rated current, voltage and other parameters should be matched with the original equipment.
2、Other parts
Lubrication and sealing materials: Reserve enough lubricating oil and grease, and their models should be consistent with the requirements of each lubrication part of the machine. For sealing materials, such as oil seals, seals, etc., reserve a variety of specifications of spare parts, the number of machine sealing parts according to the number of parts and the degree of vulnerability to determine the general specifications of each reserve 5 - 10.
Fasteners and connectors: including all kinds of screws, nuts, washers, keys, etc., reserve different specifications of fasteners, the number can be determined according to the frequency of use on the machine and the type of determination, generally each specification reserve 20 - 50.
Second, to protect the inventory setup method
1、Assessment based on frequency of use and failure rate
Collect data: record the frequency of replacement of each component and the number of failures, which can be obtained through the equipment maintenance records and production operation data. For example, a certain type of belt needs to be replaced every 3 months on average, and a sensor fails 2 times per year on average.
Determine inventory levels: Set up a guaranteed inventory based on the frequency of use and failure rate of components. For the use of high frequency, failure rate is also high parts, such as fixture chuck, to protect the stock can be set to meet the number of 2 - 3 months of production needs; for the use of less frequent but the impact of failure of the components, such as motor drive, to protect the stock can be set to ensure that the equipment in the waiting for the purchase of new parts during the normal operation of the number of, generally 1 - 2.
2, consider the procurement cycle and supply stability
Procurement cycle survey: to understand the procurement cycle of spare parts, including the supplier's production time, transportation time and so on. For parts with long procurement cycle, such as customized gears or special specification motors, increase the guaranteed stock. For example, if the procurement cycle of a component is 3 months, the guaranteed stock should be able to meet at least the quantity required for the normal operation of the machine during these 3 months, and then consider a certain margin, e.g. 10% - 20%.
Evaluation of supply stability: Evaluate the supply stability of the supplier, and increase the guaranteed stock for parts with unstable supply. At the same time, looking for alternate suppliers to reduce the supply risk.
3、Cost and storage space balance
Cost analysis: Consider the cost of spare parts. For expensive parts, such as motors and drives, reasonably control the quantity of guaranteed stock under the premise of ensuring the timeliness of equipment maintenance. You can reduce the cost of inventory by negotiating with suppliers for emergency purchase prices and establishing a leasing mechanism.
Storage space planning: According to the actual space size of the warehouse, rationally plan the storage location and method of spare parts. Adopt scientific inventory management methods, such as ABC classification method (spare parts are classified into A, B and C categories according to their importance and capital consumption, with focus on managing category A, general management of category B, and simple management of category C), to optimize the setup of guaranteed inventory. At the same time, we utilize the information system to manage the inventory in real time and grasp the inventory dynamics in a timely manner.
※ If you need any help, please contact the technical specialist of Xinhui Electromechanical Equipment Co.
