A technological upgrade of imported equipment saved over 60000 yuan, let's see how domestic accessories can play a big role!
The printing industry is a typical heavy asset industry. In pursuit of better printing quality, various printing companies have invested heavily in purchasing advanced imported printing equipment. But as the service life of the equipment increases, some electronic components of the equipment will gradually experience aging or damage. In addition, some electronic components in printing equipment often work under harsh conditions, resulting in a higher failure rate. For example, the power module of PLC and the power output module of automatic ink supply, due to long-term operation and large temperature and humidity changes in the workshop environment, the aging speed of components on electrical equipment is very fast. The system PLC or program module may experience low voltage or even damage, seriously affecting the normal operation of the equipment. Due to these minor issues, the equipment cannot be turned on normally, which will affect the overall production plan and not be worth the loss.
To ensure the normal operation of equipment, Indian companies usually purchase original electronic components for replacement. However, these electronic components are mostly imported products. Due to the rapid progress of technology, many electronic components have often been discontinued or replaced. In addition, manufacturers usually adopt the assembly method during production. If a component on a certain assembly is damaged, the entire assembly needs to be replaced, resulting in unbearable procurement costs and cycles for the enterprise.
The author has been engaged in equipment maintenance work for many years, repairing printing and binding equipment from various brands, and has summarized a set of effective equipment maintenance experience and methods. For non critical electronic devices, the use of domestically produced components for self-assembly has successfully restored their functionality multiple times, while also significantly reducing procurement costs and shortening downtime. After researching and conceptualizing the electronic components market, the author believes that using existing electrical components in China to replace the components used in the original equipment has strong feasibility. Below, the author will share a technical renovation experience for reference and correction by colleagues.
Background of technological transformation
Many electrical components on printing equipment, for the safety of personnel, the output voltage of the electrical components that can be touched will be lower than 36 volts. The power supply module of the ink key communication board of the printing machine often leads to uncontrolled ink key size with the increase of service life, large changes in environmental temperature and humidity, and the adhesion of dust and ink. The ink key communication board power supply module of a certain brand's commercial rotary printing machine unit is relatively special, which is a specialized power supply module designed for rotary machines. It is basically not available in the market, and due to the limited number of commercial rotary machines worldwide and the fast update of electronic products, this component has already been discontinued. As long as the module has a problem, the machine can only be shut down and purchased from the original manufacturer (using foreign inventory parts, with a longer supply cycle) or sought third-party repair (looking for disassembled parts, which cannot be guaranteed to be repaired), which has greatly affected the normal production of the company.
technical innovation plan
According to the output requirements of the original power supply module, multiple mature and stable domestic power supply modules are used to form the power supply mode required by the equipment.
Firstly, purchase different power supply modules as needed, redraw the wiring diagram according to the output requirements, and connect the domestic power supply modules one by one according to the wiring diagram. At this point, the output terminal is in a disconnected state. Then, switch on the power supply, measure all output power supplies with a multimeter, make a record, and after all measurements are completed, compare with the original output module to confirm that all output power supplies are the same, and turn off the power. Finally, connect the power cord to the required ink key communication board power terminal through the wiring terminal, check for errors, and then turn on the power again.
01
Expected effects of technological improvements
(1) When the device encounters this issue, with technical improvements, production can be quickly restored. It can effectively ensure the normal production of equipment, and can completely replace it technically, ensuring that the company's production tasks are completed on time.
(2) Reduce the waiting time for equipment failures. For example, if there is a problem with a certain power supply, because our company's technological transformation uses a domestic universal power module, it is easy to purchase the required power supply in the market and quickly restore production.
(3) Effectively control costs. A certain original power supply module needs to be purchased from the original factory for 30000 yuan, and repairing a damaged power supply module also requires about 3000 yuan. After technological improvement, a set of domestic electrical components is only about 1000 yuan, and the cost of spare parts is vastly different.
(4) Convenient for maintenance. After the technical improvement, the machine personnel can preliminarily eliminate the problem. When there was a problem of low voltage, the LED indicator light of the ink key board module was also on. We needed to spend time measuring with a multimeter to determine if one of the output power modules had a low voltage. Now that multiple power modules are input, when this problem occurs, we first observe whether the indicator light of the power module is on, which module is off, and then replace that module. Basically, it can solve the problem.
02
Implementation process
technical innovation plan
According to the output requirements of the original power supply module, multiple mature and stable domestic power supply modules are used to form the power supply mode required by the equipment.
Firstly, purchase different power supply modules as needed, redraw the wiring diagram according to the output requirements, and connect the domestic power supply modules one by one according to the wiring diagram. At this point, the output terminal is in a disconnected state. Then, switch on the power supply, measure all output power supplies with a multimeter, make a record, and after all measurements are completed, compare with the original output module to confirm that all output power supplies are the same, and turn off the power. Finally, connect the power cord to the required ink key communication board power terminal through the wiring terminal, check for errors, and then turn on the power again.
01
Expected effects of technological improvements
(1) When the device encounters this issue, with technical improvements, production can be quickly restored. It can effectively ensure the normal production of equipment, and can completely replace it technically, ensuring that the company's production tasks are completed on time.
(2) Reduce the waiting time for equipment failures. For example, if there is a problem with a certain power supply, because our company's technological transformation uses a domestic universal power module, it is easy to purchase the required power supply in the market and quickly restore production.
(3) Effectively control costs. A certain original power supply module needs to be purchased from the original factory for 30000 yuan, and repairing a damaged power supply module also requires about 3000 yuan. After technological improvement, a set of domestic electrical components is only about 1000 yuan, and the cost of spare parts is vastly different.
(4) Convenient for maintenance. After the technical improvement, the machine personnel can preliminarily eliminate the problem. When there was a problem of low voltage, the LED indicator light of the ink key board module was also on. We needed to spend time measuring with a multimeter to determine if one of the output power modules had a low voltage. Now that multiple power modules are input, when this problem occurs, we first observe whether the indicator light of the power module is on, which module is off, and then replace that module. Basically, it can solve the problem.
02
Implementation process
If purchasing original spare parts, the cost of the parts is 65000 yuan, and the delivery time is very long; If domestic universal accessories are used as a substitute, the cost of the parts is only 2964 yuan, and the problem can be solved quickly.
04
Technological transformation achievements
(1) The direct reduction of 62036 yuan in parts costs is beneficial for the company's cost control of maintenance expenses and increases the company's economic benefits.
(2) Shortened maintenance time and improved the production efficiency of the rotary machine.
The success of the above technological transformation is attributed to the continuous improvement of domestic spare parts production and manufacturing technology. Domestic spare parts can now meet the requirements of equipment operation and are exported overseas, with significant advantages in price and quality compared to imported spare parts from abroad.