Choosing the Right Sensor for Your Welding Application

Automotive structural welding at tier suppliers can destroy thousands of sensors a year in just one factory. Costs from downtime, lost production, overtime, replacement time, and material costs  eat into profitability and add up to a big source of frustration for automated and robotic welders. When talking with customers, they often list inductive proximity sensor …

Ensure Optimum Performance In Hostile Welding Cell Environments

Roughly four sensing-related processes occur in a welding cell with regards to parts that are to be joined by MIG, TIG and resistance welding by specialized robotic /automated equipment: Nesting…usually, inductive proximity sensors with special Weld Field Resistance properties and hopefully, heavy duty mechanical properties (coatings to resist weld debris accumulation, hardened faces to resist …

Connectivity in Welding Environments

When working in harsh environments and in heavy duty applications like welding, it is important to take a multi-angle approach to designing the application. When you are working with existing sensor installations, it is important to consider all the reasons for the sensor’s failure before determining a winning solution. An important step in any application …

Sensors Reduce Downtime in Welding Applications

Sensors in welding cells are subject to failure because, although they are intended to be non-contact devices, they tend to be located directly in the middle of the welding process. Conditions such as damage by direct mechanical impact, erosion by hot welding slag, false tripping by accumulated slag, and high intermittent heat cause conventional sensors …

Why would anyone pay more for an M18 Inductive Proximity Welding Sensor?

Answer: Because it has the extreme potential to save a lot of money.   The general mentality these days, with regards to inductive proximity sensing, has been, “Lowest price wins the business”.   Some manufacturers and industrial consumers alike have been accused of treating these devices as true commodities.  Some salespeople have also caved in over the …

Ceramic-faced Sensors Stand up to Welding Processes

Inductive proximity sensors in a welding environment face a variety of hazards.  Hot metal particles – called weld spatter – are ejected from the welding process and can melt or burn their way through unprotected plastic sensor faces.  Built-up weld spatter (often called weld slag) can eventually cause a sensor to trigger on falsely.  If …

The 5 Most Common Types of Fixed Industrial Robots

The International Federation of Robotics (IFR) defines five types of fixed industrial robots: Cartesian/Gantry, SCARA, Articulated, Parallel/Delta and Cylindrical (mobile robots are not included in the “fixed” robot category). These types are generally classified by their mechanical structure, which dictates the ways they can move. Based on the current market situation and trends, we have …

Weld Immune vs. Weld Field Immune: What’s the difference? 

In today’s automotive plants and their tier suppliers, the weld cell is known to be one of the most hostile environments for sensors. Weld slag accumulation, elevated ambient temperatures, impacts by moving parts, and strong electromagnetic fields can all degrade sensor performance and cause false triggering. It is widely accepted that sensors will have a …

Add Automation to Gain Safety and Control in Manufacturing

Industry automation not only has a positive effect on the improvement of production processes, it also significantly improves employee safety. New technologies can minimize the need for employees to work in dangerous situations by replacing them all together or by working cooperatively alongside them. Overcoming fears of automation Many workers fear technological progress due to …

IO-Link Benefits in Robotic Weld Cell Tooling

By Scott Barhorst Working previously as a controls engineering manager in robotic welding, I have seen some consistent challenges when designing robotic weld cell systems. For example, the pre-engineered-style welding cells I’ve worked with use many types of tooling. At the same time, space for tooling and cabling is limited, and so is the automation …