harsh conditions Archives - AUTOMATION INSIGHTS

Boosting Sensor Resilience in Welding With Self-Bunkering Inductive Proximity Sensors

A welding cell will press the limits of any sensor placed in its proximity. Avoiding weld spatter, magnetic fields, extreme temperatures, and impact damage are common challenges in a harsh welding environment. And when sensors fail in these conditions, it can significantly disrupt production uptime. To prevent such disruptions, manufacturers explore more robust sensor mounting solutions, such as proximity mounts, bunker blocks, and other protective devices to shield sensors from these harsh conditions. The self-bunkering inductive proximity sensor plays a key role in alleviating the issues, especially in situations where other accessories are not an option due to limited space.

Weld spatter and magnetic field resistant

In many welding applications, the substantial currents involved can generate heightened magnetic fields, making a welding cell vulnerable to interference. This interference can lead a basic proximity sensor to trigger, even though a part may not be present. The self-bunkering proximity sensor is designed to resist magnetic fields, allowing it to work much closer to the welding surface than a typical inductive sensor. Additionally, the sensor comes with a polytetrafluoroethylene (PTFE) weld coating, allowing for easy removal of the spatter buildup with abrasive tools like a wire brush.

Guard against heavy impacts

Again, the self-bunkering inductive proximity sensor is built for rugged environments. It features a thick, strong one-piece connector body and super thick brass housing to buffer the internal electronics from external impacts and conductive heat. It also includes a deflection ring and a non-brittle, ferrite-free coil carrier to protect the sensor face from direct impacts, disperse shock, and safeguard internal sensing components. The wide-radius corners offer stress relief at the major junction points of the connector body and housing.

Withstand extreme temperatures

With a ceramic PTFE-coated face plate, the sensor can resist up to 2200°F weld spatter burn through from the front. The rest of the body, coated with PTFE and paired with an extra-thick brass housing, provides protection for the sensor up to 300°F. This means that if the sensor is properly maintained, its lifetime should be quite a bit longer than a standard inductive sensor.

Don’t replace, defend

The core components of the proximity sensor can be destroyed if any of the three critical failures – conducted heat, impact, or spatter – occur in combination. To prevent this, the product incorporates a collection of design measures intended to create a virtually impenetrable shield around the internal critical components.

In summary, the self-bunkering inductive proximity sensor is a key solution to combat the challenges sensors face in harsh welding environments that will ultimately disrupt production. Its resistance to magnetic fields and ability to withstand heavy impacts and extreme temperatures, especially in situations with limited space, ensures the protection of the critical sensor components and extended sensor lifespan.

Protecting photoelectric and capacitive sensors

Supply chain and labor shortages are putting extra pressure on automation solutions to keep manufacturing lines running. Even though sensors are designed to work in harsh environments, one good knock can put a sensor out of alignment or even out of condition. Keep reading for tips on ways to protect photoelectric and capacitive sensors.

Mounting solutions for photoelectric sensors

Photoelectric sensors are sensitive to environmental factors that can cloud their view, like dust, debris, and splashing liquids, or damage them with physical impact. One of the best things to do from the beginning is to protect them by mounting them in locations that keep them out of harm’s way. Adjustable mounting solutions make it easier to set up sensors a little further away from the action. Mounts that can be adjusted on three axes like ball joints or rod-and-mount combinations should lock firmly into position so that vibration or weight will not cause sensors to move out of alignment. And mounting materials like stainless steel or plastic can be chosen to meet factors like temperature, accessibility, susceptibility to impact, and contact with other materials.

When using retroreflective sensors, reflectors and reflective foils need similar attention. Consider whether the application involves heat or chemicals that might contact reflectors. Reflectors come in versions, especially for use with red, white, infrared, and laser lights, or especially for polarized or non-polarized light. And there are mounting solutions for reflectors as well.

Considering the material and design of capacitive sensors

Capacitive sensors must also be protected based on their working environment, the material they detect, and where they are installed. Particularly, is the sensor in contact with the material it is sensing or not?

If there is contact, pay special attention to the sensor’s material and design. Foods, beverages, chemicals, viscous substances, powders, or bulk materials can degrade a sensor constructed of the wrong material. And to switch perspectives, a sensor can affect the quality of the material it contacts, like changing the taste of a food product. If resistance to chemicals is needed, housings made of stainless steel, PTFE, and PEEK are available.

While the sensor’s material is important to its functionality, the physical design of the sensor is also important. A working environment can involve washdown processes or hygienic requirements. If that is the case, the sensor’s design should allow water and cleaning agents to easily run off, while hygienic requirements demand that the sensor not have gaps or crevices where material may accumulate and harbor bacteria. Consider capacitive sensors that hold FDA, Ecolab, and CIP certifications to work safely in these conditions.

Non-contact capacitive sensors can have their own special set of requirements. They can detect material through the walls of a tank, depending on the tank wall’s material type and thickness. Plastic walls and non-metallic packaging present a smaller challenge. Different housing styles – flat cylindrical, discs, and block styles – have different sensing capabilities.

Newer capacitive technology is designed as an adhesive tape to measure the material inside a tank or vessel continuously. Available with stainless steel, plastic, or PTFF housing, it works particularly well when there is little space available to detect through a plastic or glass wall of 8mm or less. When installing the tape, the user can cut it with scissors to adjust the length.

Whatever the setting, environmental factors and installation factors can affect the functionality of photoelectric and capacitive sensors, sometimes bringing them to an untimely end. Details like mounting systems and sensor materials may not be the first requirements you look for, but they are important features that can extend the life of your sensors.

Harsh Industrial Environments Challenge Plant Operators

Most industrial processes do not take place in a climate-controlled laboratory or clean room environment. Real-world industrial activity generates or takes place under harsh conditions that can damage or shorten the life expectancy of equipment, especially electronic sensors.

A cross-section of industrial users was surveyed about operating conditions in their facilities. The responses revealed that plant operators are challenged by a variety of difficult environmental factors, the biggest being heat, dust/dirt/water contamination, vibration, and extreme temperature swings.

Over one-third of the industrial users surveyed reported that premature sensor failure is a problem in their operations. That is a surprisingly high percentage and something that needs to be addressed to restore lost productivity and maintain long-term competitiveness.

Many heavy industries are dependent on automated hydraulic cylinders to move and control large loads precisely. The cylinder position sensors are often subjected to damaging environmental conditions that shorten their life expectancy, leading to premature failure.

Fortunately, there are measures that can be taken to reduce or eliminate the occurrence of sensor-related downtime. Help is available in the form of a free white paper from Balluff called “Improving the Reliability of Hydraulic Cylinder Position Sensors”.

To learn more about this topic you can also visit www.balluff.us.