An Easy Solution to Extend Sensor Life

Quick-change prox mounts for proximity sensors.

Everyone is looking for quick tricks of the trade. Sensor failure can prove to be costly in any environment. One of the easiest ways to avoid unnecessary downtime would be to add a mounting bracket plus prox mount to the machine to extend the life of a sensor.

What is a prox mount?

It has a quick release tube mounted into a tubular bracket to change out a sensor easily. The sensor is assembled into the prox mount tube and locked into place with a compression ring and metal nut. The prox mount and sensor assembly is then mounted and adjusted as with any tubular sensor, but the prox mount will remain in place on future sensor replacement tasks.

Mounting accessories are geared toward extending sensor performance in harsh industrial conditions involving chemical attack, debris accumulation, shock/vibration/impact, and high temperatures. The brackets act as protection, as well as mounting for the sensor to extend the life of the sensor. Adding a prox mount to it add another layer of protection as well as reducing down time due to the quick release to change a sensor.

Fully Assembled Prox Mount with Sensor Installed

Mounting brackets are a simple solution to decrease installation costs by screwing in the bracket on the machine. They are also prolonging sensor life expectancy by giving it an added layer of protection. Add in the prox mount for a faster option to reduce unplanned downtime with the quick release of the sensors. This helps increase the overall performance and utility of sensors.

To get started visit www.balluff.us

Put Out the Fire

Every time I enter tier 1 and tier 2 suppliers, there seems to be a common theme of extreme sensor and cable abuse. It is not uncommon to see a box or bin of damaged sensors along with connection cables that have extreme burn-through due to extreme heat usually generated by weld spatter. This abuse is going to happen and is unavoidable in most cases.  The only option to combat these hostile environments is to select the correct components, such as bunker blocks, protective mounts, and high temperature cable materials that can withstand hot welding applications.

Example of bad bunkering. Sensor face not protected. Plastic brackets and standard cables used.
Example of bad bunkering. Sensor face not protected. Plastic brackets and standard cables used.

In many cases I have seen standard sensors and cables installed in a weld cell with essentially zero protection of the sensor. This results in a very non-productive application that simply cannot meet production demands due to excessive downtime. At the root of this downtime you will typically find sensor and cable failure. These problems can only go on for so long before a culture change must happen throughout a manufacturing or production plant as there is too much overtime resulting in added cost and less efficiency. I call this the “pay me now or pay me later” analogy.

Below are some simple yet effective ways to improve sensor and cable life:

Example of properly bunkered sensors with bunker block and silicone wrapped cable
Example of properly bunkered sensors with bunker block and silicone wrapped cable
  • Apply flush sensors vs. non-flush sensor in fixtures
  • Bunker the flush sensors to protect the face of the sensor (Let the bunker block take the spatter)
  • Apply sensors with special coatings to combat weld spatter
  • Apply sensors with steel faces for added insurance against contact damage
  • Apply high temp cables such as full silicone high durability offerings
  • Protect cables with silicone tubing and high temperature weld jackets
  • Wrap cables with weld repel tape to insure spatter will not penetrate the ends of the cable

If these simple steps are followed, uptime and efficiency will result in increased productivity with immediate improvements and positive results.

For information on welding improvements visit our website at www.balluff.us.

Inductive Sensor Protection and Positioning Made Easy – Use a Prox Mount

Written by: Jeff Himes

“Downtime” is never a good word in any manufacturing facility.  It means something has malfunctioned or broken, parts are not being made, production is reduced, and money is being lost.  In some cases this downtime may be caused by a physically damaged inductive proximity sensor.  If this failure mode is happening on a regular basis to the same location, it may be time to look at the advantages a prox mount can provide.

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