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ifm’s line of metal forming sensors
include
12, 18 and 30 mm
diamter sensors and
cordsets designed for
welding applications. |
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Inductive Sensors Designed for Welding and Stamping Applications
By Brian Crawford, ifm Product Manager, Inductive Sensors
Harsh conditions in welding and stamping applications subject a sensor to continuous impact from the part-loading process in manufacturing cells. In applications where slag builds up, sensors can also be damaged by abrasive cleaning processes in an effort to remove slag from the top of the sensing face.
Continual replacement = equipment downtime
The results of this extreme environment lead to continual sensor replacement and equipment downtime. For a traditional inductive sensor not equipped for this environment, a typical life span lasts only a few weeks before it has to be replaced.
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Problem
Plastic and teflon sensors’ life expectancies are greatly reduced due to weld slag build up and harsh physical impact from the part loading process in manufacuting cells. |
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Solution
ifm’s metal forming sensor stainless steel contruction and weld slag resistant coating withstands damage from impact and weld slag build up.
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Choose a sensor designed for the application
ifm’s line of metal face sensors are designed and tested for welding and stamping applications. Stainless steel construction and a high temperature weld slag resistant coating extend the sensor’s life-in-application by a factor of 15 compared to teflon or plastic face sensors. The metal face sensor’s durability increases plant uptime and its price point is the best value in the market.
ifm sensors are designed and tested to operate in the harshest welding and stamping applications
| ifm Impact Test |
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Application challenge
Plastic and teflon face sensors can be damaged from continuous physical impact from the part loading process in manufacturing cells.
ifm impact test
ifm engineers developed an impact test that simulates the extreme metalforming conditions. In the test fixture, the sensor is hit twice every second by a 1 kilogram hammer. The impact test conditions are harsher than real-world applications and are designed to accelerate time-to-failure and validate product design. For comparison, plastic and teflon face sensors were also tested.
Results
The metal face sensor withstood over 500,000 impacts in the test fixture. The plastic and teflon face sensors failed after 32,000 impact.
Video of impact test (Flash video)
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| ifm Abrasion Test |
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Application challenge
In a welding fixture, proximity sensors can fail when weld slag builds up. To remove the slag, abrasive cleaning techniques such as wire brushes and tools are used that can end up damaging the sensor. Furthermore, the sensing face can gradually wear away from impact in the part loading process.
ifm abrasion resistance test
ifm engineers developed an abrasion test to replicate the weld slag cleaning process. The rotary test fixture placed several ifm metal face sensors in direct contact with six wire wheel brushes. The wire brushes continuously rotated over the sensor faces. For comparison, plastic and teflon face sensors were also tested.
Results
After one million passes, the ifm metal face sensor was still operable, providing 100% of its sensing range. After 2,000 passes, the plastic and teflon sensor faces had deteriorated and the sensors failed to operate.
Video of abrasion test (Flash video) |
For more information about ifm metal face sensors, click here.
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