Minimizing Sensor Loss in Automotive Welding

Automotive structural welding at tier suppliers can destroy thousands of sensors annually in a single factory. The costs of downtime, lost production, overtime, replacements, and materials quickly add up, cutting into profitability and frustrating automated and robotic welders.

Customers frequently cite inductive proximity sensor failure as a major concern. Every day, thousands of sensors are replaced, and installations are repaired. It’s not uncommon for a company to lose a sensor on every shift in a single application – totaling three per day, 21 sensors per week, and more than 1,100 sensors per year. The financial impact is significant, with thousands of sensor installations across an automotive structural assembly line.

When working with customers to improve this, they start with three parts of a big equation:

Sensor housing: choosing the right fit for your application

Are you using the right sensor for your environment? Consider the form factor – does it match your needs? Would a coated housing provide better durability, or should the coating be on the sensor face instead?

Weld spatter can shorten a sensor’s lifespan, but a sensor with a specialized coating for welding conditions can greatly extend its durability. If impact protection is a concern, evaluate your conditions carefully and choose the right solution for long-term reliability.

Bunkering: ensuring property mounting and protection

Are you using the best mounting type for your sensor? Is it adequately protected from loading impacts? A protective block can shield the sensor from bumps and jostles during the application, ensuring better longevity and performance.

Connectivity: maintaining reliable sensor connections

How is the sensor connected to the control system, and how well does the cable hold up? Cables are often the weak point, but high-durability options, like TPE-jacketed cables or sacrificial cables, can make replacements quicker and easier while supporting long-lasting performance.

When selecting a sensor for an automotive welding application, it’s not enough to focus on whether it can perform the required task. It’s equally important to consider whether it can withstand the harsh conditions of the environment in which it operates. Factors like housing, durability, proper mounting and protection, and reliable connectivity all play a critical role in ensuring the longevity and effectiveness of your sensor.

By understanding the unique challenges of the welding environment – such as heat, impact, and weld spatter – you can make more informed decisions, minimizing sensor failures and costly downtime. A sensor built to endure these conditions can improve efficiency and protect your bottom line.