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Application example

Detecting weld nuts on a mandrel

Titelbild

The Task

In automated welding processes, the correct positioning of each individual component determines the quality of the joint. Before a weld nut is welded onto a supplied sheet metal part, it is presented on a welding mandrel. The subsequent welding process must only be enabled if the nut is correctly seated on this mandrel.
Consequently, a sensor needs to reliably check from a distance of around 500 mm whether the weld nut is correctly positioned on the mandrel.

The Challenge

The weld nut can be located on the mandrel at different angles. Depending on the alignment, parts of the emitted light beam are reflected or deflected out of the sensor to varying degrees. Sensors with background suppression and a fixed, conventional switching point reach their limits here, resulting in unstable or faulty switching signals.

Our Solution

The DTECT® Presence FT 55-RLHM is taught based on the threaded pin only (without nut) in Detect-All mode. During operation, the photoelectric diffuse sensor with background suppression then detects any deviation from this reference state – i.e. reliably detects the positioned weld nut, regardless of its angular position, surface or reflective properties. Thanks to its high-precision sensory evaluation and long range, the HGA sensor is ideal for this demanding task.

Your Advantages 

  • Reliable detection in any angular position of the weld nut thanks to the Detect-All mode
  • High process reliability, as any deviation from the reference state is detected
  • Precise detection thanks to the excellent optical properties of the sensor
  • Large operating range with minimal hysteresis

Recommended products for this application

FT 55-RLHM-600

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