Sensor related welding equipment plays a key role in the quality of welding production. For example, the automotive industry relies heavily on sensors to ensure that metal parts are fused together and properly placed.The sensor can also identify the position of the robot arm and send a signal to determine whether the welding is properly positioned before the welding starts.Welding sensor equipment is how to carry out welding tracking, what are the principles and technical problems.
1. Failure of welding sensor
The number of sensors used in practical applications varies from a few to several hundred, depending on the type, scope and scale of the operation, depending on these sensors to ensure accuracy, but many sensors are prone to failure in the welding environment.When temperatures exceed 1,200 degrees, currents range from 15,000 to 35,000 amperes, and welding flashes occur frequently, the sensor may fail three to four times a day under harsh conditions.
Although many sensor is designed for welding resistance, but some of the sensors in 5000 after welding flash no longer works, located within the solder joint sensor flicker can be exposed to 1000-2000 times a day, a single sensor can only lead to a few minutes of down time, but when the equipment under the condition of bad welding failure, due to a sharp rise in cost of replacement and installation, lower productivity significantly.Without these sensors, production losses due to improper welding may be more costly.
2. Fault solution
In order to solve this problem, the sensor is built with a strong case, encapsulated electronic components and other functions to resist the harsh welding environment. By using the sensor in the welding, the manufacturer can reliably produce the sensor without causing excessive downtime or high replacement costs.
Automated production lines are optimized to ensure the highest accuracy, but errors still occur, such as metal parts placed in the wrong order on assembly lines and robot welding arms that improperly melt parts.
In order to prevent this happening, the sensor can be placed on the conveyor belt, when the transmission along the metal components, sensors detect whether components in place, then the sensor signal at the start of welding, the robot clamping applications use similar solution, the sensor not only locate parts, also locate jaw and fixture.
Bear the sensor of bad manufacturing environment, provide enhanced reliability and ability of data collection, the structure of the solid is placed near the cylinder of the robot arm, once the configuration, sensor can detect the piston within the cylinder movement, corresponding to the Angle of the jaw clamp open, indicates the parts fixture is held open to the exact location.At the same time, another sensor can be placed in a groove inside the actual clamp to confirm that the parts are moved to the appropriate position. This custom embedding helps protect the sensor from environmental conditions.
In order to identify the smaller parts on the metal plate, a magnetic induction welding nut sensor is used. The sensor can be programmed to distinguish between the nut or bushing and the metal plate in which it is located. The sensor is installed through a hole in the metal plate.The level of welding resistance required for the sensor depends largely on proximity, and sensors exposed to welding flicker will have some negative effects, but the sensor located within the range of the welding tip must be able to withstand 10,000 to 20,000 flickers without failure.This performance may be difficult to achieve due to the strong electromagnetic field generated by welding flicker, which may cause the proximity sensor to be triggered incorrectly, and the accumulation of welding slag or spatter may lead to sensor failure.
In order to resist these environmental factors, a combination of specialized structures and numerous protection technologies provides welding resistance by providing temperature compensation, operates reliably in high temperature welding environments, and the main body is made of material capable of withstanding slag.Another technique is to put the assembled shell before sealing the sensor, so that when combined with the weld-resistant front cover or coating, it will not be exposed to the physical damage of the side, helping to protect against mechanical damage.
Using element technology combined with magnetic resistance sensor, the same range of metal can be detected, the longer the overall induction range, can be used in various applications, together with the metal, is made from the ferrite core, without magnetic field interference, this design can work high switch frequency, especially suitable for the welding operation, from the welding resistance to the coefficient of sensor welding techniques used even in challenging environments to provide accurate, lasting operation, the correct application, the system can optimize the production.
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