Magnetic-Inductive Sensors Deliver Robust, Reliable, Repeatable Detection of Weld Nuts in Harsh Automotive Environments


Minneapolis, Minn. — September 12, 2008

TURCK introduces magnetic-inductive sensors for efficient and economic detection of weld nuts. These innovative sensors use signal attenuation to reliably detect ferromagnetic components such as nuts, bushings and spacer sleeves and ensure these necessary components are present before robotic welding occurs—with no additional software or electronics required. TURCK’s weld nut sensors are easily integrated into existing production lines, replacing traditional location bolts and providing an exceptional solution for sheet metal processing in chassis construction.

These sensors deliver a cost-effective alternative to more expensive optical or vision-based systems, which can often malfunction due to residue, such as dirt and weld-splatter, and frequently changing lighting conditions in welding zones. The TURCK weld nut sensor can be mechanically protected with a customer-supplied stainless steel sleeve, which also acts as a guide to keep the weld nut in place.

Weld nut sensors are easily programmed to differentiate between the nut and the sheet metal on which it is located by using a teach adapter or by simply shorting the leads.

“TURCK’s weld nut sensor provides smooth, reject-free production runs by cost-effectively detecting nuts and spacer sleeves, using bright LEDs to indicate any missed welding positions, which are immediately displayed on the control unit,” said Brian Tarbox, TURCK product manager. “Once the sensor confirms that all weld nuts are properly placed, the welding robots are signaled to begin welding the nuts onto the sheet metal.” Tarbox adds, “This robust design provides greater process reliability at a lower cost than optical or vision-based systems—and the sensor’s rugged construction delivers the dependable performance required in harsh automotive production environments.”

Weld nut sensors are available in two versions offering different signal intensities and diameters to adapt to a wide variety of operating environments and material characteristics. The sensors also feature a rugged IP67 chrome-plated brass housing that protects internal components from harsh welding zone conditions. Plus, the sensors offer temperature compensation to withstand the thermal changes common in welding environments.

TURCK weld nut sensors facilitate continuous control of supply parts such as spacer sleeves and weld nuts, which are commonly used to assemble vehicle elements such as frames, U-shaped carriers and fuel tanks. The sensors’ affordable, accurate operation provides the robust production line monitoring required for error-free sheet metal processing in automotive applications.

In addition, several features of the weld nut sensor make it particularly simple to set-up and use:

  • Reliably detects weld nuts, sleeves and other steel components used in vehicle component assembly
  • Pairs with a customer-provided stainless steel sleeve to provide the sensor with additional mechanical protection
  • Features simplified programming and an easy-to-use teach function to effortlessly adapt to existing production lines
  • Provides an economic and process safe alternative to optical-based systems
  • Immediately signals missing components to prevent production of rejects for smooth, error-free operations
  • Features rugged IP67 chrome-plated brass body to withstand harsh automotive environments
  • Offers temperature compensation to withstand thermal changes in welding zones
  • Requires no additional software or electronics
TURCK is an industry leader providing superior quality sensing, connectivity and network products to help manufacturers improve their automated processes.
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