Issue link: https://onenorgren.uberflip.com/i/1173266
Location: Michigan, USA Customer: Suppliers of automotive welded assemblies Growth driver: Elimination of costly hand sorting Case study Requirement Metal stampers fabricating welded assemblies for automakers need to weld studs to sheet metal parts for assembly. Occasionally a stud with no threads gets welded to a part, requiring costly hand sorting and rework. Sheet metal stampers attempted to use technologies like laser or proximity sensors to detect problems, but while they could often detect the presence of a stud, they were not sensitive enough to detect threads. The industry needed a detection method sensitive enough to detect missing threads on a stud and durable enough to withstand extreme operating conditions. Solution The Automation Solutions experts at IMI Precision Engineering used their unique, proven steel-faced inductive sensor technology to develop the only stud detector in the industry with sufficient sensitivity and range to detect both the presence of studs and whether they are threaded or not. The IMI Norgren Stud Thread Detector helps users eliminate scrap caused by missing or unthreaded studs. It also eliminates hand sorting, a quality control process that can cost an average of $20,000 every time it is required. Sector image used under license from Shutterstock.com © 2016 Norgren Automation Solutions, LLC. Scrap, sorting and rework problems solved by unique new stud thread sensor Engineering GREAT Solutions Location: Michigan, USA Customer: Automotive manufacturer Key benefit: Reduced waste Case study Requirement In car assemblies, an automatic system welds nuts to sheet metal so auto body parts can be bolted together later. If a nut is missing or not aligned with the hole, the part may have to be scrapped. But these nuts are often hidden from view, making visual inspection slow and costly. Existing hidden part sensors could measure thickness, (indicating whether a nut was present) but they were expensive and difficult to configure into a workable package. Automotive manufacturers needed an affordable sensor that was sensitive enough detect the presence of a nut and easy to calibrate to detect thread quality. Solution Using their expertise in inductive proximity sensing, where a probe emits an oscillating signal, automation experts at IMI Precision Engineering developed the first-ever radial probe sensor. The probe is inserted through the hole in the sheet metal and sends a signal back to a monitor. The operating frequency of the signal indicates whether the nut is present or absent. The sensor can be calibrated to detect thread quality using a simple hand adjustment and an LED indicator. An optional spring mount allows the probe to retract without damage if a hole is missing. Radial sensor technology makes the probe affordable, and manufacturers realize significant savings by eliminating manual inspections and avoiding scrap of costly car assemblies. © Norgren, Inc. 2015 Detector for nuts, threads reduces scrap Engineering GREAT Solutions Videos User Instructions Case Studies Webstore CAD Files Nut/Stud Sensors URL: Click here or visit https://autoinplant.imi-precision.com/en/marvelous-machines/thread-nut-stud-detection » Download CAD files » Review User Instructions » Read Case Studies » Watch Videos » Shop the Webstore Visit our website to: 39 A D D I T I O N A L R E F E R E N C E S 3 For more information or for additional configurations, please contact us at NASInsideSales@imi-precision.com