Custom position sensor that detects part errors in automotive resistance welding machines

NewTek Sensor Solutions has designed a custom linear variable differential transformer (LVDT) position sensor for resistance spot welding machines used in automotive plants to detect missing or misaligned parts in nut and stud welding. Cars contain hundreds of welded nuts and studs that hold them together. Properly securing the right nut and stud to different car components is critical to safe operations.

Working in conjunction with the resistance weld control equipment, the NewTek custom LVDT detects and reports different conditions including: weld pin extended position, double part, misloaded part, incomplete weld, weld pin retraction, upside down nut, wrong or missing part. Based on programmed system spec limits, the position sensor will trigger a go/no go response with each pass.

Designed to fit inside the weld body of the machine, the AC-operated LVDT sensor has a very high stroke length ratio and excellent repeatability that is critical to the application. Remote signal conditioning allows the LVDT to fit inside the small space while being resilient to high levels of shock. With extremely high measurement resolution of ~0.0009 inches, the position sensor detects minute changes in process conditions.

As is fundamental with all LVDTs, the sensor has no contact between its core and coil structure so parts do not rub together or wear life for longer mechanical life. The linear variable displacement transformer also has internal magnetic shielding that reduces effects of AC or DC fields.

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