Assembly in Action: Sensors Improve Frame Welding Productivity
Dana Corp.'s Structural Solutions Division (St. Marys, Ontario) manufacturers frames for Ford Motor Co.'s (Dearborn, MI) F-150 truck line. Currently, Dana supplies frames for both the previous F-150 model on a replacement basis, and for Ford's 2004 F-150, which boasts a more rigid chassis than the previous model. In order to win and maintain these kinds of contracts, Dana has to produce high-quality frames at the lowest possible cost. That means no-defect frame welds that are precisely made at the fastest line rate achievable.
In past years, Dana has worked with Balluff Inc. (Florence, KY) to improve both the automated and manual welding operations that go into its production process. As part of that program, Balluff removed the system's original sensors and replaced them with 18-millimeter Proximax tubular-style sensors equipped with Duraplast-coated faces and Teflon-coated bodies. These sensors operate at a longer range and at higher temperatures, making them especially effective in harsh welding environments. They are also highly resistant to slag buildup.