I was astonished to witness a peculiar occurrence firsthand. Our maintenance team recently discovered a recurring issue with a 30mm inductive prox switch used to detect pallets on a conveyor system. This switch would often malfunction when exposed to heat, causing it to stick closed. However, once it cooled down, it would start functioning again. Surprisingly, this was a common issue that our staff had encountered several times, leading to the replacement of multiple switches, including the Allen-Bradley 872C-D15NP30-D4 model. Despite some switches being replaced before, others were still the original ones dating back to 2016. The tropical weather conditions of 36C temperature and 52% humidity, making it feel like 44C, seemed to be exacerbating the problem. Have you also faced such challenges with inductive prox switches in high-temperature environments like ours?
I have observed frequent occurrences of sensor malfunction in welded processes due to improper sensor placement or proximity to heat sources. In my experience, this issue is not typically caused by ambient temperatures alone, but rather by processes generating substantial heat. Our preferred sensors for these applications are primarily Turck proxes.
In my 38 years of experience, I have never witnessed a failure of this product due to heat. Failures typically occur from the edge of the proximity sensor getting damaged, the face being hit or rubbed off, or a small piece of metal getting stuck in the face. - James.
Instead of depending on ambient temperature, it is important to consider the actual temperature the sensor is experiencing. Instead of continuously replacing faulty sensors with the same issue, it is advisable to reach out to different proximity sensor manufacturers for alternative solutions. A quick search on the web led me to various options such as inductive proximity sensors from KEYENCE Canada, Pepperl+Fuchs Canada, ifm, Turck Canada Inc., and Balluff. These sensors offer reliable non-contact detection for a variety of applications. Contacting these manufacturers could help resolve production losses and improve efficiency.
In my 38 years of experience, I have never seen a product fail due to heat. Failures typically occur when the prox edge or face is damaged, or when a small piece of metal gets stuck in the face. Similarly, in over 30 years, I have placed these products near cookers and heaters without any heat-related failures.
It's important to note that inductive sensors can also detect non-metallic substances like conductive ceramics. When designing a kiln for diesel car exhaust particle filters made of ceramics, we initially used capacitive sensors to detect the movement of silicon carbide plates. However, they performed poorly with continuous false alarms. After realizing that inductive sensors could also detect the SiC ceramic plates, we replaced them with Schneider inductive sensors. This solved all detection issues and ensured smooth operation, even in the high temperatures of the oven.
I completely understand your predicament. I work in a power plant in Mexico, where the average temperature hovers around 35C so we had similar issues with our inductive prox switches. After a long troubleshooting process and frequent component replacements, we decided to seek a more permanent solution. We consulted with our industrial automation supplier who suggested using high-temperature resistant switches designed to withstand severe heat conditions. Of particular note was the IFM Efector range of sensors, which are reputed to withstand up to 85C. Since then, the instances of heat-related malfunctions have significantly reduced. It might be a worthwhile consideration for your situation as well.
We too have encountered the same issue with our inductive prox switches operating in warmer environments. We found that heat often changes the electrical resistance, and this could impact the performance of the switch. Using switches rated for higher temperatures offered some improvement but wasn't a complete solution. What worked for us was the combination of using high-temperature-rated switches and improving the design of our systems for better heat management. This could perhaps involve better ventilation, heat sinks, or even cooling units in extreme cases. So, in my opinion, dealing with this peculiar occurrence may require both hardware upgrade and an appropriate design alteration in the system's thermal management.
It sounds like you've been dealing with quite a frustrating issue! I can definitely relate; we had similar troubles with inductive prox switches in our facility as well, particularly in areas with high humidity and temperature. We found that switching to higher-rated temperature variants or even considering some cooling solutions for critical components helped mitigate those problems. It’s impressive that some of your switches have lasted since 2016 despite the conditions! Have you looked into any shielding or alternative sensing technologies that might be more resilient in your climate?
That's really interesting! We faced similar issues with inductive prox switches in our facility, especially with temperature fluctuations impacting their reliability. It sounds like the tropical climate is definitely not playing nice with those components. Have you considered any heat-resistant models or protective shields for your current switches? It could be worth exploring options that are specifically designed for high-temperature environments to minimize those malfunctions.
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Answer: - Inductive proximity switches can malfunction in high-temperature environments due to the heat causing them to stick closed, leading to operational issues.
Answer: - To prevent malfunctions in high temperatures, consider using switches specifically designed for high-temperature applications or implementing cooling mechanisms to regulate the temperature around the switches.
Answer: - Some manufacturers offer models designed to withstand high temperatures better than others. It may be beneficial to explore options from reputable brands known for their durability in extreme conditions.
Answer: - Environmental factors like high temperatures and humidity can affect the performance of inductive proximity switches by causing them to malfunction or stick closed, as observed in the discussed scenario. It is essential to consider these factors when selecting switches for specific applications.
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