Body shop, paint, assembly and powertrain applications where uptime is measured in vehicles per hour and a nuisance stop costs more than the sensor.
Automotive lines are the harshest mainstream environment for a sensor. A body-shop sensor sees weld spatter, magnetic fields from several thousand amps of welding current and clamping forces that would crush a plastic housing. A paint-shop sensor sees solvent vapour and ovens at 200 °C. An assembly sensor sees hundreds of thousands of cycles a year and a maintenance team that cannot afford to stop the line to investigate an intermittent fault.
Our automotive range is built around three requirements from tier-one customers: a defined service life in cycles, a diagnostics path that identifies a degrading sensor before it stops the line, and a part number that does not change between model years. The weld-immune proximity switches, IP69K hygienic sensors and drag-chain cables in this catalogue were all developed against those requirements.
DuoMy supplies both the components and the documentation that automotive quality systems expect: PPAP-style dimensional reports, IMDS material declarations, batch traceability and serialised test records for safety-relevant positions.
Application Reality
These are the failure modes we are called in to solve, and the specification change that addresses each one.
A PBT sensing face pits within weeks in a spot-welding cell, and the switching distance drifts until the robot misses a part. PTFE-faced weld-immune sensors with a spatter-resistant coating hold their distance through the cell's service life.
A conventional inductive sensor can be triggered by the welding field alone. Weld-immune models use a field-resistant oscillator circuit, and the mounting rule is one sensing distance away from the current path.
Pressure and flow signals routed alongside drive and welding cables pick up common-mode noise. Isolating signal conditioners at the panel boundary solve this without changing the sensor.
Positions inside fixtures and under clamps are inspected rarely. IO-Link sensors report switching-distance margin and internal temperature, so a degrading unit is replaced at a planned stop.
Re-validating a sensor for every model change is expensive. We hold form, fit and function for the life of the programme and issue a change notification before any revision.
Products
DM-CB10-M8-4P
DM-CJ08-JB-8P
DM-CB05-M12-5P
DM-SC08-IOL-PN
DM-PC18-8-IOL
DM-PM08-WI-2
DM-PX12-4-PNP
DM-FT80-TB-050
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Standards
| Standard | Requirement |
|---|---|
| IATF 16949 supply chain | PPAP documentation and batch traceability |
| IMDS / material declaration | Full substance reporting for every part |
| IP69K / ISO 20653 | High-pressure washdown resistance |
| ISO 13849 performance level | Sensor reliability data for safety functions |
Application Example
Situation
A tier-one body-in-white supplier was replacing inductive sensors on clamp positions every 6 to 10 weeks. Each failure caused a line stop and a quality hold while the fixture was re-taught.
What we changed
We replaced the standard M12 stainless sensors with PTFE-faced weld-immune units, added a protective bracket that moved the face 4 mm out of the spatter path, and rerouted the cable away from the welding leads.
Result
Failures dropped to one unit in 14 months across the three plants, and the customer standardised the part onto two additional lines.
FAQ
A weld-immune inductive sensor with a PTFE or coated stainless face, mounted at least one sensing distance from the weld current path, with the cable routed separately from the welding leads. Standard stainless sensors will work initially and then fail as the field and spatter erode the face.
For catalogue items, yes, when the mechanical and electrical specification matches. For custom parts we build to your drawing and your part number, typically from 100 pieces, with a first-article inspection report.
We provide the equivalent documentation package: dimensional report, material and surface finish certificates, functional test record and batch traceability. Full PPAP level 3 is available for production programmes.
Catalogue items ship in 5-10 working days for quantities up to 1,000 pieces. Custom housings and cable assemblies take 3-5 weeks after drawing approval, with scheduled releases against a blanket order.
Automotive programmes run for years, so we hold tooling and commit to a minimum ten-year supply window for custom parts. If a component inside the sensor becomes unavailable, we requalify it and issue a change notification with samples before shipping.
Send the application details and get a specification back within one business day.