When it comes to projection welding, it is common for metal stampings to stick together causing the operator to load a double part into the fixture without their knowledge of it. A blank part then gets passed through the system without the proper weld nuts or studs causing quality issues.
This was the concern by our customer for a recent project and that we would need to address this issue previous to the design of the machine. We found an easy solution by adding an analog proximity sensor into the fixture. The tooling was designed using this simple fix and the problem was solved. The fixture now detects a double part every time and makes the operator aware of it.