Projeto para melhoria na identificação da integridade de peças em dispositivo de soldagem

Abstract

This article presents a study aimed at modernizing the component identification process in welding fixtures, focusing on the replacement and adaptation of sensors to ensure greater reliability, productivity, and quality in the industrial sector. The research was carried out through a literature review, technical analysis, and a case study in an automotive industry facing recurring failures in the part identification process. Different types of sensors are addressed: inductive, capacitive, optical, ultrasonic, photoelectric, and laser and their applications within the context of Industry 4.0 are discussed, highlighting their operating principles and relevance to automation systems. As a result of the implementation of the proposed solution, a significant reduction in the number of maintenance calls was observed after the replacement of sensors and the updating of components in the second half of 2025, even while the system was still in the testing phase. In addition, quality indicators showed a marked decrease in the scrap rate during 2025, associated with a reduction in rejected parts. These results reinforce that replacing inductive sensors with laser sensors directly contributes to greater process stability, fewer unplanned stoppages, increased equipment availability, and improved traceability, aligning the system with Industry 4.0 practices and requirements.