After evaluating torque sensors from three manufacturers, the plant chose the ABB PFTL101B 5.0KN 3BSE004191R1 for its compatibility with ABB robots and reliable performance:
- Dynamic Force Monitoring: Unlike the robots’ static internal sensors, the PFTL101B measures force in real time during the tightening process, adjusting for variables like bolt friction or material hardness. Its ±0.1% accuracy ensures torque stays within the automakers’ strict ±2% tolerance.
- Seamless Robot Integration: The PFTL101B connects directly to the robots’ IRC5 controllers via Ethernet/IP, requiring no custom software. This plug-and-play compatibility cut installation time by 50% compared to third-party sensors.
- Durable Construction: The sensor’s stainless-steel housing and IP67 rating resist oil, coolant, and metal shavings—common in automotive component manufacturing. It requires calibration only once every 6 months, compared to monthly calibrations for the old internal sensors.
- Data Logging for Compliance: The PFTL101B logs every tightening event with timestamp, force value, and component ID—creating an audit trail that automakers require for quality compliance.
“We retrofitted 30 robots with PFTL101B sensors in 2 weeks,” Carter said. “The ABB team trained our robot programmers to set up force thresholds, and by the end of the first week, we saw a immediate drop in rejects.”
Outcomes: Rejects Fall, Warranty Claims Disappear
Four months post-deployment, the plant has seen transformative results:
- Rejected components down 35%: Scrapped or reworked parts fell from 12,000 to 7,800 annually, saving $192,000 in material and labor costs.
- Warranty claims eliminated: No under-tightened components have been reported since the upgrade, preserving the plant’s relationships with automakers.
- Robot uptime up 8%: Fewer rejects mean less time spent pausing robots to rework parts, increasing overall production capacity by 56,000 components annually.
“The PFTL101B turned our most problematic robots into our most reliable ones,” Carter said. “We’re now able to hit our 700,000-component target without cutting corners on quality.”
John Miller, ABB’s North American director for robotic sensors, noted the PFTL101B’s value for high-volume manufacturing. “Automotive suppliers need sensors that work as hard as their robots—24/7, with no compromises on accuracy,” he said. “The PFTL101B 5.0KN 3BSE004191R1 delivers that, and this Detroit project proves it.”
The plant plans to equip its remaining 15 robots with the PFTL101B by the end of 2024 and expand its use to new transmission component lines in 2025.
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