New BunkerProx® Reduces Sensor Impact Failure

Press Release:
  Jun 17, 2010 — Florence, KY: In abusive welding environments, “bunkering” describes the technique of mounting sensors into tough metal brackets for impact protection. However, many sensor applications have not been properly bunkered, resulting in repeated (and costly) failures from impact damage. Often, it is too difficult and time-consuming to retrofit these applications with adequate bunkering protection.

Enter Balluff’s BunkerProx: a rugged, “self-bunkering” M18 inductive proximity sensor specially designed to survive longer in abusive welding applications without external protection. The key to the BunkerProx design: a strong, massively thick housing that boosts the ability to withstand repeated mechanical impact. The extra-thick housing also serves as an intermittent heat sink to shield the sensor electronics from the intense heat of red-hot weld slag.

A frontal impact deflection ring helps protect the high-temperature ceramic face from impact damage during part loading and unloading. The ceramic face also resists the melting and burn-through that can short out the sensing coil of standard proxes, killing them instantly. Additionally, the all-important sensing coil is reduced in diameter compared to standard M18 sensors, providing a perimeter “crush zone,” so that incidental corner impacts don’t result in immediate coil damage and loss of sensor function.

An unusually thick connector/barrel junction helps to eliminate connector failures from excessive shock, vibration, heavy contact, or undue cable stress. To repel hot weld slag and prevent it from sticking, the BunkerProx is fully coated with slag-resistant material, while weld-field immune electronics eliminate false signals during the welding cycle. Offered in a PNP N.O. output configuration with a micro connector, nominal sensing range for the BunkerProx is specified as 4.0 mm.

BunkerProx gives plant maintenance personnel a new tool to combat excessive sensor failure. Installing BunkerProx into impact-prone weld fixtures can help reduce unplanned downtime, cut sensor replacement costs, and shave maintenance expenses. The increased profitability, higher throughput, and lower operating costs can be dramatic.

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Balluff Inc., the U.S. subsidiary of Balluff GmbH, Neuhausen, Germany, is a leading manufacturer of a wide range of inductive, optical, capacitive and magnetic sensors as well as linear position transducers and ID systems. Balluff products for OEM and factory floor solutions are used to control, regulate, automate, assemble, position, and monitor manufacturing, assembly, and packaging sequences for industries including metalworking, automotive, plastics, material handling, wood processing, aerospace, electrical, and electronics.

Editors: please contact Vestal Simms at 1-800-543-8390 for clarifications and additional information, or e-mail

Direct reader service inquiries to: Kelly Panko, Balluff Inc, 8125 Holton Drive, Florence, KY, Phone 1-800-543-8390, or

In Canada only, contact Norman J. Clarke, President, Balluff Canada, 2840 Argentia Road, Unit # 2, Mississauga, ON L5N 8G4, Phone 1-800-927-9654 or
Tel: 905-816-1494, 905-816-1411, E-mail:
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Tags: Balluff, welding, prox, bunkerprox
Categorized Under: Proximity Sensors
Company Details:
 Contact:Kelly Panko 
 E-mail:kelly -dot- panko -at- balluff -dot- com 
 Company:Balluff, Inc. View Company Profile 
 Address:work8125 Holton Drive 
 Location:workFlorence, KY 41042  United States 
 Web Site: