Complete Solution for Double Sheet Detection in Stamping and Feeding for the Hardware & Home Appliance Industry

1. Solution Overview
The current hardware and home appliance industry (e.g., stamping production of washing machine drums, refrigerator doors, air conditioner outdoor unit brackets, etc.) faces three core issues: double sheet stacking causing high mold wear, poor adaptability of traditional detection methods, and low efficiency in multi-product changeovers, directly impacting production efficiency and product quality. This solution, based on the Atonm Through-Beam Magnetic Induction Double Sheet Detector, leverages minimal integration, precise detection, and rapid changeover design to upgrade quality control and optimize costs in the stamping and feeding process.

2. Industry Core Pain Points and Solution Objectives

(A) Industry Core Pain Points

1. High losses caused by double sheet stackingIn hardware and home appliance stamping, sheets (such as galvanized or cold-rolled steel) are prone to double or multiple sheet stacking due to surface oil or contamination. When entering molds, this can lead to mold chipping and cavity wear, with single repair costs exceeding ¥100,000. Industry average annual mold damage rate reaches 15%-20%. At the same time, stacking causes stamping part deformation and dimensional deviations, increasing scrap rate by 3%-5%. Annual downtime due to double sheet issues averages 120 hours, directly affecting order fulfillment.

2. Insufficient adaptability of traditional detection technologies

·Mechanical contact detection (probes, rollers) can scratch lightweight thin sheets (0.2–1.2 mm) and controlling pressure is difficult, with false detection rates exceeding 8%.

·Standard photoelectric detection is affected by sheet surface reflectivity and contamination, with poor stability for ferromagnetic metals (over 80% of hardware and home appliance stamping materials), unable to accurately identify double sheets.

·Existing equipment lacks targeted recipe storage; during changeovers, sensor positions and parameters must be repeatedly adjusted, taking over 30 minutes, failing to meet multi-product, small-batch flexible production requirements.

3. Lack of quality traceability and process optimizationTraditional detection systems do not record data, making it impossible to trace quality issues caused by double sheets back to specific batches or detection times. Without data support, it is difficult to optimize robotic gripping pressure, feeding speed, and other process parameters, keeping material damage and collision rates high (about 5%).

(B) Core Solution Objectives

1. Detection Performance Objectives

·Material compatibility: 0.2–3 mm ferromagnetic metal sheets (galvanized, cold-rolled, hot-rolled steel, and other commonly used hardware/home appliance materials).

·Accuracy metrics: Double sheet detection accuracy ≥ 99.9%, false detection rate < 0.1%.

·Response speed: ≤ 200 ms, suitable for high-speed stamping lines up to 1200 sheets/min without detection delay.

2. Production Efficiency Objectives

·Cost optimization: Annual mold maintenance costs reduced by over 90%, scrap losses reduced by 30%, total costs decreased by 30%.

·Efficiency improvement: Changeover time reduced from 30 minutes to within 1 minute, overall equipment effectiveness (OEE) increased from 70% to over 85%.

·Quality control: Stamping defect rate controlled below 0.3%, with traceable detection data for each sheet.

3. Complete Solution Design

(A) Core Equipment Selection and Technical Parameters
Atonm Through-Beam Double Sheet Detector: Taking the MDSC-1000C as an example

(B) System Integration and Implementation Design

1. Installation Layout (Adapted for Robotic Gripper Feed Detection Table)

·Detection Point Positioning: Set the detection point between the robotic gripper feeding station and the stamping die feeding port, either above or below the detection table or conveyor, ensuring the metal sheet passes through the effective sensing area.

·Sensor Installation:The emitter and receiver are fixed on custom brackets on the detection table, with the emitter (T) on top and the receiver (R) below. The working surface (with the black circular disc) faces the installation direction.The installation distance between working surfaces should be 30–50 mm, with 40 mm recommended.Calibration after installation: Test with a standard thickness sheet (e.g., 1 mm cold-rolled steel) to ensure stable detection signals without drift.

2. Control Logic and Workflow

1. Normal Process:Robot picks a single sheet from the material stack → moves it to the sensor position → sheet fully covers the through-beam detection area → detector completes magnetic induction detection instantaneously (≤50 ms) → confirms “single sheet” → PLC receives OK signal → robot delivers sheet to stamping die → detection table resets for the next detection.

2. Double Sheet Exception Process:Robot places the sheet → detector detects “double sheet” → immediately sends an exception signal to the PLC → PLC stops feed and returns robot to safe position → audible/visual alarm triggers → MES system logs exception data (time, batch, sheet thickness) → operator confirms and removes double sheet → reset button pressed → system resumes normal detection.

3. Rapid Changeover Operation Process

1. Operator selects the material recipe for the product to be produced on the industrial touchscreen (e.g., “0.5 mm galvanized sheet,” “1.2 mm cold-rolled steel”).

2. System automatically loads detection parameters for that material without adjusting sensor positions.

3. Test 1–2 first-piece sheets to confirm detection works correctly, then start batch production. Total changeover time: <1 minute.

4. Data Management and Traceability Design

·Real-Time Monitoring: Industrial touchscreen displays real-time data including “current detection status (normal/exception), sheet thickness, cumulative detection count, and today’s exception count.” Exceptions trigger a pop-up with detailed information.

·Data Storage: Detection data (time, batch number, double sheet status, operator) automatically syncs to the MES system, stored for ≥1 year, and can be queried by date, batch, or exception type.

·Report Export: Supports Excel export of daily/monthly detection reports, including key metrics such as total sheets inspected, number of exceptions, exception rate, and mold protection occurrences, providing data support for process optimization.

4. Solution Implementation and Assurance

(A) Implementation Timeline Planning (Single Production Line)

(II) After-Sales Service and Technical Support

1. Warranty Period: Detectors are covered by an 18-month warranty, with free repair or replacement of faulty components during the warranty period.

2. Response Mechanism: 24/7 technical support.

3. Regular Maintenance: Provide one remote inspection per quarter to ensure long-term stable operation of the equipment.

5. Conclusion of the Proposal

This solution is based on the Atonm MDSC-1000C through-beam magnetic induction double-sheet detector. Targeting the core pain points in the metal appliance stamping feeding process, it is designed around “precise detection, minimalist integration, and rapid production changeover,” delivering three key values: “significantly reduced mold wear, markedly improved production efficiency, and comprehensive quality traceability.” The solution focuses on metal sheet detection scenarios, offering strong equipment adaptability, fast ROI, and low implementation difficulty. It can be directly applied to production lines for washing machines, refrigerators, air conditioners, and other metal stamped parts, helping enterprises achieve cost reduction, efficiency improvement, and digital transformation.