In depth analysis of the "mold explosion" accident in the stamping workshop: how to destroy a mold worth 500000 yuan with a single piece of double material?

Core Summary:

In the automotive stamping workshop, the most concerning abnormal sound for production managers is undoubtedly the dull and abnormal "muffled car" sound of the press. This usually means: double feeding. Light cases can result in production stoppage and mold repair, while heavy cases can lead to the direct scrapping of hundreds of thousands of precision molds. This article will explore why vacuum suction cups cannot prevent double suction and provide a cost-effective MDSC-1600S retrofit solution.

1、 Why is' double sheet 'a major hazard in stamping lines?

With the increasing demand for lightweight and production capacity in the automotive industry, the pace of automated stamping lines is getting faster and faster (SPM 15+). In such high-speed sheet metal transportation, the risk of double overlapping entering the mold increases exponentially. Its harm is devastating:

List of consequences of mold explosion:

Mold cracking: even causing deformation of the press crankshaft, with a single repair cost ranging from 50000 to 500000 yuan.

Unplanned downtime: Even if it's just a slight indentation, repairing the mold and retesting it will take at least 4-8 hours, resulting in a direct loss of production capacity of hundreds of sets.

Quality hazard: Damaged molds may cause subsequent batches of products to exceed dimensional tolerances, leading to claims from the host factory.

Since the harm is so great, why is it difficult to eliminate it?

Many engineers ask, "I used a powerful vacuum suction cup and added a split magnet, why do I still suck two

The reason is due to the coating of wash oil on the surface of the sheet metal. Stamping plates are covered with a layer of oil film on the surface for rust prevention and lubrication. When two sheets are tightly adhered by vacuum adsorption, the "viscous force" generated by the oil film combined with vacuum negative pressure is sufficient to firmly "stick" the lower sheet. In addition, the interlocking of burrs during sheet cutting is also the main cause of mechanical splitting failure. This kind of physical adhesion is extremely difficult to detect by relying on PLC logic judgment (such as suction cup vacuum monitoring).

2、 Misconception in selection: Why not use mechanical or photoelectric?

Many factories have taken detours when searching for anti double tension solutions:

Mechanical thickness gauge: Contact rollers are prone to scratching the exterior panel of the vehicle (A-level curved surface), and the mechanical structure wears out quickly at high speeds, making maintenance difficult.

Optoelectronic/laser sensor: The reflectivity of metal sheet is extremely high, and the photoelectric signal fluctuates greatly; And there is a lot of oil mist and dust in the workshop, so the lens needs to be wiped frequently, otherwise false alarms will be reported frequently.

3、 Breaking plan:MDSC-1600 series metal dual detector

For scenarios such as automotive stamping and home appliance sheet metal that require high cost control and stability, Atorm has launched the MDSC-1600S series (threshold version) solution. It is not an expensive precision measuring instrument, but a defense line specially designed to "protect the mold".

1. Technical principle: Through beam electromagnetic transmission

Unlike single head adsorption, the MDSC-1600 series adopts a paired probe design. The transmitting end generates an alternating magnetic field, and the magnetic lines penetrate the sheet metal to reach the receiving end.

Basic principle: Eddy currents generated inside metals attenuate magnetic field energy. The thicker the sheet metal, the stronger the eddy current effect, and the weaker the signal signal sensed at the receiving end.

Double sheet judgment: When two sheets overlap and pass through, the attenuation amplitude of the signal value will undergo a significant jump.

This change in electromagnetic characteristics is physical and is not affected by surface oil stains, light intensity, or coating color interference. The controller can accurately distinguish between a single sheet and multiple sheets by identifying this obvious signal difference and setting a judgment threshold.

2. How to choose: Threshold version (S) or Thickness measurement version (T)?

MDSC-1600The platform is divided into two versions based on different application requirements. When selecting, there is no need to worry, just match it according to your actual testing purpose:

Selection Recommendation

The core of selection is "targeted",MDSC-1600 seriesThe two versions accurately match different production line requirements, as follows:

Core requirementsFor mold protection and anti double tension (no need for precise thickness measurement), choose MDSC-1600S (threshold version)Easy to operate, cost-effective, focusing on the core function of dual card interception.

To balance dual sheet prevention and sheet quality control (requiring real-time thickness measurement and data traceability), MDSC-1600T (thickness measurement version) should be selectedAdapt to the precision and traceability requirements of high-end production lines.

threeMDSC-1600 series dual detectorcore competency

Four channel design: One controller can connect four pairs of probes and simultaneously detect four loading stations, which is efficient and saves space in the electrical control cabinet.

Broad spectrum applicability: Although mainly used for carbon steel/iron plates, thanks to high-frequency electromagnetic technology, it is also effective for non-magnetic metals (aluminum plates, stainless steel).

PLC friendly integration: with mainstream communication function, providing NPC/PNP alarm output, directly connected to the emergency stop or prohibition of mold closing circuit of the press, with a response time of less than 20ms.

4、 Application effectiveness and installation suggestions

On site installation tips:

MDSC-1600S dual material testingThe aiming probe is usually installed at the end of the automatic feeding robot or on both sides of the magnetic belt of the unstacking machine. It is recommended to maintain an Air Gap between the probe and the sheet metal between 2-5mm to avoid shaking and bumping the probe during high-speed transmission.

Actual measurement data:

After the deployment of MDSC-1600S in the side production line renovation of a stamping plant supporting the Toyota system:

1. False alarm rate: reduced from 15 times/day in the original optoelectronic scheme to 0 times/month.

2. Interception rate: During the trial operation, successfully intercepted 4 real double sheet adhesions, recovering potential mold losses of over 200000 yuan.

Appointment trial and technical consultation

Not sure if your sheet material (such as high-strength steel, aluminum magnesium alloy) is suitable?

We offer free sample shipping and testing of the MDSC-1600 series dual detector. You only need to send 3-5 samples, and we will provide a detailed feasibility test report within 48 hours.