Double-Sheet Detection Solution for Automotive Stamping Lines

Project Background 

The customer is a company specializing in robotics and factory automation. For an automotive stamping line upgrade, they required high performance metal double-sheet detectors to work with robot feeding. The end user faced pressure to reduce cost and improve efficiency, so they sought a cost effective domestic brand to replace imported products while maintaining quality. The project team contacted Atonm.

Customer Pain Points and Working Conditions

1. High cost equipment: Existing imported detectors are expensive and the customer needs to lower cost while ensuring quality.

2. Sheet characteristics: iron sheets (aluminum may be added later), size 1.2m x 0.6m, thickness 2.0mm

3. Production rhythm: stamping requires 4 pieces per minute.

Solution

To address these issues and increase automation, Atonm proposed a double-sheet detection system working with the robot to monitor sheet state before stamping.

1. Equipment Configuration：

   - Sensor model: Contact single-sensor double-sheet detector MDSC-9000S

   - Sensor quantity: 2 (monitor different positions on the same sheet)

   - Installation: Main unit mounted in the control cabinet; a sensor is installed on each side of the robot gripper to monitor feeding and prevent stacked sheets entering the die.

2. Functional Design：

   - One-to-two design: The detector main unit supports two sensor probes. By monitoring different positions, redundancy reduces missed detections.

   - High reliability: MDSC-9000S upgrades the stacking detection algorithm and anti interference capabilities, accurately detecting single, double, and multiple sheets in the 0.2-4.0mm range. When stacking is detected it outputs a signal to the PLC, which can stop production or move stacked sheets to a handling area.

   - Strong compatibility: MDSC-9000S can detect magnetic and non-magnetic materials, suitable for mixed production lines.

   - Intelligent communication interfaces: MDSC-9000S supports Profinet and RS-485 to integrate with production systems for data logging and real time analysis, optimizing processes.

Customer Benefits

After the retrofit, the automotive stamping customer achieved:

1. Cost reduction: Replacing imported detectors with the high value Atonm MDSC-9000S lowered retrofit costs and improved ROI.

2. Stable quality assurance: Atonm metal double-sheet detectors operate reliably and maintain product quality.

3. Excellent after-sales service: Close vendor cooperation enabled fast support and maintenance, greatly reducing downtime and improving equipment uptime.

The project successfully replaced high cost imports with a cost effective domestic solution, ensuring continuous and stable production. Contact Atonm for custom solutions and support.