Dual-Sheet Detection System | Stamping Line Stack Detection Solution

Industry Background

With wide adoption of automation, production and handling of stamping parts rely heavily on robots and manipulators. On automatic stamping feed units, oil film and other factors can cause sheets to stick together. While air separation or magnetic separation help, they are not always sufficient.

If double or multiple sheets enter the press, quality issues or serious equipment and die damage can occur, leading to high repair costs and downtime. Real-time detection of sheet count before the press is necessary so the system can alarm or pause the machine for cleanup when needed, ensuring smooth production.

This case describes a stamping stacked-sheet detection solution for a major automaker in Changzhou, Jiangsu.

Production Conditions

1. Line speed: 15 SPM

2. Materials: steel and aluminum

3. Sheet thickness: 0.2mm-2mm

4. Line system: Beckhoff

5. Communication: R485IO

Solution

The solution uses a contact one-to-two double-sheet detector and a non-contact double-sheet detector for dual-stage automated feeding detection to ensure accuracy and prevent stacked sheets entering the press.

Detailed Plan

Equipment Selection:

1.  Contact double-sheet detector MDSC-9000S: sensors mounted on the palletizing robot gripper to perform the first single/double-sheet check during pick-up. One main unit with two sensors ensures comprehensive detection across positions.

2. Non-contact double-sheet detector MDSC-1200C: through-beam detector installed at the centering table before the press for secondary detection on moving sheets. Advantages: detects on-the-fly, saves time; non-contact extends sensor and cable life; detection values unaffected by air gap between sheets.

Advantages:

1. High-precision detection: combining contact MDSC-9000S and non-contact MDSC-1200C reduces errors at different stages and ensures accuracy.

2. Improved safety: timely detection prevents defective sheets entering presses, protecting equipment and dies and reducing repair costs.

3. Improved efficiency: optimized detection flow increases throughput and reduces downtime.

4. Flexible interfaces: supports R485 and IO to adapt to various automation systems for easy integration.

5. Stable operation: continuous monitoring ensures smooth production and avoids unexpected stoppages.

Customer Benefits

Applying MDSC-9000S and MDSC-1200C in depalletizing and centering significantly reduced detection errors and improved error-proof control, protecting equipment and dies, increasing line utilization and automation. This efficient detection system makes production smoother and more reliable.