Solution for Stamping Overlap Detection of Automotive Battery Current Collector Plates - MDSC-8100S Metal Double-Sheet Detector

I. Project Background

In the production process of metal current collector plates for new energy vehicle battery packs, the stamping process is extremely critical, as it is directly related to product quality and performance. During the feeding of metal current collector plates, sheet overlapping—i.e., multiple aluminum sheets entering the stamping press simultaneously—can trigger a series of severe issues. The stamping die may be damaged due to excessive pressure, increasing equipment maintenance costs and downtime; in addition, stamping with overlapping sheets can lead to higher product defect rates, resulting in raw material waste and reduced production efficiency.

II. Pain Point Analysis

In the stamping process of the metal current collector plate production line, the mechanical sheet separation method previously adopted by the customer to handle robotic feeding had obvious drawbacks. This method featured slow cycle times and low efficiency, with a per-minute throughput far below the actual production line requirements. It failed to meet the production line rhythm, becoming a bottleneck restricting the improvement of production efficiency and capacity expansion.

III. Solution

To effectively address the above pain points, this project innovatively introduced a metal double-sheet detector into the feeding process of the metal current collector plate stamping line, enabling automatic overlap detection of flat sheet materials.

Equipment Selection

The contact-type single-probe double-sheet detector MDSC-8100S was selected. With outstanding performance among similar products, this device has passed rigorous testing and market validation, and can accurately adapt to the production environment of metal current collector plates.

Scheme Advantages

High Safety

The MDSC-8100S Double-Sheet Detection Sensor is based on advanced electromagnetic induction and eddy current principles, adopting next-generation sensor technology to accurately detect the single/double sheet status of non-magnetic metal materials such as aluminum sheets. By detecting and warning of sheet overlapping in advance, it effectively avoids stamping die damage, product quality issues and potential safety accidents caused by overlapping sheets from the source, providing reliable safety guarantee for the production process.

Fast Detection Speed

The detection speed of the MDSC-8100S Double-Sheet Detection Sensor can reach 200 pcs/min, far exceeding the processing speed of traditional mechanical sheet separation methods. It can easily meet the high-speed production requirements of the production line, ensure the continuity and efficiency of the production process, and greatly improve production efficiency.

High Automation Level

The MDSC-8100S Metal Double-Sheet Detector is built with a 485 communication module, which can be easily connected to a touch screen for control. Operators can conveniently complete equipment parameter setting, detection status monitoring and other operations through the touch screen, and operation records can be traced back. This feature not only improves work efficiency, but also realizes the automation of flat sheet feeding and detection, reduces manual intervention, lowers human error, and further enhances production efficiency.

IV. Customer Benefits

Cost Reduction

It effectively avoids stamping die damage caused by sheet overlapping, reduces die maintenance and replacement costs, and at the same time reduces raw material waste due to defective products, lowering production costs.

Efficiency Improvement

With fast detection speed, the equipment meets the high-speed rhythm requirements of the production line, greatly improves production efficiency, helps enterprises expand production capacity and meet market demand.

Quality Assurance

Accurate detection of sheet overlapping reduces product defect rate, improves product quality, and enhances product market competitiveness.

Convenient Communication

The 485 communication module of the MDSC-8100S has good compatibility, which can be easily integrated into the factory automation system to realize real-time data sharing and interaction. It can work with other equipment without complex wiring modification, improving the integration of the production system. Production managers can grasp equipment status and detection data in real time in the remote monitoring center, quickly handle abnormalities, shorten fault troubleshooting time, and improve the timeliness and accuracy of management.