Application Case of Single/Double Sheet Detection in Automotive Parts Welding Feeding

I. Project Background

The customer, an enterprise specializing in the R&D and production of welding robots, undertook an important project for automotive parts welding. On the production line of this project, the material used is iron sheets with a thickness of 1.2mm and dimensions of 1200*400mm. As the welding process has extremely high requirements for the single/double-sheet status of materials, any double iron sheets entering the welding process may lead to a serious decline in welding quality and even damage the welding equipment. Therefore, the customer is in urgent need of a reliable single/double-sheet detection solution for iron sheets to ensure that the welding robots work under optimal conditions.

II. Solution

To meet the customer's requirements, the Atonm through-beam metal double-sheet detection sensor MDSC-1000B was introduced, paired with circular through-beam probes. The specific installation method is as follows: one end of the probe is mounted on a movable fixture, and the other end is installed under the operation table. When the iron sheet is placed on the operation table, the fixture moves to the table to fix the iron sheet, and the sensor is activated synchronously to perform single/double-sheet detection on the sheet. Once a single iron sheet is detected, the system will immediately send a signal to the welding robot, which then starts working immediately. If the sensor identifies double iron sheets, it will output a double-sheet signal instantly, and the buzzer will emit a loud alarm prompt at the same time. After receiving the alarm signal, the staff will conduct manual intervention in a timely manner to remove the double iron sheets, ensuring the normal progress of the production process.

III. Customer Benefits

Improved Product Quality

With precise single/double-sheet detection, double iron sheets are prevented from entering the welding process. This fundamentally eliminates welding defects caused by material overlapping, greatly improves the welding quality of automotive parts, reduces the defective rate, and enhances the product's market competitiveness.

Enhanced Production Efficiency

The sensor’s fast and accurate detection mechanism ensures that welding robots can perform welding operations on qualified single iron sheets immediately. It reduces time wasted on waiting for material detection or addressing welding defects, leading to a significant improvement in overall production efficiency.

Reduced Equipment Wear and Tear

It effectively prevents additional wear and potential damage to welding robots caused by double iron sheets, extends the service life of welding equipment, lowers equipment maintenance and replacement costs, and saves substantial capital investment for the enterprise.

Guaranteed Production Continuity

The combination of alarm prompts and manual intervention mechanisms enables timely resolution of double-sheet issues during production. This avoids prolonged production line shutdowns caused by severe quality problems, ensuring production continuity and stability.

By adopting the solution of Atonm through-beam metal double-sheet detection sensor MDSC-1000B paired with circular through-beam probes, the customer has achieved significant benefits in product quality, production efficiency, equipment maintenance, and production continuity, laying a solid foundation for the enterprise's sustainable development.