Application Case of 3.5mm Steel Plate Double-sheet Detection in Automotive Stamping Line - MDSC-8200S

I. Project Background

In automotive stamping lines, the problem of sheet overlapping during feeding is extremely troublesome. Sheet overlapping during feeding can lead to a series of serious consequences. First, the stamping die may be damaged due to bearing pressure exceeding the design limit. Once the precision structure of the die is damaged, the maintenance cost is high and time-consuming, which will greatly affect production efficiency. Second, products stamped from overlapping sheets are inevitably defective, which increases the scrap rate, causes raw material waste, and raises production costs. Moreover, frequent equipment failures and production interruptions will also affect the smoothness of the entire production line, disrupt production plans, and have a negative impact on the enterprise's on-time product delivery.

II. Working Conditions and Requirements

This automotive stamping line adopts robotic arm feeding, and the thickness range of steel plates to be processed is 0.6 - 3.5mm. During the robotic arm feeding process, to ensure feeding accuracy, it is necessary to equip with a sheet single/double-sheet detection device to prevent overlapping sheets from entering the stamping process.

III. Solution

After connecting with the customer and understanding the customer's needs and working conditions in detail, Atonm engineers matched a corresponding solution: introducing the contact-type single-probe metal double-sheet detector MDSC-8200S

MDSC-8200S是一款针对导磁金属材料单双张检测的产品，它能检测的材料厚度范围是0.2-4.0mm，能针对客户0.6-3.5mm的厚度需求

The MDSC-8200S is a dedicated product for single/double-sheet detection of magnetic conductive metal materials. It can detect materials with a thickness range of 0.2-4.0mm, fully meeting the customer's thickness requirement of 0.6-3.5mm.

The MDSC-8200S is a 1-to-2 double-sheet detector controller, where one main unit can control 2 sensors. In view of the large size of the customer's sheet materials, the sensors are installed at both ends of the end effector. When the robotic arm grabs the sheet, the sensors at both ends of the end effector can simultaneously perform single/double-sheet detection on the same sheet. This layout enables a more comprehensive detection of the sheet status by monitoring different positions of the sheet, greatly improving detection accuracy, effectively eliminating various problems caused by sheet overlapping during feeding, and ensuring feeding precision.

The MDSC-8200S is equipped with a 200-group recipe storage function, which brings great convenience to actual production and significantly reduces operational hassle. This function can store and manage multiple sets of material parameters. When it is necessary to detect different metal sheets, the host computer can quickly switch the metal to be detected without requiring operators to reset complex parameters every time, which greatly shortens production preparation time and enhances production flexibility.

The MDSC-8200S adopts a new generation of sensor technology, delivering more reliable detection performance. By upgrading the overlapping detection algorithm, it boasts excellent anti-interference capability, which can effectively eliminate external interference factors and ensure stable and accurate detection results even in complex industrial environments.

In terms of communication, it supports Profinet and RS-485 communication protocols, enabling convenient connection with upper computers such as PLCs and easy realization of system control. This means the automation level of the entire stamping line is improved, data interaction between various devices is smoother, and the production process can be regulated with higher precision, further guaranteeing feeding accuracy and effectively preventing various issues caused by sheet overlapping during feeding.

IV. Customer Benefits

Reduced Equipment Failure Rate

By accurately detecting and preventing sheet overlapping during feeding, the stamping die damage caused by abnormal pressure is significantly reduced. The stable operation time of equipment is prolonged, and the frequency and cost of equipment maintenance are lowered.

Improved Product Quality

The generation of defective products caused by sheet overlapping is effectively prevented, leading to a marked increase in product qualification rate. It reduces raw material waste caused by scrapped products and improves the economic benefits of the enterprise.

Guaranteed Production Continuity

Production interruptions caused by sheet-related issues are reduced, enabling the production line to operate continuously and stably. Production plans are implemented smoothly, which improves the enterprise's ability to deliver products on time and enhances customer satisfaction.

Enhanced Production Efficiency

The reduction in equipment failures and production interruptions increases the effective production time per unit period, improving overall production efficiency. This helps the enterprise gain a more favorable position in market competition.

With its unique design and high-efficiency detection performance, the contact-type single-probe metal double-sheet detector MDSC-8200S has successfully solved the problem of sheet overlapping during feeding in automotive stamping lines. It has brought comprehensive efficiency improvements to the enterprise and become a powerful assistant for optimizing the production process of stamping lines.