Metal Double Sheet Detector MDSC-900E: Application Case for Single/Double Sheet Detection of Foil Liners Inside Aluminum Foil Cap

Ⅰ. Project Background

In the cap manufacturing industry, aluminum foil liners for bottle caps are being increasingly adopted due to their excellent barrier properties, sealing performance and aesthetic appeal. During the production and conveying process, the 28MM and 38MM-specification aluminum foil liners for bottle caps are prone to double-sheet overlapping. If double-layered aluminum foil liners enter subsequent processes, they will damage the sealing structure of the caps. To ensure production quality and efficiency, a well-known cap manufacturer has introduced the Atonm Metal Double Sheet Detector MDSC-900E to conduct accurate double-sheet detection on 28MM and 38MM aluminum foil liners for bottle caps.

Ⅱ. Detection Requirement Analysis

Aluminum foil liners for bottle caps are characterized by light weight, good ductility, and high electrical conductivity. These properties make the appearance difference insignificant when double-layered aluminum foil liners overlap, and they are prone to adhesion due to electrostatic adsorption. The enterprise requires that the detection equipment can not only quickly and accurately detect double-layered aluminum foil liners, but also have anti-interference ability to adapt to the characteristics of aluminum foil materials. In addition, the equipment must meet the operation requirements of high-speed production lines, feature simple operation, and facilitate daily maintenance and management.

Ⅲ. Characteristics of Atonm MDSC-900E Detector

The Atonm Metal Double Sheet Detector MDSC-900E is optimally designed for double-sheet detection of metal and metal-like materials. It adopts advanced electromagnetic induction detection technology, which can effectively overcome the detection challenges caused by aluminum foil materials. The specific characteristics are as follows:

High-Precision Detection

With unique magnetic induction detection technology, the detection accuracy for 28MM and 38MM aluminum foil liners for bottle caps can reach ±0.01mm. It can sensitively identify extremely subtle double-sheet conditions and avoid missed detection.

Wide-Range Adaptability

It is suitable for detecting aluminum foil liners of different thicknesses and sizes, and can achieve stable detection for both 28MM and 38MM specifications.

High-Speed Response

The detection response time is extremely short, with millisecond-level reaction time, which is fully compatible with the high-speed operation rhythm of bottle cap production lines.

Easy Operation

The equipment is equipped with an intuitive human-machine interface. Workers can proficiently operate it after simple training, and daily maintenance is convenient, which lowers the threshold for use.

Ⅳ. Equipment Installation and Commissioning

When installing the Atonm MDSC-900E Detector, the technicians mounted the detection head directly above the gasket conveying track, at a distance of approximately 8-12mm from the aluminum foil gasket conveying plane. This ensures that the detection head can fully cover the conveying area of both 28MM and 38MM aluminum foil gaskets. Meanwhile, the detector control unit is connected to the PLC control system of the production line to realize the linkage control between detection signals and the production line.

After installation, the technicians conducted commissioning using single and double aluminum foil gaskets of different specifications, optimizing the device to achieve the best performance in double-sheet detection for 28MM and 38MM aluminum foil gaskets. Through multiple tests and adjustments, the device now delivers stable and accurate detection results.

Ⅴ. Detection Workflow

When 28MM or 38MM aluminum foil bottle cap liners enter the detection area via the conveying track, the detection head of the Atonm MDSC-900E Detector senses the gaskets in real time. If a single sheet is detected, the detector outputs no signal, and the gasket passes through normally to enter subsequent processing procedures. If double sheets are detected, the detector immediately sends an alarm signal and transmits it to the PLC control system of the production line. Upon receiving the signal, the PLC control system automatically stops the operation of the conveying track and activates the audible and visual alarm device to notify the operator for handling. After the operator removes the double sheets and presses the reset button, the production line resumes normal operation.

Ⅵ. Detection Effects and Benefits

Since the Atonm MDSC-900E Detector was put into use, it has brought significant production improvements to the enterprise, specifically reflected as follows:

Quality Improvement

Effectively prevents quality issues such as bottle cap seal failure caused by double-layered gaskets.

Efficiency Enhancement

The fast and accurate detection of the device reduces equipment failures and downtime caused by double aluminum foil gaskets, increasing the average operational efficiency of the production line by about 25%.

Cost Reduction

Cuts down rework costs, raw material waste, and equipment maintenance expenses resulting from product quality problems, saving the enterprise approximately 600,000 yuan annually.

Enhanced Production Stability

The stable and reliable operation of the device reduces uncertainties in the production process, strongly ensuring the enterprise's ability to fulfill orders on time and with high quality.

Ⅶ. Conclusion

The successful application of the Atonm Metal Double Sheet Detector MDSC-900E in the double-sheet detection of 28MM and 38MM aluminum foil bottle cap liners fully demonstrates its strong performance in the field of metal material detection. This device not only perfectly meets the enterprise's requirements for high precision, high speed, and high stability in double-sheet detection of aluminum foil gaskets, but also creates significant economic benefits for the enterprise and improves the market competitiveness of its products. This application case proves that the Atonm MDSC-900E is a reliable device for double-sheet detection of aluminum foil and metal gaskets, and can provide effective solutions for quality control in the bottle cap manufacturing and related industries.