Double Material Detection Case in Home Appliance Stamping Production Line: Atonm MDSC-9000S Solves the Problem of Galvanized Sheet Feeding

Ⅰ. Project Background: The "Invisible Killer" of Thin Sheet Stamping

In the stamping workshop for air conditioner outdoor units of a leading home appliance enterprise, 0.5-1.5mm galvanized sheets are used to produce key components such as casings and brackets. However, during manual de-stacking and feeding, double/multiple sheet adhesion caused by smooth coatings and electrostatic effects occurs frequently: mold jams and downtime happen every shift. Each downtime requires manual inspection and mold cleaning, which seriously disrupts the high-speed production rhythm of 12 cycles per minute. More critically, double-sheet feeding often leads to mold scratches or sheet scrapping; in subsequent processes, dimensional deviations of stamped parts may even cause batch rework—becoming a "major hidden trouble" for the stable operation of automated production lines.

Ⅱ. Solution: Atonm Contact Detection Technology Accurately Breaks the Dilemma

1. Customized Hardware Configuration

Install the Atonm MDSC-9000S contact-type double-sheet detector under the suction cup group at the end of the de-stacking robot, equipped with a corrosion-resistant titanium-plated alloy probe. The detection surface is vertically attached to the sheet to ensure single/double sheet identification is completed within 0.1 seconds before the robotic arm picks up the material. It communicates with the production line PLC in real time via PN bus; upon triggering an abnormal signal, it immediately pauses material picking and issues an alarm.

2. Six Core Technical Advantages

Big Data Feature Modeling

By collecting over 170,000 sheet samples, a feature database covering different materials, thicknesses, surface conditions, and geometric dimensions is built in depth, providing strong data support for accurate detection.

Dynamic Anti-Interference System

Through triple collaborative optimization of electromagnetic shielding algorithm, adaptive filtering algorithm, and dynamic baseline compensation, industry-leading multi-level noise reduction is achieved to realize accurate extraction and stable output of detection signals under complex working conditions.

High-Speed Response

The single-cycle detection time is only 80ms, fully matching the high-speed stamping rhythm. When double sheets are detected continuously, the system outputs a double-sheet signal, and the robotic arm places the abnormal material into the recycling stack and re-picks the material.

Seamless System Integration

It supports multiple industrial communication protocols such as Profinet, Modbus, and IO, and can connect to the MES system to realize real-time interaction of sheet information, providing efficient data integration and collaboration capabilities for intelligent manufacturing production lines.

Strong Anti-Interference Capability

It has been verified to detect stably under working conditions of 50Hz power frequency interference and 1000 Gauss stray magnetic field.

Fault Monitoring System

Equipped with an intelligent fault monitoring system, in extreme cases such as sensor disconnection, it can immediately trigger an alarm and block sheet conveying, effectively preventing press damage and ensuring production safety.

Implementation Effects: From "Manual Troubleshooting" to "Intelligent Management & Control"

After the introduction of the Atonm MDSC-9000S Double-sheet Detector, the production line has achieved three key improvements:

Drastic Reduction in Downtime Frequency

The number of mold jams has dropped from over ten times per shift to only 1-2 times. The frequency of manual intervention has been reduced by more than 80%, ensuring a much more stable production rhythm.

Controllable Quality Risks

Rework issues in subsequent processes caused by missed detection of double sheets no longer occur. The pass rate of first-article inspection has been significantly improved, and the workload of quality inspection personnel has been reduced by 40%.

Customer Testimonial

"What surprises us most is the detection performance for 0.5mm thin sheets — we used to worry about missed detection due to their thinness, but now even the thinnest sheets can be identified accurately. Moreover, it can connect to the MES system for real-time interaction of sheet information, making operations more intelligent and simple. We no longer have to deal with frequent downtime caused by double-sheet problems."

— Mr. Li, Technical Supervisor of the Stamping Workshop, the Enterprise

Industry Enlightenment: Precision Detection Empowers Intelligent Upgrading

In this home appliance stamping scenario with extremely high precision requirements, the contact-type double-sheet detection technology has become the core solution to the thin-sheet feeding dilemma, thanks to its excellent anti-interference capability and thickness adaptability.

With its triple advantages of hardware reliability, algorithm intelligence, and production line interoperability, the Atonm MDSC-9000S not only solves the pain point of double-sheet detection for galvanized sheets, but also serves as a key infrastructure driving the transformation of stamping production lines towards fewer personnel and digitalization.