Application Case of Atonm Double-Sheet Detection Sensors in Stamping Production of Automotive Parts

I. Project Background

In the automotive manufacturing industry, the stamping production of components is a critical process, whose quality and efficiency directly impact the performance and cost of the entire vehicle. As a well-known domestic automobile manufacturer, the client has extremely high standards and requirements for the production of auto parts.

This application scenario targets the auto parts stamping line, where the stamping materials are steel plates of various specifications—including 0.5mm thickness, 50×1100mm and 200×1000mm dimensions. During the stamping process, if the suction cups pick up double or multiple steel plates from the stack, it will lead to subsequent issues such as stamping die damage, product dimensional accuracy deviation, and reduced production efficiency, which seriously affect the stable operation of the production line. Therefore, accurate single/double-sheet detection has become an urgent key problem to be solved for this stamping line.

II. Solution

Equipment Selection

To meet the requirements of the auto parts stamping production line, a detection solution integrating the Atonm Metal Double-Sheet Detector MDSC-1200C with through-beam round probes was adopted.

The specific workflow is as follows: After the suction cup picks up the steel plate from the stack, it moves with the plate past the through-beam sensor, which then performs single/double-sheet detection on the steel plate.

The Atonm Metal Double-Sheet Detector MDSC-1200C features high precision and reliability, capable of accurately identifying single or double layers of steel plates with a thickness ranging from 0.2mm to 4.5mm. Equipped with an integrated 485 communication module, it supports recipe configuration and recall via the button panel or upper computer. Boasting a 100-recipe storage function for saving and managing parameters of various materials, the upper computer enables quick switching between different metal types for detection without repeated calibration, thus improving work efficiency.

Equipment Installation

The through-beam round probes are properly installed behind the suction cup material-picking station on the auto parts stamping line. The transmitter and receiver of the probes are placed on opposite sides of the steel plate’s moving path, perpendicular to the plate surface, to ensure accurate detection signals. The Atonm Metal Double-Sheet Detector MDSC-1200C is mounted in the control cabinet near the probes for convenient wiring and maintenance.

System Commissioning

After equipment installation and parameter configuration, system commissioning is performed. By manually simulating the suction cup picking up single and double steel plates, the detection results of the detector and the response of the production line control system are observed. Through multiple rounds of debugging, the detection system is verified to accurately and timely identify single/double-sheet conditions. When double sheets are detected, it immediately triggers an alarm and controls the suction cup to stop feeding, preventing double steel plates from entering the stamping die.

Ⅲ. Application Effects

High Detection Accuracy

The Atom Double-sheet Detection Sensor System can accurately detect whether 0.5mm-thick steel plates are in single-sheet or double-sheet condition. It effectively prevents double-sheet steel plates from entering stamping dies, reduces the risk of die damage, and improves the dimensional accuracy and quality stability of products.

Improved Production Efficiency

By promptly detecting double-sheet conditions and stopping material feeding, the system avoids equipment downtime and product scrapping caused by double-sheet stamping, thus reducing downtime and material waste in the production process. Statistics show that after the application of this detection system, the production efficiency of the automotive component stamping production line has been improved.

Reduced Production Costs

It lowers equipment maintenance costs, material costs, and labor costs by reducing die damage, product scrapping, and downtime.

Strong System Stability

The Atom Metal Double-sheet Detector (MDSC-1200C) and circular through-beam probes have excellent anti-interference capabilities and can operate stably in complex industrial environments. During long-term production, the system has not experienced production interruptions caused by detection equipment failures, ensuring the continuous and stable operation of the production line.

Ⅳ. Summary and Outlook

The application of the Atom Double-sheet Detection Sensor in the automotive component stamping production line has achieved remarkable results. It effectively solves the double-sheet detection problem, improves production quality and efficiency, and reduces production costs. In the future, as the automotive manufacturing industry continues to raise requirements for production quality and efficiency, Atom will continue to focus on the R&D of more advanced detection technologies and equipment to provide customers with better solutions. At the same time, it will strengthen cooperation with automobile manufacturers, gain a deep understanding of customer needs, and continuously optimize product performance to make greater contributions to the development of the automotive industry.