Improving Stamping Safety and Efficiency: Dual Detection Upgrade for Visual Centering Platform in Stamping Line of a Domestic Automobile Brand

1. Customer Background

The customer is a leading domestic supplier of stamping automation equipment, specializing in providing intelligent and automated stamping production line software development and system integration solutions for the automotive manufacturing industry. This project serves a well-known domestic automobile brand.

2. Project Background and Challenges

The customer is carrying out an upgrade and transformation of the gravity centering platform at the start of a key stamping production line for this automobile brand. In the original production process, the manipulator grabs steel plates (magnetic conductive steel plates with a thickness of 0.7-0.8mm) from the feeding stack, places them on the gravity centering platform for positioning and centering, and then grabs them again to send into the stamping die. However, the original system lacks an effective detection method for the number of sheet metal layers, leading to the following severe risks:

Double/Multi-sheet Risk: The manipulator may accidentally grab two or more overlapping steel plates.

Die Bursting Hazard: If overlapping sheets (double or multi-sheets) are not detected and directly sent into the high-tonnage stamping die for stamping, the internal pressure of the die will instantly exceed the design limit by a large margin, which is very likely to cause a catastrophic "die bursting" accident. This will result in damage to molds worth millions of yuan, long-term production line shutdowns, and even endanger personal safety.

Production Interruption and Cost Loss: The costs caused by die bursting accidents, such as mold repair/replacement, production line downtime, and waste product losses, are extremely high.

Therefore, one of the core objectives of this upgrade and transformation is to add a fast and reliable metal single/double-sheet detection process at the gravity centering platform link, ensuring that only single-sheet metal plates are allowed to enter the subsequent stamping process.

3. Solution: Atonm MDSC-9000S Metal Double-Sheet Detector

After rigorous technical evaluation and on-site testing, the customer finally selected the Atonm MDSC-9000S Metal Double-Sheet Detector as the core equipment for this safety protection link.

Detection Principle: Based on the principles of electromagnetic induction and eddy current, the MDSC-9000S can detect magnetic conductive and non-magnetic conductive metal materials with a thickness of 0.2-4.0mm (such as the 0.7-0.8mm steel plates in this project). It can accurately distinguish between a single sheet and two or more stacked metal sheets.

System Composition:

MDSC-9000S Main Unit: Responsible for signal processing, logical judgment, alarm output, and parameter setting.

Detection Sensors (2 units): According to the structure of the gravity centering platform and the sheet placement position, two high-sensitivity eddy current sensor probes are accurately installed. The probes are firmly mounted at the detection points of the gravity centering platform (under the specific position where the sheet is placed to ensure effective coverage of the detection area).

Installation Position and Integration:

The MDSC-9000S main unit is installed in the safe area for easy maintenance and monitoring. The 2 sensors are directly integrated into the gravity centering platform, located at the precise detection points where the sheet stays after being placed by the manipulator.

4. Working Process

(1) The manipulator grabs the sheet metal from the feeding stack.

(2) The manipulator places the sheet metal at the designated position on the gravity centering platform for positioning and centering.

(3) At the moment when the sheet metal stably stays on the centering platform, the MDSC-9000S system is triggered (either via PLC signal or the sensor's built-in triggering mode).

(4) The two sensors detect the sheet metal simultaneously.

(5) The MDSC-9000S main unit analyzes the sensor signals in real time: if a single sheet is confirmed, it sends an "OK" signal to the PLC; if double or multiple sheets are detected, it immediately sends an "NG" alarm signal to the PLC.

(6) After receiving the "OK" signal, the manipulator grabs the single sheet metal and sends it to the stamping die for stamping.

(7) Upon receiving the "NG" signal, the manipulator executes the preset safety procedure (such as placing the stacked sheets in the scrap area, triggering an alarm and stopping the machine to wait for manual handling), preventing the stacked sheets from entering the die.

5. Solution Advantages

Eliminates die bursting risk completely: Before sheet metal enters high-value stamping dies, double/multi-sheets are accurately intercepted at the gravity centering platform, fundamentally preventing die bursting accidents caused by stacked sheets and ensuring the safety of core assets (dies) and personnel.

High precision and reliability: The MDSC-9000S double-sheet detector is specially designed for metal sheets. Its high-frequency eddy current technology and upgraded stacked-sheet detection algorithm ensure high-precision, high-repeatability detection of single/double 0.7–0.8 mm magnetic steel plates, effectively overcoming detection challenges posed by the magnetic conductivity of steel.

Seamless integration: The compact, robust sensors are easy to integrate into existing gravity centering platform structures. The main unit provides standard switching signals (NPN/PNP) and PN communication interfaces, enabling simple and efficient integration with the production line PLC control system.

Fast response: Detection time is extremely short (millisecond level), consuming almost no production cycle time, and meeting the requirements of high-speed stamping lines.

Strong anti-interference capability: Shielded cables and excellent grounding design effectively resist electromagnetic and vibration interference common in stamping workshops.

Easy operation and maintenance: The main unit features a clear interface and intuitive parameter settings; the sensors are durable and require minimal maintenance.

4. Implementation Effects and Customer Evaluation

1. Project Effects

Successfully implemented online double/multi-sheet detection at the gravity centering platform.

Since system commissioning, all stacked-sheet incidents have been effectively intercepted, completely eliminating die bursting accidents caused by stacked sheets.

Significantly improved production line safety and operational stability, reducing unplanned downtime.

Avoided potential huge losses from die damage and production delays.

The detection process is fast and reliable, with no negative impact on the original production cycle.

2. Customer Evaluation

“Atonm’s MDSC-9000S double-sheet detector was key to the safety upgrade of our gravity centering platform. It is easy to install and highly integrated, and most importantly, the detection results are extremely stable and reliable. Detecting double sheets of 0.8 mm steel plates was a challenge for us, but the MDSC-9000S solved it perfectly. Since installation, it has acted as a reliable ‘safety gate’, completely eliminating our biggest safety hazard—the risk of die bursting. We are also very satisfied with the equipment’s stability and Atonm’s technical support services.”

5. Project Summary

The Atonm MDSC-9000S Metal Double-Sheet Detector has significant application value in automotive stamping automation, especially in the line-start feeding and centering processes. By precisely deploying this detection system on the gravity centering platform, a solid safety defense line has been successfully established for a domestic automotive brand’s stamping line, effectively eliminating die bursting risks from stacked sheets, ensuring production safety, equipment safety, and economic benefits. It is an exemplary solution for intelligent and safety upgrades in stamping production lines.