Atonm MDSC-1000L Single/Double Sheet Detection Sensor Application Case in New Energy Battery Cover Production

1.  Project Background

A company in Guangdong specializes in the production and manufacturing of battery covers. In its production process, the connecting sheets of battery covers often overlap with each other. The minimum size of these connecting sheets is 15mm in width, 0.2mm in thickness and about 50mm in length. Meanwhile, the company also produces other similar products of larger sizes. If this problem of sheet overlapping is not solved, it will directly affect product quality and adversely impact the enterprise's production efficiency and market reputation. Therefore, the enterprise is in urgent need of an effective solution to address this issue.

2.  Customer Requirements

The customer's core requirement is to solve the sheet overlapping problem of battery cover connecting sheets and other similar products during the production process, ensure that product quality meets standards, and avoid quality defects caused by sheet overlapping.

3.  Solution

To meet the customer's requirements, we provided a solution consisting of the Atonm MDSC-1000L paired with M12 sensors. The specific implementation method is as follows: the controller is installed on the cabinet, and the through-beam sensors are mounted above and below the production line belt. When the stacked battery sheet trays pass through the sensor detection range, the device can perform real-time detection and quickly output detection signals. When the PLC receives the abnormal signal sent by the sensors, it will immediately trigger an alarm to remind the staff to inspect and handle the abnormal situation in a timely manner.

This solution has significant advantages in multiple aspects, fully reflecting the excellent performance of Atonm products:

Precise Adaptation to Small and Thin Material Detection: The Atonm MDSC-1000L is a dedicated double-sheet detector for the lithium battery industry. Tailored to the characteristics of "lightweight", "small-sized" and "thin" materials in the industry, it is equipped with a customized M12 small probe. This probe can accurately detect connecting sheets with a minimum size of 15mm in width, 0.2mm in thickness and about 50mm in length, and can also stably detect other larger-sized products, ensuring no detection blind spots.

Non-contact Detection to Ensure Quality: Adopting a non-contact detection method that does not directly touch the materials, it fundamentally avoids damage and loss to materials such as battery cover connecting sheets, thus guaranteeing the original quality of products.

Ultra-fast Response to Improve Production Efficiency: With an ultra-fast detection response speed of up to 1200 pcs/min, it can complete detection and output signals instantly, adapt to the high-speed operation of the production line, and ensure production continuity and efficiency.

Stable and Reliable Detection Performance: It is equipped with the patented MultisCom algorithm, which effectively enhances detection stability and ensures accurate detection even in complex production environments. Meanwhile, its specially designed alloy shell with a thickness of 3mm, combined with the use of surface mount components and a 4-layer circuit board design, delivers strong anti-interference capability, high durability, as well as magnetic and shock resistance. It is not affected by factors such as oil contamination, temperature changes and surface coatings, ensuring the long-term stable operation of the equipment.

Intelligent and Convenient Control & Traceability: Built-in with a 485 communication module, it can be connected to a touch screen for control, improving work efficiency. Moreover, operation records are traceable, facilitating enterprises to manage and track the production process.

4. Customer Benefits

Improved Product Quality: With the accurate detection of the Atonm MDSC-1000L double-sheet detector, sheet overlapping issues can be detected and addressed in a timely manner. This effectively avoids product quality defects caused by sheet overlapping, significantly improves product quality, and meets the customer's requirements for high-quality products.

Reduced Production Costs: Before using this detection equipment, due to sheet overlapping issues, the enterprise had to rework or scrap unqualified products, which undoubtedly increased production costs. After using the equipment, problems can be detected and resolved promptly during the production process, reducing the generation of unqualified products and cutting down rework and scrap costs, thus saving a substantial amount of production costs for the enterprise.

Enhanced Production Efficiency: The equipment enables real-time detection and rapid response. Once an abnormality is detected, an alarm is triggered immediately, allowing staff to handle the issue in a timely manner. This prevents production line shutdowns or interruptions caused by sheet overlapping problems, ensures production continuity and stability, and improves overall production efficiency.

Strengthened Market Competitiveness: The improved product quality makes the enterprise's products more competitive in the market, helping to win more customer trust and preference. It is conducive for the enterprise to expand market share and enhance its economic benefits and market position.

Lower Labor Costs: In the past, the enterprise had to assign dedicated staff to conduct manual inspections on products to identify sheet overlapping issues. The adoption of this automated detection equipment reduces reliance on manual inspection, cuts down labor costs, and avoids detection errors caused by factors such as fatigue and negligence in manual inspection.

Elevated Enterprise Management Level: The application of this detection equipment realizes intelligent monitoring of the production process. Enterprises can grasp the quality status in the production process more timely and accurately, facilitating refined management and optimization of the production process and improving the overall management level of the enterprise.