Single/Double Sheet Detection Solution for Automotive Parts Stamping — Atonm MDSC-8000S

1. Customer Background

The customer is a professional automotive component manufacturer, specializing in the production of various automotive parts. The components it produces are widely used in the vehicle assembly of multiple mainstream automobile brands. In the production process of automotive components, the stamping process is one of the key procedures to ensure component quality, which directly affects the subsequent assembly accuracy and product performance. The customer's production line needs to add a piece of equipment for detecting stacked materials, and the double-sheet detector is exactly an important support to ensure the stable and efficient operation of this key process.

2. Production Line Working Conditions

Sheet Material: Iron

Sheet Thickness: 3mm

Sheet Diameter: 16mm

Production Line Speed: 25 strokes/minute

3. Solution

To effectively solve the problem of single/double sheet detection during feeding prior to the stamping process on the production line, the customer introduced the Atonm Contact-type Metal Single/Double Sheet Detection Sensor MDSC-8000S, forming a highly efficient stacked material detection solution.

Equipment Installation

1.  Install the 8000S controller in the cabinet on the safety fence of the production line. This installation method not only saves production line space, but also effectively protects the controller from external environmental interference to ensure its stable operation.

2.  Mount the contact sensor on the end effector of the manipulator, and conduct single/double sheet detection synchronously with the material grabbing action of the manipulator.

The specific detection process is as follows: When the manipulator grabs the iron sheet, the contact sensor immediately detects the grabbed iron sheet. Once it is confirmed that the material is a single iron sheet through detection, the sensor sends a signal to release the iron sheet, which is then transferred to the next process for stamping by the conveying device. If double or multiple sheets are detected, the system promptly issues an alarm and the conveying device pauses feeding, preventing non-conforming materials from entering the stamping process.

4. Customer Benefits

Improved Product Quality

With the accurate detection capability of the Atonm MDSC-8000S double-sheet sensor, the entry of double or multiple iron sheets into the stamping process is effectively prevented. In the past, the presence of double or multiple sheets during stamping would cause quality defects such as dimensional deviations and deformation of the stamped components, which seriously affected product qualification rates. Now, only confirmed single iron sheets are allowed to proceed to the subsequent stamping process, which greatly enhances the quality stability of stamped components and reduces the scrap rate caused by material-related issues.

Enhanced Production Efficiency

This double-sheet sensor enables simultaneous single/double sheet detection while the manipulator is grabbing materials, eliminating the need for additional dedicated detection time and integrating seamlessly with the production flow. This synchronous detection method avoids production line bottlenecks caused by separate detection steps, streamlines the production process, and allows more materials to be processed per unit time, thereby significantly boosting overall production efficiency.

Reduced Production Costs

On the one hand, it minimizes scrap generation and raw material waste. Iron sheets that would have been scrapped due to double/multi-sheet stamping are now identified in advance through detection, and can be reprocessed and reused in production, resulting in savings in raw material costs.

On the other hand, it cuts down on rework and repair expenses caused by quality defects. Previously, non-conforming stamped parts required rework and repair, which consumed substantial manpower and resources while delaying production schedules. Now, the improved product quality has led to a significant reduction in the rework rate, effectively lowering overall production costs.

Guaranteed Production Safety

When double or multiple iron sheets are detected, the system promptly triggers an alarm and stops the materials from entering the stamping process. This prevents equipment malfunctions such as overload and jamming of stamping machines caused by excessive material thickness. It not only protects expensive stamping equipment and reduces equipment maintenance and replacement costs, but more importantly, avoids potential safety accidents arising from equipment failures, thus safeguarding the personal safety of frontline production workers.