Application of Atonm Double Sheet Detector MDSC-8200S in BYD Automotive Stamping Production Line

Project Background

As a global leader in the new energy vehicle sector, the Stamping Workshop of BYD Shenshan Base undertakes the precision manufacturing of key automotive body cover parts (such as doors, hoods, and fenders). As the first critical link in body manufacturing, the stamping process directly affects the efficiency and quality of subsequent welding and painting processes.

In the high-speed automated stamping line, "double-layer sheet metal" has always been a hidden major risk. If the robotic arm absorbs two overlapping steel sheets at one time, it is likely to cause mold damage, part scrapping, and production line shutdown. BYD urgently needs a reliable and efficient online detection solution to ensure that each sheet entering the mold is in a single-layer state.

Production Line Working Conditions and Challenges

This production line mainly processes cold-rolled steel sheets, with thickness ranging from 0.2mm (inner panel parts) to 2.0mm (structural parts, outer panel parts), adapting to the production of diverse body components. The production line adopts automated feeding by robots and manipulators, with a designed rhythm of 7 SPM (strokes per minute), which places strict requirements on the response speed, accuracy and compatibility of detection equipment.

The core challenges focus on three aspects:

Prominent double-sheet risk: Stacking of steel sheets is likely to cause manipulators to "mistakenly grasp" double-sheet materials. Once they enter the mold, it may lead to serious failures such as mold edge chipping and cracking;

High demand for flexible production: It is necessary to frequently switch steel sheets of different thicknesses from 0.2mm to 2.0mm. The long time-consuming mold change and adjustment of traditional detection equipment restrict the production line's rapid response to the production needs of multiple vehicle models;

Detection blind spots for large sheets: Large-area sheets such as doors and hoods are prone to partial double-sheets at the edges, and the single-point detection method may have the risk of missed detection.

Solution: Atonm Metal Double Sheet Detector MDSC-8200S

After multiple rounds of technical verification, BYD selected the Atonm MDSC-8200S Metal Double Sheet Detector as the core detection equipment, which is integrated into the feeding link of the stamping line. Two sensors are installed on the robotic arm end effector, adjacent to the suction cup, and seamlessly cooperate with the production line's automated system.

Workflow

When the robotic arm picks up materials, the sensors are activated simultaneously to quickly detect the sheet metal and output signals: an "OK" signal is output for a single sheet, and an "NG" signal is immediately triggered for double sheets. The detection results are transmitted to the PLC at the millisecond level via the Profinet protocol, forming a closed-loop control. For a single sheet, normal feeding proceeds; for double sheets, the robotic arm is triggered to stop, the sheet metal is returned to its original position, and an audible and visual alarm is activated, blocking risks at the source.

Advantages of the Solution

The core features of the Atonm MDSC-8200S Double Sheet Detector precisely match the production line’s needs:

Wide Thickness Range with Accurate Detection: The 0.1-4.0mm detection range fully covers the production line’s requirement for 0.2-2.0mm steel sheets, ensuring stable and reliable detection for both ultra-thin and medium-thick sheets.

High-Speed Response Detection: With an instantaneous detection speed of 0.2 seconds, it can accurately match the high-speed operation rhythm of the production line, avoiding production delays caused by detection lag and ensuring a stable improvement in continuous production efficiency.

Efficient Storage of Multiple Recipes: Equipped with 200 built-in sheet material recipes, it allows pre-loading of the production line’s materials into the device. During production line model changes, parameters can be quickly retrieved via the LCD screen buttons, reducing parameter adjustment time to within 1 minute and significantly improving the response speed of flexible production.

High-Speed Profinet Communication: As a core advantage of the PN version, it supports the Profinet communication protocol to achieve millisecond-level data interaction with the production line’s PLC and MES systems, providing efficient data support for intelligent scheduling and quality traceability.

One-Driver-for-Two Dual-Point Detection Design: The dual-sensor configuration can be installed on both sides of large sheets respectively, completing simultaneous detection of edge and central areas, and completely solving the problem of detection blind spots for partial double sheets in large-area sheet materials.

Customer Benefits

The Atonm MDSC-8200S Double Sheet Detector has brought significant value improvements to BYD’s stamping line:

Upgraded Mold Safety Protection: Annual mold maintenance costs are reduced by over 2 million yuan, and mold service life is extended by more than 30%.

Substantial Improvement in Production Efficiency: The rapid recipe retrieval function during model changes shortens process switching time to 1 minute. Combined with the stable detection capability matching the 7 SPM rhythm, the effective operation rate of the production line is increased.

Enhanced Intelligent Level: Through seamless connection with the MES system via the Profinet protocol, real-time traceability and analysis of detection data are realized, providing data support for process optimization and meeting the strict quality control standards of the automotive industry.

Rapid Return on Investment (ROI): Compared with the equipment investment cost, the investment can be recovered within 6 months just by reducing mold maintenance and waste losses, with significant long-term comprehensive benefits.

The outstanding performance of the Atonm MDSC-8200S Metal Double Sheet Detector in ensuring mold safety, improving production efficiency, and reducing quality costs not only perfectly solves the material stacking problem of BYD’s stamping line but also demonstrates the technical benchmark status of Atonm products in the high-end automotive manufacturing field. It provides a replicable practical model for the intelligent upgrading of automotive stamping lines. If you also have similar double-sheet detection troubles or production line efficiency improvement needs, please feel free to learn about Atonm’s material stacking detection solutions.