Application of Atonm MDSC-8100S Double-Material Detection Sensor in Feeding Detection of Automotive Battery Stamping Production Lines

I. Project Background

With the large-scale expansion of the new energy vehicle industry, a leading automotive battery enterprise has invested in building a new fully automated production line, focusing on the precision manufacturing of battery shell components. One of the core processes of this production line is the robotic feeding-stamping process for 1.2mm-thick aluminum sheets (non-magnetic metals). To ensure production precision, efficiency, and equipment safety after commissioning, a reliable double-sheet detection solution must be deployed in the robotic feeding stage. If aluminum sheets are stacked (double/multiple sheets) and enter the stamping die, it will directly cause die jamming, aluminum sheet scrapping, and even equipment shutdown, affecting the new production line's capacity ramp-up and quality stability goals.

II. Core Production Line Requirements and Design Pain Points

- Accurate Adaptation to Non-Magnetic Aluminum Sheet Detection: The new production line uses 1.2mm standard aluminum sheets. The detection equipment needs to be optimized for the characteristics of non-magnetic metals to avoid subsequent losses caused by sheet stacking from the source.

- Compatibility with High-Efficiency Feeding Cycle Design: After the robot grabs the sheets, it needs to immediately determine whether they are single or double. Traditional through-beam sensors require additional movement of the sheets to the space between the sensors for detection, which wastes feeding time and slows down the production line cycle. Therefore, a single-side probe deployment that enables detection while grabbing is required, without the need for additional movement paths.

- Matching High-Cycle Automated Integration: The production line cycle rate is 12 SPM. The detection equipment must have rapid response capability and support linkage with the MES system and robot control system to realize the full-process automation of "detection-alarm-shutdown."

- Low Maintenance and Rapid Commissioning Requirements: The new production line needs to quickly enter a stable operation stage after commissioning. The detection equipment must be easy to commission with "plug-and-play" functionality, and at the same time resist electromagnetic interference from surrounding stamping equipment and high-frequency motors on the production line, reducing long-term maintenance costs.

III. Solutions: Atonm MDSC-8100S Double-Material Detection Sensor

(I) Core Matching Points for Product Selection

(II) New Production Line Deployment Plan

Sensor Pre-installation and Integration: Reserve an installation position on the side of the manipulator's material picking end to fix the SE-8300SC-M42 single-probe sensor. The 16-meter standard cable is adapted to the production line wiring plan to avoid later modifications.

Host and Control Cabinet Integration: Reserve installation space in the production line control cabinet according to the product opening size (121mm×105mm). Connect the host to a DC24V/500mA power supply, and complete the communication debugging with the manipulator PLC and MES system in advance.

Simulation Debugging Before Commissioning: Before the production line trial run, debug the equipment to enable the manipulator to quickly identify single/double sheets after grabbing the sheets. If it is a single sheet, it will be normally released to the next process; if double sheets are detected, the equipment will immediately send a signal, and the manipulator will stop releasing and re-grab the sheets for detection. Formal commissioning will be carried out only after the process runs smoothly during the simulation test phase.

IV. Implementation Effects

After the new production line was commissioned, the MDSC-8100S Double-Material Detection Sensor achieved a "zero trial-and-error cost" launch, with the core effects as follows:

Proactive Avoidance of Quality Risks: Since commissioning, there has been no die jamming or aluminum sheet scrapping caused by stacked sheets, fully meeting the initial quality control goals of the new production line.

Efficient Advancement of Capacity Ramp-Up: The detection response speed matches the production line cycle rate, with no feeding interruptions caused by detection delays. The production line reached full capacity in only 15 days, 3 days ahead of the plan.

Controllable Maintenance Costs: The equipment's anti-interference design (3mm alloy shell + 4-layer circuit board) ensures stable operation. Within 3 months of commissioning, there was no downtime caused by detection equipment failures, significantly reducing maintenance labor and spare parts costs.

Realization of Intelligent Management: Through in-depth linkage with the MES system, it can real-time monitor detection data and automatically count the frequency of single/double-sheet detection. This enables full-process traceability of the feeding detection status of each aluminum sheet, enhancing the intelligent management level of the production line.

V. Customer Feedback

"Since the design phase of the new production line, we have chosen the Atonm MDSC-8100S Double-Material Detection Sensor, precisely because we value its convenience of single-probe installation, accuracy in non-magnetic metal detection, and detection speed. Since commissioning, the detection link has had zero failures and zero misjudgments. It not only helps us avoid potential equipment and quality risks but also accelerates the capacity ramp-up process, fully meeting the core demands of high efficiency and stability for the newly built production line."

— Comment from the Project Manager of the New Production Line of the Automotive Battery Enterprise

VI. Project Support

If your new automotive battery production line also faces demands for accuracy and efficiency in aluminum sheet double-sheet detection, please feel free to contact Atonm (Guangzhou) Intelligent Technology Co., Ltd.! We will provide customized integration solutions, equipment 3D models, and full-process debugging guidance to help your production line start efficiently and operate stably.