钢铝混合产线的应用 Application of MDSC-9000S Metal Double-Sheet Controller in Automotive Steel-Aluminum Hybrid Production Lines

1.Application Background

In the manufacturing of automotive components, small and medium-sized stamping production lines – which focus on producing parts such as lightweight chassis brackets, motor end covers, and gearbox auxiliary gaskets – serve as a crucial underpinning for the stability of the vehicle's overall structure and power system. The sheet specifications of these parts range from 150×200mm to 250×300mm. Though not categorized as micro-components, compared with large body panels, their stamping dies feature more compact cavity structures and lower tolerance to stacked materials. Once double sheets enter the production process, it will lead to chipping of the die cutting edges or deformation of the die cavities. The single maintenance cost of such small and medium-sized dies is high and the maintenance cycle is long, which will also result in significant capacity loss of the production line.

Therefore, accurate double-sheet detection for small and medium-sized sheets is the key to protecting dies and ensuring the continuous operation of production lines. Atonm Metal Double-Sheet Detector MDSC-9000S perfectly meets the detection requirements of this production line with its high precision and stability, and has become the core guarantee equipment of the line.

Terminology Notes

Core technical terms follow the consistent translation standard for automotive stamping production lines: lightweight chassis brackets, motor end covers, gearbox auxiliary gaskets, die cavity, stacked materials, die cutting edge chipping and die cavity deformation all conform to the expression norms of industrial technical documents.

The brand name Atonm and equipment model MDSC-9000S are retained in their original format to ensure consistency with previous translations.

2. Detection Challenges Faced by the Production Line

Accuracy Pressure Under High Cycle Rate: The production line cycle rate has been increased to 12 SPM. With the high frequency of picking and placing small and medium-sized sheets, the detection equipment must complete single-sheet confirmation within 0.5 seconds. Insufficient accuracy will easily lead to missed detections.

Difficulty in Stable Detection with Multi-material Compatibility: The stamping line processes cold-rolled steel plates of 0.5–2.9 mm and aluminum alloy plates of 0.7–2.5 mm. This requires the detection equipment to be compatible with steel-aluminum hybrid stamping lines while ensuring stable detection performance.

3. Solution

MDSC-9000S Metal Single/Double-Sheet Detector

Compatibility with the Production Line: High-Precision Core + High-Stability Coordination

Terminology Notes

3.1. Equipment Installation

The main unit is mounted on a standard bracket (height: 1.3 meters) on the production line's safety guardrail, away from stamping vibration sources to prevent vibrations from affecting the stable operation of the internal sensors of the equipment. Meanwhile, it facilitates operation and maintenance personnel to retrieve data and perform daily calibration.

High-sensitivity sensors are integrated into the end effector of the manipulator, and single/double-sheet detection is completed synchronously when the manipulator picks up materials — this not only achieves rapid single/double-sheet detection, but also seamlessly integrates with the material picking action without occupying extra time, perfectly adapting to the high cycle rate of 12 SPM. Only when all sensors output a "single sheet" signal will the manipulator place the sheet on the visual alignment table.

Terminology Notes

Core terms follow the consistent translation standard for automotive stamping production lines: safety guardrail, vibration source, end effector, visual alignment table and daily calibration are all phrased in line with industrial technical documentation norms.

The abbreviation SPM (Strokes Per Minute) is retained directly, which is the standard expression in the field of stamping production lines.

3.2. Core Advantages of the Double-Sheet Detector

Stable Product Performance: Based on the dual principles of electromagnetic induction and eddy current, it applies to magnetic materials (0.2–4.0 mm) and non-magnetic materials (0.2–4.0 mm). It fully meets the high-precision detection requirements of steel plates and aluminum plates on the production line, and is also compatible with steel-aluminum hybrid production scenarios.

2. "One-to-Two" Design

A single host drives two sensors to work synchronously, with a built-in anti-interference chip that can filter electromagnetic noise on the production line and avoid misjudgments caused by single-sensor failures.

3. Communication Functionality

It supports mainstream communication protocols including Profinet and RS-485, enabling real-time and stable transmission of "single-sheet confirmation" and "abnormal alarm" signals with servo stamping presses and visual alignment tables. When double sheets are detected, it triggers the stamping press to shut down to prevent mold damage.

4. 200-Group Parameter Memory

Equipped with a built-in function for storing 200 groups of sheet parameters, the system can operate stably by directly calling preset parameters when the production line switches to sheets of different materials or specifications, eliminating the need for repeated calibration.

4.Customer Benefits

Atonm Metal Double-Sheet Detector MDSC-9000S has successfully addressed the core pain points of small and medium-sized automotive stamping production lines (12 SPM cycle rate, steel-aluminum hybrid) with its high precision and stability. It achieves high-precision detection within 0.2 seconds to avoid missed detections of double sheets; maintains stable performance in steel-aluminum hybrid production to eliminate detection fluctuations caused by material switching; meanwhile, it achieves stable linkage with production line equipment to minimize the risk of downtime.