OTU × Atonm: Localized Application Case of Double-Sheet Detection for Feeding in Automotive Stamping Production Line

In the Automotive Manufacturing Industry

The efficient and stable operation of stamping production lines is directly related to the overall vehicle production schedule and product quality, and double-sheet detection in the feeding process is a key node to ensure the smooth flow of the production line. As a leading domestic automotive manufacturing equipment integrator, OTU has profound technical accumulation and an extensive customer base in the industry, and maintains a stable cooperative relationship with us. The two parties have achieved win-win results in multiple automotive manufacturing detection projects. Its requirements for the accuracy, stability and intelligence of production line equipment have always been at the forefront of the industry.

This time, we have further deepened our cooperation with OTU. Aiming at the pain points in the feeding process of its automotive stamping production line, we have customized a solution centered on Atonm's contact-type single-probe double-sheet detector 9000S. With the accurate detection performance and stable implementation effect of the solution, it has not only won full recognition from OTU, but also consolidated our leading position in the automotive manufacturing detection field.

1. Cooperation Background: Feeding Detection Challenges of OTU's Stamping Production Line

The automotive stamping production line of this project is mainly responsible for the stamping processing of key parts such as body covers and structural parts. The feeding process requires accurate and single-time transportation of stacked metal plates into the stamping die. During this process, if two or more plates are fed in an overlapping manner, it will not only cause mold damage and product scrapping, but also lead to production line shutdown, bringing huge economic losses to the enterprise.

With the acceleration of the localization replacement trend in the automotive manufacturing industry, localized double-sheet detection solutions with reliable performance, high cost-effectiveness and rapid service response are more in line with OTU's development needs for reducing production line costs, improving efficiency and achieving independent control. They also build a broader platform for the two parties to deepen cooperation. Based on the cooperative trust between the two parties and the recognition of our technical strength, OTU has chosen to deepen cooperation with us and introduce Atonm series localized double-sheet detectors.

2. Solution: Customized Deployment of Atonm Double-Sheet Detector

In response to the actual working conditions and requirements of OTU's stamping production line, we customized and deployed the Atonm MDSC-9000S Metal Double-Sheet Detection System for it, with specific implementation as follows:

2.1 Product Selection: Atonm MDSC-9000S Metal Double-Sheet Detection System

The Atonm MDSC-9000S Metal Double-Sheet Detection System was selected as the core equipment. The entire system consists of 1 controller + 2 sensors, and relies on the principles of electromagnetic induction and eddy current to demonstrate six core advantages for the needs of OTU's production line:

Anti-interference and Stable Detection: Relying on the principles of electromagnetic induction and eddy current, the 9000S Double-Sheet Detector builds a big data feature model covering different materials, thicknesses and other dimensions by collecting more than 170,000 sheet samples. It is equipped with a dynamic anti-interference system optimized by three measures (electromagnetic shielding + adaptive filtering + dynamic baseline compensation) to achieve multi-level noise reduction. Supported by intelligent algorithms and high-precision sensors, it ensures long-term stable operation under complex working conditions.

Double-Sensor Collaborative Detection: The main unit connects 2 sensors synchronously to conduct collaborative detection and data verification on the same sheet, improving detection reliability from the source and perfectly adapting to the production line's demand for accurate feeding.

All-Metal Compatible Detection: Integrated design for magnetic and non-magnetic materials, no need to distinguish sheet types. It can cover 0.2-4.0mm magnetic materials (such as steel plates) and 0.2-3.0mm non-magnetic materials (such as stainless steel, copper plates), adapting to OTU's demand for multi-material sheet detection.

200 Groups of Recipe Storage: Built-in function to store 200 groups of sheet parameters, which can preset parameters of common materials (such as stainless steel, aluminum/aluminum alloy) for body covers and structural parts, eliminating the need for repeated learning when switching detection materials.

Intelligent Communication Integration: Supports Profinet and RS485 communication protocols, and can be directly connected to OTU's production line PLC control system to realize real-time upload of detection data and linkage of abnormal alarms, facilitating intelligent management of the production line.

Fault Monitoring System: Equipped with real-time sensor disconnection monitoring function. In case of disconnection, it immediately triggers an alarm and pauses feeding, preventing the risk of double-sheet caused by continuous operation in fault state, and avoiding the risks of mold damage and product scrapping from the source.

2.2 Installation Layout: Integrated Deployment at the First On-Line Position

A one-to-two metal double-sheet detector was installed at the first on-line position of the stamping production line to realize front-end accurate control of sheet feeding. Among them, 2 sensors are integrated and installed at key positions of the end effector to ensure double-sheet detection can be completed during the sheet grabbing process; the controller is installed in the console, facilitating operation and maintenance personnel to monitor the detection status in real time, view data and set parameters. This installation method not only ensures the timeliness and accuracy of detection, but also does not affect the normal operation rhythm of the production line.

3. Implementation Effects: Dual Optimization of Cost Reduction and Efficiency Improvement

After the solution was officially put into use in the stamping production line, it quickly showed significant application effects, mainly reflected in the following aspects:

Outstanding Detection Accuracy and Adaptability: Relying on the contact detection principle and anti-interference characteristics of Atonm 9000S, it can stably adapt to various material sheets (such as steel plates, stainless steel, aluminum alloys, etc.) in OTU's production line with high detection accuracy. Since the implementation of the solution, there has been no accident of mold damage or product scrapping caused by double-sheet feeding.

Reduced Production Line Downtime: Due to the strong stability of the detection equipment, no frequent calibration is required, and the average daily production efficiency has increased by about 15%, effectively ensuring the overall vehicle production schedule.

Dual Optimization of Cost Reduction and Efficiency Improvement: Compared with imported equipment, the procurement cost per production line has been reduced by more than 50%, and the response time for localized technical support has been shortened to within 2 hours, achieving dual optimization of cost reduction and service efficiency.

4. Cooperation Endorsement: Demonstrating Industry Leading Position

The cooperation with OTU is a continuous recognition of our Atonm products and services. As a professional service provider in the automotive manufacturing detection field, we have always taken technological innovation as the core driving force and are committed to providing customers with customized and high-reliability solutions. This cooperation case with OTU fully proves our technical strength and industry status in the automotive stamping production line detection field, and also lays a solid foundation for us to serve more automotive manufacturing enterprises. In the future, we will continue to deepen cooperation with leading enterprises in the industry, continuously iterate and upgrade products and solutions, and contribute to the high-quality development of the automotive manufacturing industry.