ABB Robot Stamping Demonstration Line Double Material Detection Solution

1. Project Background

In automated stamping production lines, double material (stacked material) is one of the major risks leading to production interruption, mold damage, and product scrapping. When the manipulator mistakenly feeds two or more sheets into the mold simultaneously, it will cause the following consequences:

Catastrophic Mold Damage: High maintenance costs and long maintenance cycles.

Increased Product Defect Rate: Generation of waste products and raw material waste.

Unplanned Shutdown: Severe impact on the production rhythm and efficiency of the entire line.

As an industry benchmark, the ABB Robot Stamping Demonstration Line has extremely high requirements for the reliability and safety of the feeding process. To eliminate the risk of double material from the source, ABB has selected the combined solution of Atonm 9000S Contact-type + 1500S Through-type Double-sheet Detectors, building a dual-insurance double material detection system.

2. Solution: Atonm Dual-Insurance Double Material Detection System

This solution deploys two different types of Atonm Double-sheet Detectors at key stations to ensure that each piece of material entering the mold is a single sheet.

2.1. First Line of Defense: De-stacking Area - Atonm 9000S Contact-type Double-sheet Detector

Installation Location: Integrated into the suction cup device of the feeding manipulator in the de-stacking area.

Detection Principle: Adopts contact-type detection. When the manipulator sucks the sheet metal, the detector probe contacts the surface of the sheet metal, and accurately judges whether the adsorbed material is a single sheet or multiple sheets through the principle of eddy current + magnetic induction.

Core Function: Source interception. Detection is performed at the very moment when the sheet metal leaves the stack. Once double material is detected, an alarm is triggered immediately to prevent the manipulator from transferring, intercepting the risk at the initial station.

2.2. Second Line of Defense: Conveyor Line - Atonm 1500S Through-type Double-sheet Detector

Installation Location: Mounted above the conveyor belt, between the de-stacking station and the stamping station.

Detection Principle: Adopts the non-contact electromagnetic induction principle. When the sheet metal passes under the detector, it emits an electromagnetic field and detects the disturbance of the electromagnetic field caused by the sheet metal. There is a significant difference in the disturbance value of the electromagnetic field between single and multiple sheets, thereby achieving high-precision discrimination.

Core Function: Secondary review. As an independent detection checkpoint, it conducts 100% re-inspection on all sheet metals passing through the conveyor belt, capturing any sheet metal that may have slipped through the first line of defense.

3. Solution Value and Customer Benefits

1. Mold Protection: Fundamentally avoids mold damage such as extrusion and cracking caused by double-sheet stamping, saving huge maintenance and replacement costs.

2. Yield Rate Improvement: Ensures stable quality of stamping parts, significantly reduces the scrap rate, and saves raw materials.

3. Production Efficiency Guarantee: Minimizes unplanned shutdowns caused by handling double-material issues to the greatest extent, ensuring efficient, continuous and stable operation of the stamping production line.

4. Safety Enhancement: Provides key process quality control for the fully automatic stamping line, improving the safety and reliability of the entire line's operation.

4. Why ABB Chose Atonm?

1. High Product Reliability: Equipped with upgraded stacked material detection algorithms and anti-interference capabilities, it can maintain stable detection in complex industrial environments such as vibration, oil pollution and electromagnetic interference in stamping workshops.

2. Precise Matching of Customer Needs: The combination of 9000S and 1500S double-sheet detectors covers the full-scenario detection needs from contact-type source detection to non-contact online review.

3. Outstanding Brand and Technical Strength: The product can be seamlessly integrated into the ABB robot system, meeting its strict requirements for high performance and high integration of core components.

The selection of Atonm double-sheet detectors for the ABB Robot Stamping Demonstration Line fully reflects the product's reliability and technological advancement. As a world-leading industrial automation enterprise, ABB has strict screening standards for the product quality and performance of partners. This cooperation is not only a high recognition of Atonm's products, but also highlights Atonm's brand strength in the field of double-material detection, laying a solid foundation for expanding more high-end industrial automation application scenarios in the future.