Automotive Stamping Production Line Double-Material Interception Application Case

1. Project Background

In the automotive body manufacturing process, the stamping process is a core pre-process, and its production stability directly determines the efficiency and quality of subsequent processes such as welding and painting. An automated automotive parts enterprise needs to optimize the double-sheet detection solution for large steel plates to improve the quality control level of the stamping production line and avoid the risk of double-material stamping, in line with the strict quality system requirements of the automotive industry.

2. Project Working Conditions

The core working conditions of the enterprise's stamping production line are as follows:

Processed Workpiece: Large steel plates of 1.5×2.2m

Steel Plate Thickness: 0.6-3mm

Production Rhythm: 10 spm (stamping times per minute)

Loading and Unloading Mode: Fully automated robotic arm loading and unloading

Core Risk: Steel plate stacking is prone to cause the robotic arm to grab double sheets, which in turn leads to workpiece scrapping and mold damage

3. Solution Design: Dual Detection + Dual-Channel Redundancy for Accurate Double-Sheet Interception

To address the production line's requirements for large plate detection, 10 spm rhythm, and the core goal of double-sheet interception, the core design of the solution focuses on two key advantages:

Select the Atonm MDSC-8200S contact-type one-to-two double-sheet sensor. Relying on its dual-channel design, 2 sensors are deployed at both ends of the large plate for synchronous detection, enhancing detection comprehensiveness and safety.

Build a defense line of "initial detection during depalletizing + visual centering re-inspection". Install one set of dual-channel detectors at each of the two key workstations. Through "single-station redundant detection + dual-station full-process verification", ensure that the plates enter the mold in a single sheet.

3.1. Core Equipment Selection: MDSC-8200S Contact-Type Double-Sheet Detector

This sensor has a number of adaptive features to ensure the implementation of the solution:

Wide-Range Detection: Supports 0.2-4.0mm magnetically permeable metal plates, covering the production line's 0.6-3mm requirement and adapting to flexible production.

High-Speed Response: With a response speed of 200pcs/min, which is much higher than the 10spm rhythm, it enables "detection while grabbing" without affecting efficiency.

Dual-Channel Design: One host connects 2 sensors to detect different areas of large plates simultaneously, improving reliability.

Strong Anti-Interference: New-generation algorithm + electromagnetic shielding to filter workshop interference and ensure stable detection.

200 Groups of Recipe Storage: Preset parameters for multiple specifications, which can be directly called during production change to shorten mold change time.

Intelligent Interconnection: Supports Profinet and RS485 protocols, and connects to PLC and MES to realize data traceability and alarm linkage.

3.2. Deployment of Dual Detection System

Two sets of contact-type MDSC-8200S double-sheet detection systems are deployed in the depalletizing area and the visual centering platform respectively, forming a full-process closed-loop detection:

First Line of Defense: Initial Detection in Depalletizing Area (Interception at Source)

Installation Method: 2 sensors are integrated beside the gripper at the robotic arm end, symmetrically distributed on both sides of the large plate.

Working Logic: Synchronous detection is performed when the robotic arm grabs materials. If it is a single sheet, an "OK" signal is sent for normal transfer; if it is double sheets, an "NG" signal is sent, the robotic arm stops rotating, the double sheets are placed in the NG area, and an audible and visual alarm is given to prompt handling, realizing interception of double sheets at the source.

Second Line of Defense: Re-Inspection at Visual Centering Platform (Ultimate Guarantee)

Installation Method: 2 sensors are embedded in the fixed station of the visual centering platform, with the detection surface aligned with the platform surface; the host is embedded in the control cabinet.

Working Logic: After a single sheet of plate is placed, re-inspection is initiated. If the re-inspection is qualified, the plate is sent to the mold; if double sheets are detected, an emergency stop is triggered immediately for interception and an alarm is activated to avoid equipment damage.

3.3. Full-Process Collaborative Workflow

When the production line starts, first "learn" the workpiece to be stamped in this batch, store the parameters in the equipment, and complete the loading.

The depalletizing robotic arm grabs the plate and completes the first round of detection simultaneously.

The single plate is transferred to the visual centering platform, and the second round of detection is initiated after placement.

If both detections are qualified: The plate is sent to the mold to enter the next cycle.

If any detection is unqualified: Trigger an alarm and interception, and restart the process after handling.

4. Implementation Effects and Customer Value

After the implementation of this dual detection solution, it effectively solves the problem of double-material stamping in the production line and brings significant economic and management value to the customer:

Accurate Double-Sheet Interception: Relying on the advantages of dual detection and dual channels, it realizes full interception of double sheets before stamping, with no mold damage or workpiece scrapping accidents.

Production Line Efficiency Improvement: Detection is synchronized with the movement of the robotic arm to meet the rhythm requirements; the 200-group recipe storage function greatly shortens the mold change time and improves flexible production capabilities.

Comprehensive Cost Reduction: Reduces mold maintenance costs, extends mold service life, and lowers workpiece scrap rate and material waste.

Intelligent Upgrade: Detection data is uploaded to MES in real time to realize full-process traceability and meet the requirements of industry quality systems.

5. Summary

The customized solution of Atonm MDSC-8200S double-sheet detector accurately matches the stamping working conditions of large automotive steel plates and builds a full-process double-sheet interception defense line.

The solution achieves comprehensive coverage of large plate detection and accurate and reliable double-sheet detection, providing a solid guarantee for stamping quality and safety. At the same time, it helps the production line achieve efficient and intelligent production through features such as high-speed response and intelligent adaptation, providing a replicable solution for quality control in the stamping process of the automotive industry.

Currently, this solution has been promoted and applied in many automotive OEMs and parts enterprises, and has won industry recognition for its high reliability, high adaptability and significant benefits.