Project Services
Solution Design
Application Validation Support
Parameter Optimization Guidance
Commissioning Support
2025-12-25
Application Case of Dual-station Cap Liner Insertion & Double-layer Detection
1. Project Background
In the automation of bottle cap production, the core pain point of the gasket insertion process is that ultra-thin gaskets are prone to double/multiple sheet stacking and zero-sheet missing feeding. This directly leads to bottle cap sealing failure and gasket insertion mechanism jamming, causing an increase in defective product rate and production line shutdown. Customers are in urgent need of high-sensitivity single/double sheet detection equipment to achieve real-time monitoring.
2. Core Requirements of Working Conditions
| Working Condition Parameters | Specific Requirements |
|---|---|
| Detection Object | Bottle Cap Sealing Gasket (Aluminum Foil Ultra-thin Gasket) |
| Gasket Thickness | 0.05mm |
| Production Rhythm | Dual-station, 80 pieces per minute per station (synchronous operation) |
| Core Demands | 1. Accurately identify single/double sheets; 2. Response speed matches the 80 pieces per minute rhythm; 3. Adapt to compact space, easy to install; 4. Dual stations operate independently without interference; 5. Seamless linkage with PLC, abnormal shutdown/alarm |
3. Solution
3.1 Core Product Selection and Advantages
Through in-depth communication with the customer to understand their actual needs and working conditions, the Atonm MDSC-2100L metal double sheet detector (single probe version) was finally selected.
The selection and core advantages are highly aligned with the working condition requirements:
Ultra-thin Adaptation: Specifically designed for 0.01-0.1mm thin metal sheets, perfectly matching the 0.05mm gaskets in the customer's production line and solving the "ultra-thin detection blind area" of traditional equipment.
High-speed Response: With a maximum response speed of 1200pcs/min, it far exceeds the 80 pieces per minute rhythm of a single station, enabling full-load operation of dual stations without delay.
Dual-station Independence: Adopting a high-power single-probe structure, a single probe completes independent detection. Two sets of units are configured to achieve no interference between stations and accurate shutdown in case of abnormalities.
Flexible Installation: Compatible with M12 small-size probes, it can be embedded in the compact space of equipment without modification.
Efficient Model Change: With 100 groups of parameter memory, multi-specification gaskets can be switched with one click, adapting to flexible production.
3.2 Core Equipment List
| Equipment Name | Model Specification | Quantity | Purpose |
|---|---|---|---|
| Double Sheet Detection Controller | MDSC-2100L | 2 units | Corresponding to dual stations, independently control detection logic |
| Detection Probe | SE-2100LC-F6.0 (M12 Single Probe) | 2 pieces | Compact design, independently cover the detection area of each station |
| Connection Cable | Standard 6m (customizable) | 2 sets | Connect the host and probes to meet wiring requirements |
3.3 Installation and Linkage Scheme
Probe Installation: Fix each probe above the conveying track of the corresponding station, with the probe axis perpendicular to the detection surface to accurately cover the central area of the gasket. After the bottle cap with the inserted gasket rotates to the detection area and is positioned, the single probe moves down to contact the bottle cap and quickly completes single/double sheet detection.
Host Installation: Install the host above the production line, away from strong electrical interference, and connect the cables to the probes of each station correspondingly.
Signal Linkage: Connect the "single/double/zero sheet" signals of the controller to the PLC. Set up abnormal triggers to stop the corresponding station and activate sound and light alarms, without affecting the operation of the other station.
4. Application Effects
1.Detection Accuracy: Solved the problem of defective products caused by gasket stacking/missing feeding.
2.Rhythm Adaptation: Realized full-load operation of 80 pieces per minute for dual stations, with no detection lag or freeze.
3.Response Efficiency: Abnormal signals are fed back within 50ms, enabling accurate shutdown and alarm to reduce batch defects.
4.Benefit Improvement: The defective rate is reduced, shutdown losses are decreased, and the comprehensive efficiency of the production line is improved by more than 30%.
With its targeted ultra-thin detection design, efficient response performance and flexible adaptation characteristics, the Atonm MDSC-2100L metal double sheet detector has successfully solved the single/double sheet detection problem of the dual-station bottle cap gasket insertion production line, effectively ensuring the product sealing quality and significantly improving the production line operation efficiency and comprehensive benefits. In the future, Atonm will continue to deepen its focus on the industrial automation detection field, providing products and services that are more in line with scenario needs to help enterprises achieve intelligent manufacturing upgrading and jointly create a new production model of high efficiency, stability and low cost.
