Solution for Dual Sheet Inspection of Automotive Parts Stamping Line - Atonm1000C Dual Sheet Detector to Prevent Stacking Damage to Molds

01 | Project Background: The "stacking" of the material section on the robotic arm results in significant hidden costs

This project was initiated on a stamping line of a certain automotive parts supplier: when the robotic arm/robot grabs the steel plate for feeding, there will be a situation where multiple pieces of material are taken away together. The dual material was fed into the mold, causing a series of subsequent problems:

Mold tooth breakage, mold breakage (long maintenance cycle, high cost)

Scrap and rework of stamped parts (combined with material and labor costs)

Production line shutdown (OEE decrease, delivery delay)

02 | Solution: Install AtormMetal dual detector MDSC-1000C

This case involves installing a set between the end of the robotic arm and the feeding mechanismMDSC-1000C dual beam detectorWhenever the robotic arm delivers the material in place, the detector first determines whether there are double/multiple sheets:

Single sheet → output OK, continue feeding

Double/multiple sheets → output NG, trigger material return/alarm/rejection

This solution does not require any changes to the robot's grasping logic, only adding detection and judgment at key nodes, so the transformation cycle is short and the risk is low.

03 | Result: Decrease in mold accidents and more stable production line operation

On site improvement data (production line of a certain automotive parts supplier)

Mold damage frequency: tooth breakage/mold breakage caused by double tension decreased from 1-2 times/month to 0 times (lasting for 3 months)

Number of downtime: reduced from 8 times/week to 0 times/week

Production line utilization rate: more stable rhythm, efficiency improvement of about 3-5%

Debugging hours: 1-2 on-site debugging sessions can complete a single teaching demonstration and ensure stable operation

At the customer's site, the application of this solution has significantly improved reliability and stability compared to relying on manual inspection or ordinary optoelectronics in the past, and does not require complex modifications.

04 | Key points for quick landing

Installation position and spacing

Suggest setting the detection point at "after the mechanical arm grabs the material and before feeding" as the last step before entering the mold

Suggested probe spacing is 30-50mm (40mm recommended)

When space is limited, install near the feeding port

PLC/Robot Linkage Approach

Material arrival signal triggers 1000C detection

OK signal allows feeding/discharging through PLC

NG signal triggers material return, alarm or jump, and records abnormalities

Key points of on-site debugging

Verify "single/double/empty load" with real samples

If there is a false alarm, you can re execute the 'learning demonstration'

Suggest combining line edge inspection: record alarm conditions and analyze the reasons

This plan can effectively reduce the risk of mold damage and downtime caused by double tension, improve delivery stability, and provide clear investment returns. The equipment adopts standard NPN/PNP/I/O output, which can be easily connected to PLC and robot control systems, and has functions of disconnection alarm and abnormal judgment; During installation, only one set of detection points needs to be added to the feeding path, without changing the structure of the robotic arm. When the material changes, it can be adapted by re teaching. Comparing mold repair with downtime losses, it is a low-cost and high-yield protection solution