Domestication Empowers Flexible Stamping Production Line | Application of Atorm Dual Sheet Detector in Automotive Steel Aluminum Production Line

1、 Project Background

A mainstream new energy vehicle company's stamping workshop has built a steel aluminum mixed material stamping automation production line to meet the production needs of multiple vehicle models on the same line. The main responsibility is the stamping and forming processing of body coverings and structural components. The thickness range of the production line sheet metal processing is 0.3-4mm, covering various materials such as cold-rolled steel plates and aluminum alloy plates, with a high degree of overall automation and rhythm.

This is a newly planned and constructed steel aluminum mixed stamping automation production line for the workshop, which focuses on flexible co production of multiple vehicle models. The production materials cover multiple specifications of steel plates and aluminum plates, with a processing thickness span of 0.3-4mm. During the equipment planning and selection stage of the production line, the customer clearly proposed two core construction requirements based on the current intelligent manufacturing upgrade needs and actual production conditions on site. Firstly, priority should be given to selecting domestically produced brand testing equipment with mature technology and stable performance, in order to achieve localization substitution of key workstation testing equipment; The second requirement is a high-precision dual sheet detection scheme that is compatible with steel aluminum mixed materials and fully covered with thick and thin materials, to eliminate the risk of dual sheet stacking entering the mold, ensure the production stability and finished product quality control accuracy of the new production line, and meet the high standard requirements of automated mass production.

2、 On site working conditions and core requirements

1. On site working conditions

This project is a newly constructed automated stamping production line designed for all-weather continuous operation mode, with high frequency of production changes, large thickness span of sheet materials, and alternating production of ultra-thin materials, conventional materials, and thick plates. It has high standards for material compatibility, environmental anti-interference, and long-term operation stability of front-end double tension detection equipment.

2. Core requirements

One is to achieve precise detection of double layered steel and aluminum sheets with a full thickness range of 0.3-4mm, eliminating problems of missed or false detections;

The second is to adapt to the installation and testing scenarios of different workstations for dismantling, grabbing, and belt conveying, and match the pace of automated production lines;

Thirdly, it is compatible with multiple materials and specifications of boards for quick production changes, without the need for complex debugging, ensuring production continuity;

The fourth is to strengthen pre detection and protection, avoid equipment damage and product defects caused by stacking and stamping from the source, and reduce production losses and operation costs.

3、 Overall solution

Based on the workstation layout, material characteristics, and design quality control standards of the new production line, the project adopts a differentiated matching scheme for division of labor, and selects two Atorm modelsDual detection equipmentEstablish a full process feeding protection system of "disassembly pre inspection+belt conveyor review inspection", matching the production design requirements of new production lines for automation, high cycle, and flexibility.

1. Dismantling area workstation: Deploy 2 AtonmsDual channel 9000T contact dual detectorThis device is adapted to the working conditions of the dismantling and stacking robot arm grasping and feeding. It adopts a contact detection method and has strong resistance to on-site equipment vibration interference. It can work with the robot arm to accurately identify the stacking status of single, double, and multiple sheets. It completes pre detection interception before feeding and prevents stacking from entering the next process from the source. The equipment supports steel aluminum all metal material detection and can perfectly adapt to on-site mixing production mode.

2. Belt conveyor station: equipped with AtormFour channel 1600 series through type dual material detectorFor the working conditions of continuous conveyor and high-speed flow on the belt line, the equipment adopts a non-contact through type detection structure, which does not interfere with the rhythm of sheet conveying and can perform real-time review and detection of the sheet during the conveying process, making up for the omissions of single station detection and forming a dual quality control guarantee.

The entire solution covers the testing needs of 0.3-4mm thickness sheet materials, supports the storage of multiple sets of material and thickness parameter formulas, and is equipped with 999 sets of formulas. When changing production, parameters can be switched with one click, without the need for repeated debugging. It is suitable for the mixed production mode of multiple vehicle models and multi specification sheet materials by car companies, balancing testing accuracy and production efficiency.

4、 Core advantages and adaptability of equipment

1. High precision detection across the entire area: The combination of two devices can fully cover the 0.3-4mm plate detection range, which can stably identify the stacking status of 0.3mm ultra-thin steel and aluminum sheets, and accurately adapt to the detection of 4mm thick structural plates. It fully matches the design conditions of the new production line's steel aluminum mixed line and alternating production of thick and thin materials, with no detection blind spots and stable and reliable detection accuracy.

2. Strong workstation adaptability:9000T contact dual material detectorTargeted adaptation to work scenarios with limited space in the unpacking area, high equipment vibration, and follow-up grabbing, ensuring stable and effective detection;1600 series pass through detectorAdapt to continuous conveyor conditions on conveyor belts, without hindering material flow, and adapt to the rhythm of high-speed automated production lines.

3. Efficient production switching and high stability: The equipment is equipped with 999 sets of process formulas, which can store detection parameters for different materials and thicknesses of sheets. When changing production models or materials, there is no need to recalibrate, and parameter switching can be completed in seconds, greatly reducing production switching and debugging time. At the same time, the device has a fast response speed and can seamlessly match the high-speed production rhythm of the production line, without affecting the output of production capacity.

4. Anti interference and low false alarm: Targeting complex environments such as dust, equipment vibration, and electromagnetic interference in stamping workshops, the equipment optimizes detection algorithms and hardware structures to effectively reduce false alarms and missed alarms caused by environmental interference. It has strong long-term continuous operation stability and is suitable for industrial normal production conditions.

5. Integrated thickness measurement and error prevention function: The equipment integrates precise thickness measurement and detection capabilities. In addition to basic double sheet stacking detection, it can compare the actual thickness of the incoming sheet with standard process parameters in real time, accurately identify material errors in the production process, and effectively avoid specification mixing and sheet misuse problems during manual feeding and automatic feeding processes. Under the alternating production conditions of steel aluminum mixed production lines and multi thickness plates, multiple protections such as "double sheet detection+thickness verification+wrong material interception" are achieved, further improving the production line's fault tolerance and quality control rigor.

5、 Application effect

After the installation of the complete set of Atorm domestic double sheet testing equipment, it fully meets the design, production pace, and quality control standards of the new stamping production line, successfully solving the problem of double sheet testing for steel aluminum mixed materials and wide thickness span plates, and laying a solid foundation for front-end protection for stable mass production of the new production line.

One is to solve the problem of missed and false alarms in stacking, successfully intercepting various hidden dangers of double stacking of thick and thin steel and aluminum sheets, avoiding mold collision and sheet scrap caused by stacking into the mold, significantly reducing the frequency of mold maintenance and sheet loss costs, and reducing unplanned downtime.

The second is to adapt to the production needs of mixed production lines. The alternating production of steel and aluminum materials and the replacement process of different thickness plates are smooth, without the need for manual repeated equipment debugging. The replacement efficiency is significantly improved, effectively ensuring the flexibility requirements of multi vehicle co production. At the same time, the equipment comes with a thickness measurement and verification function, which can accurately intercept the problem of wrong materials and completely eliminate the production hazards of mixing different specifications of boards on the machine.

Thirdly, standardized protection measures have been established for the entire feeding process, covering the entire process of unpacking, loading, and conveyor belt transportation. The production defect rate and equipment failure rate have significantly decreased, and the overall automation stability, production efficiency, and product yield rate of the production line have steadily improved, providing reliable guarantees for efficient, low-cost, and normalized stable production of the stamping production line.

6、 Project Summary

For the newly constructed automotive steel aluminum mixed material stamping production line, the customer adopts the construction concept of domestic equipment selection, high adaptability, and easy operation and maintenance, and adopts the Atorm domestic dual sheet detection combination solution. Through the workstation based combination of 9000T contact dual sheet detector and 1600 series through dual sheet detector, it accurately adapts to different work scenarios in the unpacking area and belt line. The equipment combines dual sheet detection and precise thickness measurement to prevent errors, fully meeting the flexible production needs of new steel aluminum mixed production lines, wide thickness ranges, and high-frequency switching. The complete set of domestically produced equipment has mature technology, high deployment adaptability, stable operation, and easy operation and maintenance in the later stage. On the premise of ensuring the accuracy of production line detection and the stability of mass production, it effectively eliminates the two major production hazards of stacking and wrong materials, smoothly realizes the localization of key detection station equipment, effectively controls the overall construction and later operation and maintenance costs of the production line, and provides reliable application reference for the selection and localization of detection equipment for the same type of automotive stamping and mixing production line.