Double sheet testing scheme for steel aluminum hybrid stamping production line: 9000T+1600S landing case

Abstract: New energy vehicle companies are building multi model co line stamping production lines, facing complex working conditions such as steel aluminum mixed production, large plate thickness span, high-frequency production changes, and high-speed rhythms. This article provides a detailed explanation of the design, on-site debugging process, and mass production landing effect of the "disassembly pre inspection+transportation re inspection" dual protection scheme, based on Atorm's complete supporting dual detection landing project. It provides practical reference for the standardized configuration of dual material protection in steel aluminum mixed line stamping production lines.

1、 Project background: Pain points of dual sheet detection in complex mixed line stamping

This landing project is a new self built stamping production line for a new energy vehicle enterprise, with a core positioning of steel aluminum hybrid production and multi vehicle co line switching, adapted to the stamping needs of multiple categories of vehicle components. With the acceleration of the iteration of new energy vehicle models, this production line has the production characteristics of high replacement frequency, diverse sheet specifications, and fast running pace. It also puts forward extremely high requirements for double sheet material detection and mold protection.

In stamping production, problems such as oil film adsorption on the surface of the sheet metal, production static electricity, burrs on the edges of the sheet metal, and misalignment of stacking materials can easily lead to the simultaneous grabbing of double sheets of material during disassembly and material retrieval. Once the double sheet metal flows into the mold, it can cause batch parts to be scrapped and production costs to rise. In severe cases, it can lead to mold crushing and collapse, directly causing unplanned downtime of the entire production line and seriously affecting the production line's utilization rate. Therefore, in the production line planning stage, car companies use high-precision dual detection systems as the core supporting protective equipment to avoid production risks from the source and replace the passive mode of traditional post rectification.

Core operating parameters of the production line

Production line configuration: palletizing robot+conveyor belt line+multi station stamping machine, fully automatic assembly line operation

Production mode: alternating mixed production of steel plates and aluminum plates, with a single team capable of switching between 2-3 vehicle models and frequent production changes

Sheet thickness range: 0.2mm-3mm, with a wide span of thick and thin sheets

Working condition requirements: 15SPM high-speed production cycle, no delay, no missed detection, and no occupation of production cycle during testing

2、 Core solution: Dual defense line to comprehensively avoid the risk of double sheet molding

In response to the complex working conditions of steel aluminum mixed production, multi specification plates, and high-frequency switching on this production line. This plan adopts AtormMDSC-9000TPre inspection of unpacking+MDSC-1600SThe dual protection architecture for conveying and re inspection includes source interception and mold re inspection, with closed-loop protection throughout the entire process, effectively blocking the entry of double sheet metal into the stamping mold.

First line of defense: Pre inspection at the unpacking end - interception of double sheets at the source

Deployment of end pickups in palletizing robotsMDSC-9000T dual detectorIntegrate two independent single probes on the inside of the suction cup holder to achieve synchronous grasping and detection, with zero cycle time occupation, perfectly adapting to the high-speed production needs of the production line.

This equipment is designed specifically for steel aluminum mixed wire working conditions, with full material compatibility and adaptability: magnetic steel plate detection range of 0.2mm-4.0mm, non-magnetic aluminum plate detection range of 0.1mm-8.0mm, fully covering all production plate specifications of this project.

At the same time, the device is equipped with a dynamic anti-interference algorithm, which can effectively counteract external interference such as vibration of stamping workshop equipment, complex electromagnetic environment, dust and oil pollution, ensuring long-term stable detection. Once the double sheet material is identified, the robot immediately stops in an emergency and automatically transports the abnormal sheet material to the NG area, blocking the flow of double sheet material into the back end of the production line from the source.

The second line of defense: conveyor line re inspection - final re inspection after entering the mold

Erect at a position 1.5 meters above the conveyor belt and at the front end of the mold entranceMDSC-1600S channel dual detectorAdopting a four channel full coverage scanning layout for precise secondary review of the conveyed sheet metal.

The equipment adopts a non-contact through detection method, which does not touch the sheet metal and does not affect the conveying rhythm. The maximum processing capacity can reach 750pcs/min, fully matching the high-speed cycle of the production line. Comprehensive coverage of testing specifications: iron sheet 0.2mm-6.0mm, aluminum sheet 0.1mm-8.0mm, suitable for the production of all types of thick and thin sheets.

The system has an abnormal locking function. If double materials are detected in any channel, the conveyor belt will immediately stop and lock the abnormal state. The production line can only be restarted after manual confirmation, cleaning, and resetting, effectively avoiding the risks of missed detection and false release, and guarding the last line of safety before the mold is put into the mold.

3、 On site implementation: rapid debugging, seamless integration with mass production

Relying on the localization service advantages of domestic equipment, the project has achieved rapid implementation. After the equipment arrives, Atorm's dedicated engineers will follow up on site throughout the entire process, completing equipment installation, parameter calibration, communication debugging, and personnel training in a closed-loop service.

For various mainstream board specifications on site, engineers complete precise parameter calibration one by one, storing detection parameters of different materials and thicknesses as independent equipment formulas. When switching car models, it can be switched in one click and seconds, perfectly adapting to high-frequency production needs.

The system supports Profinet industrial communication protocol and can directly interface with production line PLC and enterprise MES system, achieving real-time uploading of detection data, automatic retention of abnormal data, and full traceability of production records, adapting to the digital production management needs of intelligent factories.

Compared to the long after-sales response cycle and high debugging costs of imported equipment, Atorm provides 24/7 technical support, with fast on-site delivery, high debugging efficiency, and complete landing services. From pre-sales solution customization to on-site delivery and operation, it forms a complete service loop.

4、 Mass production landing effect

After the complete set of dual sheet detection system was put into operation, it perfectly solved the problem of dual sheet material in steel aluminum mixed line stamping, greatly improving the production line protection ability and production efficiency. The core landing data are as follows:

Realize zero double material in mold mass production operation, and avoid mold damage risks from the root

The detection rate of dual images is 100%, and the false alarm rate is stably controlled within a reasonable range in the industry

The formula for vehicle model replacement has been switched to the second level, with no additional replacement time required

100% of the detection data is connected to the MES system, and production abnormalities can be traced and reviewed throughout the entire process

Significantly reduce the problems of downtime, mold maintenance, and parts scrap caused by double sheet materials, and increase the overall production efficiency of the production line by about 15%

5、 Project Summary

At present, automobile stamping production has been developing towards high-speed, mixed line, and flexible directions. Steel aluminum mixed production and multi vehicle co production have become the mainstream production modes for automobile enterprises. The working conditions of thin sheet metal, multiple specifications, and fast production changes make double protection no longer an optional configuration, but a standard safety bottom line for stamping production lines.

The dual line solution of "dynamic pre inspection at the unpacking end+full coverage re inspection at the conveying end" has a simple structure, strong adaptability, high stability, and is suitable for high-speed and high-frequency production needs. It can provide a mature and replicable dual sheet detection solution for steel aluminum mixed line stamping production lines of new energy vehicle companies and automotive parts manufacturers.

Keywords:Double sheet inspection for automotive stampingDouble material detection scheme for stamping production line, dual detector steel aluminum mixed line, stamping mold protection