Case Study of Double Sheet Inspection for Stamping Production Line of Automotive Thermal Management System Components - AtonmMDCS-8100S

1、 Project Background

The customer is a heat exchanger manufacturing enterprise, and its stamping production line products cover core components such as intercoolers and radiators. The material of the production line is aluminum, with a thickness range of 1-2mm. A mechanical arm is used in conjunction with an end picker to automatically pick up plates from the material stack and send them to the stamping machine for processing and forming. The entire production line is designed with efficient pace and high degree of automation.

In the aluminum plate stamping process, due to the lubricating oil coated on the surface of the plate, the thin plates are prone to adhesion due to adsorption force, and there is occasional risk of stacking when the mechanical arm picks up the material. If the stacked material enters the stamping process, it will have an impact on the quality of the mold and product. Therefore, in the planning stage of the new production line, the customer incorporated online stacking detection into the standard process configuration, requiring the elimination of hidden dangers from the source of material retrieval.

After comprehensive evaluation, the customer chose AtormMDSC-8100S dual detectorInstalled on the end effector of the robotic arm, it achieves real-time and automatic dual sheet detection in the board picking process.

2、 Solution

1. Compact installation, compatible with end effector space

MDSC-8100SContact type dual detectorThe sensor is designed to be compact and installed on the suction cup bracket of the robotic arm end effector, occupying minimal space. It can be deployed without changing the original fixture structure, fully meeting the requirements of the production line for equipment integration.

2. Multi formula management, compatible with flexible production

This production line needs to switch production of aluminum materials with various thicknesses and specifications. MDSC-8100S has 200 sets of formula storage space built-in, which can independently calibrate parameters for each material. The operator only needs to select the corresponding product model on the touch screen, retrieve the formula with one click, and complete the switching process in seconds without repeated debugging, perfectly adapting to the needs of flexible production.

3. High speed detection, matching production line rhythm

The detection speed of 8100S dual detector is 200 pieces per minute. The probe completes the board picking and detection with the action of the robotic arm, and the judgment result is output immediately without adding additional action time, ensuring that the efficiency of the production line is not affected.

4. Communication interconnection and integration into smart factories

MDSC-8100S comes standard with RS-485 communication interface and supports standard Modbus protocol, making it easy to connect to on-site PLC and factory MES systems. Real time uploading of detection signals enables automatic closed-loop control of material retrieval, detection, judgment, and execution, while providing support for production data traceability and process analysis, and assisting in the digital construction of factories.

3、 Application value

1. Source interception to ensure the safety of molds and products

The detector is installed at the source of material collection, and the stacking judgment is completed immediately after each plate collection. Once an abnormality is detected, the system immediately outputs an alarm signal, and the linked robotic arm automatically transfers the stacked material to the recycling box and reclaims it, ensuring that only qualified single sheet metal enters the stamping process and guaranteeing mold safety and product quality from the source.

2. Stable and reliable, suitable for on-site working conditions

MDSC-8100SDual material detection sensorIt has good adaptability to common on-site interferences such as oil stains on the surface of aluminum materials, and the detection results are stable and consistent, providing reliable guarantee for the long-term continuous operation of the production line.

3. Easy to operate, reducing personnel dependence

One click formula switching, automatic detection and judgment, and automatic handling of abnormalities, the entire process does not require manual intervention. Operators only need minimal training to be on duty, reducing reliance on skilled workers and minimizing the possibility of human error.

4. Data traceability to support continuous improvement

After connecting to the MES system through the communication interface, each detection result can be recorded and traced. Production managers can analyze the frequency and pattern of stacking based on this, providing data basis for process parameter optimization and equipment maintenance.

4、 Conclusion

In the new aluminum stamping production line, the AtonmMDSC-8100S dual detector has become the standard configuration solution for stacking prevention and control on the production line due to its precise detection capability, convenient formula management, compact installation design, and complete communication expansion function. While ensuring the safety of stamping molds from the source and improving product yield, it also provides reliable support for the flexibility and intelligence of production lines.