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2026-07-22
Deeply cultivating the quality control of whole vehicle stamping | Atorm dual detector landing on high-end new energy vehicle enterprise large tonnage stamping production line
01 Project Background
Body stamping is the first core process in vehicle manufacturing, and the precision, flatness, and structural strength of component forming directly determine the quality, safety performance, and user end experience of the entire vehicle. With the upgrading of new energy vehicles towards high-end, refined, and large-scale mass production, large tonnage high-speed stamping production lines have become the mainstream core configuration.
The stable, safe, and efficient operation of stamping production lines is a key lever for automotive companies to achieve lean production and strictly control comprehensive manufacturing costs. The common problem faced by the industry is the stacking and feeding of double/multiple sheets of sheet metal, which can easily lead to mold damage, batch scrap of parts, and unplanned downtime of the production line. This is the core pain point that urgently needs to be solved in high-end stamping mass production.
In response to the above scenario requirements, our company's Atorm series dual detector has successfully landed in the intelligent production base of a leading domestic new energy vehicle enterprise. Based on different working conditions of the stamping production line, we accurately match exclusive equipment solutions and build a full process pre quality control barrier for high-end automotive stamping production with high stability and precision intelligent detection capabilities.
02 Overview of on-site production line
In this cooperation, the intelligent production base of the automotive company has achieved full process automation and closed-loop operation in the stamping workshop, with three core features:
High speed and high cycle: The large tonnage high-speed stamping line operates stably, with extremely high requirements for feeding continuity and cycle consistency;
High flexibility hybrid production: It needs to be compatible with multiple vehicle models, large quantities, and multi specification body parts (including large exterior panels and small and medium-sized structural components) for co production;
Intelligent conveyor chain: The unpacking robot seamlessly connects with the belt conveyor line, and the entire process is unmanned and automated.
Under such high-precision and fast-paced working conditions, traditional manual re inspection and universal sensors are no longer able to meet quality control requirements. To this end, our company has deployed customized dual sheet detection dedicated equipment for the two core workstations of unpacking and grabbing the source and the middle section of the belt conveyor, and built a front to back linkage quality control barrier.
03 Core bottleneck of traditional control methods
In the scenario of large tonnage high-speed stamping, precise feeding of single sheet metal is the red line of the process. However, traditional control measures have three fatal shortcomings:
| traditional method | Specific defects | Direct losses caused |
| Manual sampling | Unable to match high-speed beats, extremely low coverage, relies on personnel experience, and has fatigue errors | Stacking missed inspection enters the stamping process, batch parts deform and are scrapped, and material costs skyrocket |
| Ordinary single point sensor | Weak anti-interference ability, severe signal drift in workshop dust and high-frequency vibration environment, and sudden increase in false alarm rate | Frequent false alarms lead to inexplicable interruptions in the production line, resulting in a continuous decline in overall equipment efficiency (OEE) |
| No linkage shutdown mechanism | After detecting anomalies, only sound and light alarms are issued, requiring manual confirmation and processing, resulting in a response time difference | Within the delay window from alarm to manual emergency stop, the stacked material has been stamped and formed, and the high-precision customized mold is irreversibly damaged |
The ultimate consequence of short board stacking is: at least one batch of parts will be scrapped, and rework hours will increase; In severe cases, it can damage customized molds worth millions of dollars, trigger unplanned downtime on the production line, disrupt production schedules, and drag down delivery cycles. Under the lean management system of high-end car companies, such hidden waste caused by "out of control stacking" has become an urgent cost black hole that needs to be overcome.
04 Solution and Implementation Advantages
Combining the differentiated working conditions of "follow-up grabbing" in the unpacking area and "continuous mixed flow conveying" on the conveyor belt, our company abandons universal standard products and creates customized solutions for different scenarios with two exclusive Atorm devices:
| Workstation scene | Adapting devices | Core Strategy and Hard Power |
| Dismantling area (source) | AtonmMDSC-9000T(2 units) | Integrated into the end effector of the robotic arm, it completes detection synchronously with the grasping action, and performs parallel detection without increasing independent beats. Specializing in addressing the stacking hazards during the grabbing of large aluminum/steel exterior coverings, and preventing the first risk of jamming from the source |
| Belt conveyor line (middle section) | AtonmMDSC-1604T one to four(1 unit) | Specially designed for mixed line mass production, with a one to four multi-channel architecture, it can simultaneously perform comprehensive scanning of various types and specifications of small and medium-sized components on the conveyor belt, without fear of high-frequency mold changes, filling the blind spots in the middle of the production line inspection |
Three core landing advantages
| Benchmarking pain points | The solution path of Atorm solution |
| Manual missed detection | 7 × 24-hour fully automatic operation, no need for manual supervision, 100% detection coverage, eliminating human errors from the source |
| False alarm shutdown | Our self-developed high-precision anti-interference algorithm effectively shields dust and high-frequency vibration interference. Under complex working conditions, the measured false alarm rate is zero, and the false alarm rate approaches zero |
| No linkage emergency stop | After identifying abnormal stacking, a millisecond level warning is triggered, and the production line is urgently shut down to block stacking and stamping from the source, comprehensively protecting high-value molds |
After the deployment of the equipment, it runs automatically throughout the entire process and seamlessly integrates into the existing production process. There is no need for manual supervision, no need to stop for re inspection, no additional occupation of production pace, no need to interrupt the operation of the production line, and it matches the high-speed stamping rhythm and fast mold changing mode of the production line.
05 Project Implementation Value
After the entire project is put into operation, we have established a pre fabricated, automated, and closed-loop stamping quality control system for our customers, and the implementation results are intuitive and significant
Quality improvement: effectively avoiding part defects and forming deviations caused by stacking, maintaining high-precision stamping process standards, and ensuring unified and compliant quality of body parts;
Capacity improvement: significantly reducing mold loss, equipment failure rate, and product scrap rate, effectively reducing unplanned downtime, and maximizing the release of large tonnage stamping equipment capacity;
Cost reduction and efficiency improvement: Precise pressure reduction for mold replacement, material loss, equipment maintenance, downtime and other comprehensive costs, helping the workshop achieve refined and lean production management.
Taking this cooperation as an example, after the production line was put into use, the unplanned downtime caused by stacking approached zero, and the annual comprehensive cost savings of a single production line were significant, providing customers with a quantifiable and replicable quality control benchmark for lean production.
06 Project Summary and Outlook
The successful implementation of our double detector in the large tonnage and flexible stamping production line of a leading new energy vehicle enterprise fully verifies the stability and adaptability of our company's dual detector in the harsh scenarios of high-end automotive intelligent manufacturing.
Our company has long been deeply involved in the automotive stamping quality control track, focusing on providing customized intelligent testing solutions for stamping production lines of different tonnages and working conditions. In the future, we will continue to iterate algorithms and hardware performance, polish technology products that are more suitable for industrial mass production, continuously empower automotive companies to upgrade their intelligent manufacturing, and help the automotive industry achieve high-quality lean development.
Quick overview of core parameters of the plan
| Device Model | Deploy workstations | core functionality | Adaptation scenario |
| MDSC-9000T (2 units) | Dismantling area mechanical arm end pick up device | Synchronized detection without adding new beat time | Large external coverings, high-strength structural components, steel/aluminum full range plates |
| MDSC-1604T (1 unit) | Belt conveyor line | One to four multi-channel global monitoring | Small and medium-sized components, high-frequency mold changing, multi category mixed line conveying |
Deeply cultivate stamping quality control and empower intelligent manufacturing upgrading.
If you need customized solutions or technical white papers, please feel free to contact our engineer at 13342814291.
