Solution for Anti Stacking of Thin Plates in High Speed Stamping Production Line | Application Case of Double Sheet Inspection in 1200T Washing Machine Sheet Metal Stamping Production Line

1、 Project Overview

This project serves a leading home appliance manufacturing enterprise in East China, upgrading its production line to prevent errors in the stamping and mass production scenario of core sheet metal parts for drum washing machines. The customer uses a 1200T stretching and stamping production line to produce structural components such as washing machine shells and inner tubes. The production material is 0.8mm galvanized sheet, with a standard production cycle of 10s per piece, belonging to high-speed precision continuous stamping working conditions.

Due to the influence of the material characteristics of thin plates, the plates are prone to adhesion during the production process, resulting in frequent double sheet stacking and feeding problems, which can easily cause poor product stretching, batch scrap, and damage to stamping molds by squeezing, leading to frequent shutdowns for maintenance, seriously affecting the yield, production capacity, and production stability of the production line.

To address the risk of stacking production, the customer has introduced AtormMDSC-8000S Contact type Single probe Dual detectorMatch the high-speed stamping conditions of household appliance thin plates, establish an automated feeding and error prevention system, achieve precise risk control and unmanned error prevention in the stamping process, and effectively improve the comprehensive production efficiency of the production line.

2、 Core production parameters and equipment configuration

This renovation focuses on the precision stretching and stamping process of washing machine sheet metal, with highly adapted production line conditions, material parameters, and supporting testing equipment parameters. The specific configuration is as follows:

• Stamping production line specifications: 1200T drum washing machine dedicated stretch stamping automation production line

• Processing materials: Industrial galvanized sheet (magnetic conductive metal material), compatible with the production standards for anti-corrosion and rust prevention of household appliances

• Material thickness: 0.8mm thin sheet, belonging to the high difficulty sheet of precision stretching forming

• Production cycle: 10s/piece, high-speed continuous automated stamping production

• Processed products: Core stretch sheet metal parts such as inner drum, outer shell, and back panel of drum washing machine

3、 Solution

In response to the problem of high-speed stamping and stacking of 0.8mm galvanized sheet on site, the AtonmMDSC-8000S contact single probe dual sheet detection solution was adopted this time. Relying on the equipment's exclusive working condition adaptation capability, customized production line transformation integration was completed to solve the hidden danger of dual sheet feeding from the source

The implementation details of the plan are as follows:

1. Suitable for single-sided installation of large sheet metal in household appliances: The equipment adopts a single probe independent detection design, which directly adapts to the working conditions of large-sized sheet metal in on-site washing machines and single-sided feeding of mechanical arms, without the need to modify the original mechanical arm structure and production line layout. It is easy to install, has low modification costs, and has strong adaptability.

2. High speed response matching production rhythm: The equipment has a maximum response speed of 200pcs/min, fully covering the high-speed stamping rhythm of 10s/piece. The double sheet inspection can be completed in an instant without any detection delay or delay in production rhythm, ensuring continuous and uninterrupted operation of the production line.

3. Intelligent formula storage, suitable for flexible production: Built in 200 sets of material formula storage function, can store detection parameters of different thicknesses and specifications of home appliance sheet metal parts. When switching between different categories of sheet metal parts for washing machines in production, the corresponding formula can be directly called without repeated debugging, greatly improving production efficiency.

4. Integrated production line to achieve automation and error prevention: The equipment is equipped with a built-in 485 communication module, which can seamlessly integrate with the production line PLC control system. When double stack material is detected, it will immediately output a switch signal, triggering the production line to automatically alarm, pause feeding, and remove abnormal pieces, forming a fully closed-loop automated error prevention process of "detection warning interception reset", without the need for manual intervention.

4、 Project implementation effectiveness

MDSC-8000S dual detectorAfter being fully put into use, it is adapted to the production conditions of 0.8mm galvanized sheet and 10s high-speed cycle on the 1200T production line, effectively solving the pain points of stacking production and achieving significant upgrades in four dimensions: quality, cost, production capacity, and equipment protection

1. Intercept stacking defects and significantly improve product yield: achieve precise interception of hidden dangers in stamping and feeding double sheets, eliminate defects such as tensile cracking, wrinkling, and dimensional deviation caused by double sheet feeding, and steadily increase the yield of sheet metal products to over 99.5%, solving the problem of batch scrap caused by stacking.

2. Protect the core mold and reduce maintenance costs: block the entry of double sheet metal into the mold from the source, avoid mold extrusion damage faults, significantly extend the service life of the mold, reduce equipment downtime for maintenance, mold repair and replacement frequency by more than 90%, effectively reducing equipment maintenance and spare parts replacement costs.

3. Liberate labor and reduce labor costs: Replace traditional manual visual inspection and error prevention, achieve full automation of material feeding and error prevention, reduce labor input in positions, avoid risks of manual omission and false inspection, and synchronously reduce labor management and production costs.

4. Stable production pace and efficient release of production capacity: Equipment testing is conducted without delay or malfunction, and is adapted to a standardized production pace of 10 seconds per piece. The continuous production stability of the production line has been greatly improved, and the equipment utilization rate has been significantly increased. The overall production capacity has increased by more than 40% compared to before the renovation, effectively solving the bottleneck of production capacity.

5. Adapt to flexible mass production and enhance production universality: With a storage function for 200 sets of material formulas, it can adapt to the production needs of enterprises for multi specification home appliance sheet metal parts in the future. The equipment has strong reusability and lays the foundation for flexible and diversified production in the production line.

5、 Project Summary

The optimization project of the 1200T drum washing machine stretching and stamping production line accurately matches the core working conditions of 0.8mm galvanized sheet high-speed precision stamping in the home appliance industry, and deploys AtormMDSC-8000S Contact Double Sheet DetectorWith a solution of lightweight transformation, high adaptability testing, and fully automatic error prevention, the common pain points in the industry such as thin plate stacking, mold damage, low yield, and unstable rhythm have been effectively solved. The solution does not require significant modifications to the existing production line, and is easy to debug, responsive, and versatile. It not only ensures high-precision and efficient mass production of core sheet metal parts for washing machines, reduces overall production costs, but also provides an efficient and practical mature application model for the automation and error prevention upgrade of similar thin plate high-speed stamping production lines in the white goods industry.

6、 Frequently Asked Questions (FAQ)

Q1: Can the response speed of the equipment keep up with the high-speed production rhythm of the production line with a production cycle of 10 seconds per piece? Will it slow down production capacity?

A: Fully compatible. The maximum detection response speed of the equipment can reach 200pcs/min, far higher than the production cycle of 360pcs/h (10s/piece) on site. The detection can be completed in an instant without delay or lag, and does not affect the original production rhythm. It can ensure continuous high-speed mass production of the production line throughout the process.

Q2: Does the device adopt a single probe installation method, suitable for large-sized sheet metal feeding conditions of washing machines? Do we need to renovate the existing equipment?

A: Highly adaptable. The equipment is designed specifically for single-sided material extraction scenarios in automotive parts and home appliances, with a single probe for independent detection. It does not require traditional upper and lower shooting structures, nor does it require the modification of existing robotic arms, molds, or production line layouts. It is easy to install, has low modification costs, and is suitable for various large-sized sheet metal part loading and detection scenarios.

Q3: Do I need to re adjust the equipment for the production of washing machine sheet metal parts with different thicknesses and specifications in the future?

A: No need for repeated debugging. The device is equipped with 200 sets of material formula storage function, which can input the detection parameters of sheet metal parts with different thicknesses and specifications in advance. When changing production, the corresponding formula can be directly called to quickly switch production and greatly improve the efficiency of flexible production.

Q4: Can the equipment be linked with the stamping production line PLC to achieve automated error prevention, or does it require manual monitoring and troubleshooting?

A: Fully automatic linkage without the need for manual supervision. The equipment comes with a 485 communication module, which can seamlessly interface with the production line PLC. After recognizing double stack materials, it automatically outputs signals, triggers production line alarms, pauses feeding, and eliminates abnormalities, forming a closed-loop automated error prevention system, replacing manual visual inspection.