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2026-10-09
Case Study of Double Sheet Inspection Solution for Automotive Stamping Production Line - MDSC-8200S Metal Double Sheet Detector
Case Study of Dual Sheet Inspection Solution for Automotive Stamping Production Line
MDSC-8200S Metal Double Sheet Detector safeguards every mold drop in the automotive stamping production line
Dual station detection+secondary re inspection closed-loop, intercepting the risk of double sheet stacking outside the mold, reducing downtime losses and mold maintenance costs.
| Application Industry | Application scenarios | Core product | Solution Architecture |
| automobile manufacturing | Dismantling area of stamping workshop | MDSC-8200S | Dual station detection+secondary re inspection closed-loop |
01 Project Background: Double material dilemma of stamping production line
In the automotive manufacturing process, stamping is the first of the four major processes and also the first hurdle for body quality. A modern stamping production line can reach a pace of more than ten times per minute, and the value of supporting molds can easily reach millions of yuan. Once double stack material enters the mold, it may cause the parts to be scrapped, the mold blade to crack, and even damage to the entire mold cavity.
The client of this project is a well-known automobile factory in East China. The production line is a newly built high-speed stamping line, and the dismantling area mechanical arm adopts a "one to two" material picking mode, grabbing two steel plates at once. The customer clearly stated during the production line planning stage that reliable protection against the risk of double sheet stacking is necessary to avoid affecting production pace and mold safety due to inspection processes.
Customer core requirements
1. The mechanical arm in the dismantling area grabs 2 steel plates at once, and there is a risk of double stacking missed due to the influence of surface oil stains and thickness tolerances on the steel plates.
Once the double sheet material enters the mold, it can cause the parts to be scrapped, the mold blade to crack, and in severe cases, the entire mold cavity to be damaged, resulting in huge losses.
3. The customer requires the testing solution to be suitable for high cycle production, with stable and reliable operation, and not to slow down the production line rhythm due to the testing process.
Key loss items estimated by the customer side
| project | Customer side estimation |
| Value of a single set of large molds | Millions-level |
| Mold maintenance and downtime losses | Tens of thousands of yuan per transaction |
| Production line shutdown troubleshooting time | Several hours/time |
For high tempo and high-value stamping production lines, dual sheet inspection is not an auxiliary function that adds icing on the cake, but a core defense line that safeguards production line safety and investment returns. The customer requires a stable and reliable dual sheet detection solution that is compatible with high-speed beats.
02 scheme design: dual station detection+secondary re inspection closed-loop
In response to the characteristics of "one to two" material retrieval in the customer unloading area and the demand for high cycle production lines, the Atorm technical team has designed a "first inspection+re inspection" dual station closed-loop solution, deploying MDSC-8200S metal double sheet detectors at two key nodes to effectively intercept the risk of double sheet stacking.
Level 1: First inspection of dismantling area - synchronous detection of one tow and two
Install one MDSC-8200S at the material retrieval station of the dismantling area robotic arm, equipped with two single probes corresponding to the two steel plates grasped by the robotic arm. Each steel plate is independently detected and output signals to achieve accurate double sheet discrimination under the "one driven two" mode.
2 single probes, independent channels, synchronous detection
Second level: Visual re examination of the center stage - double insurance
Before the steel plate enters the press, visually inspect the middle platform and install another MDSC-8200S for secondary re inspection. Even if there is a missed inspection in the initial inspection process due to extreme working conditions, the re inspection station can still accurately identify and stop the machine in a timely manner, forming a double safety loop.
Secondary re inspection, closed-loop protection, and reduction of the risk of double stack material entering the mold
Why choose MDSC-8200S?
200 sets of material formulas: Built in 200 sets of material category formulas, with one click switching between different thicknesses and materials, suitable for multiple vehicle models and specifications of boards.
One to Two Design: Two single probes for independent detection, matched with the "One to Two" material retrieval mode of the robotic arm, with one device covering two detection points.
200pcs/min high-speed response: The response speed can reach 200 pieces/minute, meeting the requirements of high-speed stamping production line rhythm without slowing down the production line rhythm.
Multiple communication methods: Supports communication methods such as Profinet, RS485, and terminal control, and can be directly connected to the production line PLC system to achieve data exchange and remote monitoring.
MDSC-8200S adopts the principle of magnetic induction detection, designed specifically for ferromagnetic materials, with a detection range covering 0.2-4.0mm magnetic materials. It has good detection performance for commonly used cold-rolled sheets, hot-rolled sheets, galvanized sheets, etc. in automotive stamping. The device provides 12 optocoupler isolated inputs and 7 NPN/PNP outputs (default NPN), flexibly adapting to various industrial control scenarios.
03 Implementation effect: Quantifiable cost reduction and efficiency improvement
After the deployment of the plan was completed and stable operation for three months, the double detection and mold protection effects of the customer's stamping production line were significantly improved, and various key indicators reached or exceeded the expected goals.
| indicator | Project feedback |
| Double detection accuracy | The actual measurement of the project is close to reaching the full standard |
| Mold damage rate | Decrease by 90%+ |
| Shutdown time caused by double tension | significantly reduce |
| Overall utilization rate of the production line | Significantly improve |
| operational stability | Stable operation for three consecutive months |
Investment return analysis
Based on the scale of the customer's production line, only one medium-sized mold damage accident needs to be avoided, and the saved maintenance costs and downtime losses can cover the investment in the entire testing plan. Taking into account factors such as extended mold lifespan, decreased defect rate, and increased production line utilization rate, this solution has a good input-output ratio and is a typical "small investment, large guarantee" production line safety upgrade path.
The dual station closed-loop detection architecture has established a layered protection system for the stamping production line: the first inspection intercepts the vast majority of double sheet anomalies, and the second inspection covers extreme working conditions. The two lines of defense are mutually backup, reducing the hidden danger of "single point failure, risk directly reaching the mold". For modern stamping workshops that pursue high safety goals, the value of this architecture design far exceeds the equipment itself.
04 Customer Reviews
Previously, I was always worried about double sheet molding, and whenever I heard the abnormal noise of the press, my heart would go up to my throat. After implementing Atorm's dual station inspection plan, the combination of initial inspection and re inspection has indeed made me feel much more at ease. After running for several months, it has been very stable and has not missed anything that needs to be checked. Finally, I have a clear idea about the mold. ”
——Stamping process manager of a large automobile manufacturing enterprise
05 Product Core Parameters Quick Overview
MDSC-8200S metal dual detector
| parameter item | Specification |
| Product Model | MDSC-8200S |
| Detection Principle | Magnetic induction testing (specifically for ferromagnetic materials) |
| Testing Scope | Magnetic material 0.2-4.0mm |
| reaction speed | 200pcs/min |
| Material group | 200 sets of material category formulas |
| sensor configuration | 2 single probes (magnetic induction sensor, IP65, cable 16 meter pluggable) |
| input | 12 optocoupler isolated inputs, 7 NPN/PNP outputs (default NPN) |
| Communication method | Profinet、RS485、 Terminal control, etc |
| Operating Voltage | 24V DC |
| Protection rating | Front panel IP65, rear shell IP20 |
| host size | 132 × 116 × 78.5mm, embedded installation |
| warranty period | 18 months |
Why choose Atorm
Atorm Intelligent Technology has been deeply involved in the field of industrial sensors for many years, focusing on the research and application of metal dual sheet detection technology. Its products are widely used to serve customers in industries such as automobiles, home appliances, lithium batteries, and metal stamping. It is one of the mainstream brands in the domestic dual sheet detection field.
Focused on technical research and development: Deeply cultivating the dual sheet detection track, continuously iterating product performance, covering all metal and non-metal scenarios.
18 month warranty: Providing an 18 month warranty period, the product is stable and reliable, allowing customers to use it with peace of mind.
Professional technical services: one-on-one technical support, follow up from selection to installation and debugging, and respond quickly.
