Tesla Auto Parts Double-Sheet Detection Case

Project Background

    The feeder first separates single metal sheets using magnetic separation before the press forms them. When the metal surface is clean, magnetic separation effectively supplies single sheets; however, if the metal sheets are oily or surface tension between two sheets is high, the separator may treat two sheets as one, resulting in double-feed.

Project Objective

Objective:

        Accurately and effectively detect double-sheet overlap.

Challenges:

        1. Large sheet area and thickness;      2. Installation area is close to the magnetic separation device.

Solution Summary

    When the robot arm places the sheet within the detector range, the double-sheet sensor is moved into detection position to protect the sensor and avoid collision with the sheet during feeding. If a single-sheet signal is detected, the robot proceeds; if a double-sheet signal is detected, the robot stops and an alarm is sent.

System Overview

      The product includes a controller and sensor. The controller handles current signal processing while the sensor transmits and receives magnetic field signals. Working principle: two sensors form an electromagnetic field when powered. When a metal sheet passes through, different thicknesses induce different voltages; the controller analyzes current differences to determine single or double sheets.

System Features

1. High reliability: MultisCom optimization algorithm, anti-interference circuit and patented full-metal housing;

2. High response speed: detection up to 2000 pcs/min;

3. Multi-material detection: any metal material; automatic learning for various sheets including stainless steel, iron, aluminum, copper foil;

4. Simple tuning: no need to set thickness; material-agnostic self-learning method completed in four steps.

Solution Advantages

1. Multiple trigger options adapted to site conditions, supporting real-time data transmission or manual-triggered events;

2. The metal double-sheet detector supports 485 communication control and can store up to 100 material recipes; when switching materials, the operator can recall saved recipes via the touchscreen without re-adjusting.