Information from the abstract
In this study, a double-sheet detection system for automated metal stamping is developed and modeled. This study aims to address the issue of die damage caused by overlapping workpieces (double sheeting), a significant contributor to production line stoppages. The proposed solution involves a control system utilizing a programmable logic controller (PLC), combined with inductive proximity sensors installed on the die, for real-time processing of workpiece status. The system is designed to immediately halt machine operation upon detecting any abnormalities. The experimental results demonstrate that the developed system successfully reduced double-sheet incidents from one occurrence to zero and eliminated production downtime (reducing it from 4 days to zero), resulting in a total of 32,972.26 USD saved in potential damage costs per incident. Furthermore, the system reduced the production cycle time from 11 s to 9.5 s per piece, increasing the production capacity by 1240 pieces per day. The economic assessment indicates that an initial equipment investment of only 483.2 USD yielded a return on investment (ROI) of 6723.73%, a payback period of 5.35 days, a net present value (NPV) of 89,333 USD, and an internal rate of return (IRR) of approximately 6830%. These figures demonstrate a very high level of economic feasibility. Therefore, this system is a cost-effective, reliable, and practical approach to enhance productivity and sustainably support the Smart Factory concept in the metal stamping industry, aligning with the automotive parts manufacturing industry.
Why this record is monitored
This record has an Impact Signal of 85/100 based on recency, source, collaboration, and bibliographic signals. It prioritizes monitoring and is not a judgment of research quality.
Related topics: Industrial Automation and Control Systems · Industrial Vision Systems and Defect Detection · Manufacturing Process and Optimization
Thai researcher and institutional participation
Thanapat Yiamram · Santipont Ananwattanaporn · Chaiyan Jettanasen · King Mongkut's Institute of Technology Ladkrabang
Data limitations
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