Device and method for detecting waste blockage of automobile stamping part die

Abstract

The invention provides an automobile stamping part die waste blockage detection device and method, and relates to the technical field of automobile dies. According to the device, the diffuse reflection sensor is arranged to monitor the waste discharge state in the waste slide way in real time, a reasonable signal shielding time threshold value is set in combination with the time relay, and the conditions of normal waste sliding and abnormal blocking are effectively distinguished; the control module automatically cuts off a workpiece sensor signal and triggers a press to stop and give an alarm, so that fault expansion is prevented in time, and die damage and batch waste production are avoided; according to the device, modular design is adopted, lossless and rapid mounting and dismounting of the sensor are achieved through the magnetic jointing clamp, flexible switching and use among different dies are facilitated, die recognition and signal matching are achieved in cooperation with the encoder, system compatibility and reliability are ensured, and the automatic monitoring level and operation safety of a stamping production line are improved.

Description

Technical Field

[0001] This invention relates to the field of automotive mold technology, and in particular to a device and method for detecting waste blockage in automotive stamping molds. Background Technology

[0002] In the automated production line of cold stamping dies, scrap blockage is a long-standing industry problem. Due to limitations such as product shape, stamping process, and casting cost, the space for scrap disposal during the trimming process is narrow and the sliding angle is not ideal, making blockage particularly prone to occur when multiple scrap materials share a single cavity. Once scrap accumulates, it can lead to product rework, increased scrap, and production stoppages, or even serious damage to the die, resulting in high repair costs, supply disruptions, and claims. Currently, the industry mainly uses methods such as dedicated monitoring, early die optimization design, or AI vision inspection to address this problem, but all have significant drawbacks: manual monitoring has poor accuracy and high labor costs; die structure optimization cannot completely eliminate blockages; and while AI vision systems have certain detection capabilities, they have limitations such as high investment costs, difficulty in retrofitting older equipment, and inability to adapt to diverse blanking methods on the stamping equipment worktable. Summary of the Invention

[0003] The purpose of this invention is to provide a device and method for detecting waste blockage in automotive stamping molds, in order to solve one or more technical problems existing in the prior art, and at least provide a beneficial option or create conditions.

[0004] The solution to the technical problem of this invention is as follows: On the one hand, this invention provides a device for detecting blockage of waste material in automotive stamping die, comprising: The detection module is used to detect the blockage status of waste in the mold waste chute. It includes at least one diffuse reflection sensor, which is installed next to the mold waste inlet and configured to emit infrared light and receive reflected signals. When the waste is blocked, the waste blocks the infrared light to cut off the reflected signal. The control module, electrically connected to the detection module, includes a terminal box; the terminal box has wiring terminals inside, and a time relay and an encoder are provided on the surface of the terminal box; the time relay is used to configure a preset time threshold, and the encoder is used to set the mold code. A connection module, including a multi-core connecting wire, electrically connects the detection module to the control module and electrically connects the control module to the control system of the stamping equipment; The fixing module includes a magnetic connector that detachably fixes the diffuse reflection sensor to the side of the mold waste inlet; When the reflected signal of the diffuse reflection sensor is continuously blocked by the waste material for a period of time that reaches the preset time threshold of the time relay, the terminal box sends a stop signal to the control system of the stamping equipment, controlling the stamping equipment to stop working and triggering an alarm.

[0005] Furthermore, by installing the diffuse reflection sensors next to the different waste chute inlets of the same mold, multi-channel synchronous detection can be achieved.

[0006] Furthermore, the diffuse reflection sensor is a PNP three-line infrared switch, which detects the spatial dimensions of the mold waste slide at a distance adapted to the target mold.

[0007] Furthermore, the encoder is a binary rotary switch, which is disposed on the surface of the terminal box. By switching the switch state, an encoding corresponding to each mold is set, enabling rapid identification when multiple molds are used together. When changing molds, the device can be adapted simply by switching the state of the binary rotary switch, without the need for rewiring.

[0008] Furthermore, the connection module also includes a connector assembly and a connector assembly. The connector assembly is used for quick plug-in connection between the terminal box and the worktable of the stamping equipment. The connector assembly has a 4-pin 4-hole structure to adapt to the signal transmission of the multi-core connection cable.

[0009] Furthermore, the time relay is a 24V DC relay; the time threshold is determined by software simulation based on the size of the waste chute space and the waste sliding method, adapting to the waste sliding speed under different stamping processes.

[0010] Furthermore, the shutdown signal is transmitted through the multi-core connecting line to ensure that the stamping equipment stops in time before the waste blockage expands, thus avoiding damage to the mold.

[0011] Furthermore, the magnetic force of the magnetic clamp is not lower than a preset magnetic force threshold, ensuring that the diffuse reflection sensor does not shift under the vibration environment of the stamping equipment, and that the diffuse reflection sensor is not damaged during disassembly.

[0012] Furthermore, the diffuse reflection sensor is equipped with a protective housing to make it shockproof, waterproof, dustproof and oil-proof.

[0013] On the other hand, this application provides a method for detecting blockage of automotive stamping die scrap, applied to the aforementioned automotive stamping die scrap blockage detection device, comprising the following steps: The diffuse reflection sensor is fixed at a preset position next to the mold waste inlet using a magnetic clamp, so that the infrared light of the diffuse reflection sensor covers the outlet area of ​​the waste chute. The control module is electrically connected to the diffuse reflection sensor and the control system of the stamping equipment via a connection module; The encoder of the control module sets the current mold code, and the time threshold for judging waste blockage is preset by the time relay; After the stamping equipment is started, the diffuse reflection sensor continuously emits infrared light and detects the reflected signal. When there is no blockage in the die scrap chute, the infrared light is unobstructed and the reflected signal is normal; when the scrap is blocked, the scrap blocks the infrared light and the reflected signal is interrupted. The duration of the interruption of the reflected signal is monitored in real time by the time relay. When the duration reaches the time threshold, the terminal box of the control module sends a stop signal to the control system of the stamping equipment, controlling the stamping equipment to stop working immediately and triggering an audible and visual alarm. When the reflected signal is restored, the time relay is reset and the detection process restarts.

[0014] The beneficial effects of this invention are as follows: This application provides a device and method for detecting waste blockage in automotive stamping part dies. The device uses a diffuse reflection sensor to monitor the waste discharge status in the waste chute in real time. Combined with a time relay to set a reasonable signal blocking time threshold, it effectively distinguishes between normal waste sliding and abnormal blockage. When the sensor is continuously blocked by waste accumulation for a preset time, the control module automatically cuts off the part sensor signal and triggers the press to stop and alarm, thereby preventing the fault from escalating and avoiding die damage and batch scrap. The device adopts a modular design, using magnetic clamps to achieve non-destructive and rapid installation and removal of the sensor, facilitating flexible switching between different dies. An encoder is used to achieve die identification and signal matching, ensuring system compatibility and reliability, and improving the automation monitoring level and operational safety of the stamping production line. This application also provides a corresponding method, the beneficial effects of which are similar and will not be elaborated here.

[0015] Other features and advantages of this application will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practicing the application. The objectives and other advantages of this application may be realized and obtained by means of the structures particularly pointed out in the description, claims and drawings. Attached Figure Description

[0016] The accompanying drawings are provided to further understand the technical solutions of the present invention and constitute a part of the specification. They are used together with the embodiments of the present invention to explain the technical solutions of the present invention, and do not constitute a limitation on the technical solutions of the present invention.

[0017] Figure 1 This is a structural diagram of the automotive stamping die waste blockage detection device provided in this application; Figure 2This is a structural diagram of the wiring terminals provided in this application; Figure 3 This is an assembly diagram of the automotive stamping die waste blockage detection device and the die provided in this application; Figure 4 This is a flowchart of the method for detecting blockage of automotive stamping die scrap provided in this application; The labels are as follows: 100, scrap; 101, diffuse reflection sensor; 102, magnetic terminal clamp; 201, terminal box; 202, time relay; 203, encoder; 204, terminal block; 301, 4-core connector; 302, connector assembly; 303, 50-core connector; 304, connector assembly; 305, quick-plug connector. Detailed Implementation

[0018] To make the objectives, technical solutions, and advantages of this application clearer, the following detailed description is provided in conjunction with the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the scope of this application.

[0019] The present application will be further described below with reference to the accompanying drawings and specific embodiments. The described embodiments should not be considered as limitations on the present application, and all other embodiments obtained by those skilled in the art without inventive effort are within the scope of protection of the present application.

[0020] In the following description, references are made to “some embodiments,” which describe a subset of all possible embodiments. However, it is understood that “some embodiments” may be the same subset or different subsets of all possible embodiments and may be combined with each other without conflict.

[0021] Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this application belongs. The terminology used herein is for the purpose of describing embodiments of this application only and is not intended to limit this application.

[0022] In the automotive manufacturing industry, cold stamping is a crucial step in the production of body panels and structural components, widely used in the forming of large sheet metal parts such as doors, hoods, side panels, and floors. Stamping production is typically carried out on automated high-speed press production lines. The die, as the core tooling, completes multiple processes in each stamping cycle, including blanking, drawing, trimming, punching, and flanging. The trimming process generates a large amount of strip-shaped or block-shaped metal scrap (hereinafter referred to as "scrap"). This scrap must automatically slide down into a scrap collection box below the equipment by gravity through a scrap chute (or "discharge channel") designed inside the die, ensuring continuous production.

[0023] However, in actual production, due to various factors such as complex product structure, material properties, stamping process parameters, and mold structure limitations, scrap blockage has become a long-standing "stubborn problem" in automated cold stamping lines. Scrap blockage refers to the phenomenon where, during the stamping process, scrap material fails to slide smoothly out of the mold and instead accumulates, jams, or even completely blocks the channel within the slideway. Although this fault does not occur frequently, its consequences are severe: at best, it prevents subsequent stamped parts from forming properly, resulting in scrap or requiring manual rework; at worst, the accumulation of scrap material causes abnormal closure of the upper and lower molds, leading to severe mechanical damage such as mold surface tearing, punch breakage, and slide block jamming. This not only results in high mold repair costs (a single incident can cost hundreds of thousands of yuan to repair) but also causes prolonged downtime of the entire production line, seriously affecting production rhythm and delivery cycle. In the current automotive industry, with increasingly stringent requirements for production efficiency, quality stability, and supply chain continuity, scrap blockage has become a significant factor affecting the OEE (Overall Equipment Effectiveness) and manufacturing costs of stamping workshops. To solve this problem, the industry has tried various technical means, mainly including the following typical solutions.

[0024] Manual monitoring is currently the most common method for dealing with scrap blockage in stamping production. This involves assigning dedicated personnel or inspectors to periodically observe the scrap chute outlet of the die to determine if scrap is being discharged normally. If an anomaly is detected, the machine is stopped for repair. However, this method has several significant drawbacks: First, it requires additional manpower, significantly increasing labor costs, especially in factories with multiple shifts and continuous equipment operation. Second, manual monitoring is inefficient and inaccurate, easily affected by operator fatigue, distraction, and changes in ambient light, leading to missed detections or misjudgments. Third, the response is severely delayed; from the start of scrap accumulation to its discovery, multiple stamping cycles have often passed, and the fault has progressed to a more serious stage, potentially causing die damage or batch scrap. Finally, operators need to be close to high-speed equipment for observation, posing certain safety risks. Therefore, manual monitoring is essentially a passive and inefficient remedial measure, unable to provide real-time, automatic, and accurate early warning of scrap blockage, and failing to meet the basic requirements of automation and reliability in modern intelligent manufacturing.

[0025] To reduce the risk of waste material blockage at the source, the industry generally adopts structural optimization measures during the mold design stage, such as optimizing the trimming line layout, expanding the width of the waste material slide, improving the slide angle, and adding guide plates or material distribution structures to improve the smoothness of waste material sliding. Nevertheless, this method still has significant limitations: on the one hand, due to the complex and ever-changing body shapes of modern automobiles and the strict stamping process constraints, the waste material generated by trimming often presents irregular shapes, excessively large or long sizes, making it difficult to completely avoid jamming problems through structural design; on the other hand, the internal space of the mold is already compact, and it needs to take into account multiple functions such as strength, guidance, and ejection, leaving very little room for modifying the waste material slide; in addition, to save costs and space, waste material from multiple trimming processes is often designed to share a single slide cavity, which can easily lead to overlapping, interference, and blockage during the sliding process, a problem that is difficult to completely solve through structural optimization; more importantly, even with careful design, it is impossible to guarantee that blockage will not occur under all production conditions (such as fluctuations in material properties, changes in lubrication conditions, and deviations in equipment precision), and accidents still occur from time to time in actual production. Therefore, although mold structure optimization is a fundamental approach, its effectiveness is limited and it cannot fundamentally eliminate waste blockage. Other monitoring technologies are still needed as a supplement.

[0026] In recent years, some high-end stamping production lines have attempted to introduce AI vision inspection systems to monitor waste discharge status. This system uses industrial cameras installed at the waste chute outlet to capture images and employs artificial intelligence algorithms to identify whether waste is sliding out normally, thereby determining if a blockage has occurred. However, this technology faces multiple obstacles in practical applications: First, the system hardware cost is extremely high, including high-definition industrial cameras, dedicated light sources, image acquisition cards, industrial control computers, AI algorithm software, and system integration, resulting in a low return on investment and making it difficult to promote on a large scale in the industry. Second, for a large number of old stamping equipment in service, adding a vision system requires complex mechanical and electrical modifications, lacks standard interfaces, and is difficult and time-consuming to construct, and may affect the original functions of the equipment. Third, the stamping workshop environment is harsh, with oil mist, dust, vibration, and electromagnetic interference, which can easily lead to camera lens contamination, image blurring, or signal distortion, affecting recognition accuracy and long-term system stability. Fourth, the scrap chute exit positions, directions, and structural forms of different molds are diverse (such as vertical drop, oblique sliding, multi-stage chutes, etc.), making it difficult to standardize the deployment of the vision system. It needs to be designed separately for each point, resulting in poor versatility. Fifth, system maintenance is complex, relying on professional technicians for algorithm optimization and hardware maintenance, and the ability to quickly recover on-site is weak. In conclusion, although AI visual inspection technology is advanced, it is difficult to become a universal solution due to problems such as high cost, high complexity, and low adaptability.

[0027] To address the aforementioned issues, this application aims to provide an innovative solution that integrates low cost, high reliability, easy installation, maintenance-free operation, and universal applicability. This solution enables real-time monitoring and automatic shutdown protection of mold waste discharge status without relying on expensive hardware and complex systems, fundamentally solving this long-standing industry problem that has plagued stamping production.

[0028] Specifically, this application provides an integrated, modular, and highly practical device and method for detecting waste blockage in automotive stamping die. Its technical features include: a detection module consisting of a diffuse reflection sensor installed near the die waste inlet; real-time sensing of the waste slide's status using infrared light reflection principles; and a time relay determining whether the interruption continues beyond a preset threshold when waste accumulation blocks light, effectively distinguishing between normal sliding and abnormal blockage. The control module integrates a terminal box, a time relay, and an encoder (such as a binary rotary switch) to perform signal processing, delay judgment, and die encoding settings, supporting rapid switching and identification of multiple dies. A magnetic connector is used to attach the sensor to the die surface. The non-destructive, detachable fixing mechanism facilitates repeated use between different molds and is easy to install. The connection module adopts standardized interfaces such as multi-core connecting wires, connector assemblies, and connector assemblies to ensure a fast and reliable electrical connection between the detection device and the stamping equipment control system. When the duration of blockage reaches the threshold, the control module immediately sends a stop signal to the stamping equipment and triggers an alarm to prevent the fault from escalating. The overall solution, with its low cost, high reliability, strong environmental adaptability (the sensor has shockproof, waterproof, dustproof, and oil-proof characteristics), and ease of maintenance, solves the shortcomings of existing technologies such as low efficiency of manual monitoring, high cost of AI vision, and incomplete mold structure optimization, and realizes automated, accurate, and real-time monitoring and protection against waste blockage.

[0029] First, the automobile stamping die waste blockage detection device provided in this application embodiment will be described in detail below with reference to the accompanying drawings.

[0030] Reference Figures 1 to 3 The automotive stamping die waste blockage detection device provided in this application includes a detection module, a control module, a connection module, and a fixing module.

[0031] In some embodiments of this application, the detection module is used to detect the blockage status of waste in the mold waste chute, including at least one diffuse reflection sensor 101. The diffuse reflection sensor 101 is installed next to the mold waste inlet and is configured to emit infrared light and receive reflected signals. When the waste 100 is blocked, the waste 100 blocks the infrared light to cut off the reflected signal.

[0032] The core function of the detection module is to monitor the discharge status of the mold scrap chute in real time and non-contactly to determine the risk of blockage. This module mainly consists of at least one diffuse reflection sensor 101, installed beside the mold scrap inlet. Its working principle is based on the emission and reflection mechanism of infrared light: the sensor continuously emits a beam of infrared light. When the scrap chute is unobstructed, the light undergoes diffuse reflection at the chute outlet or the metal surface below, and part of the reflected light is received by the sensor, forming a stable "signal present" state. However, when scrap begins to block the chute due to jamming or accumulation, the accumulated metal scrap blocks the propagation path of the infrared light, preventing the reflected signal from returning to the sensor, thus producing a "signal interruption" state. This non-contact detection method avoids wear and malfunctions caused by mechanical contact and has the advantages of fast response speed and long lifespan. By monitoring the continuity of the reflected signal, the detection module can detect abnormal scrap discharge in real time, providing raw data for subsequent judgment and control, which is the foundation for achieving automated monitoring.

[0033] In some embodiments of this application, the diffuse reflection sensor 101 is a PNP three-line infrared switch that detects the spatial dimensions of the mold waste slide at a distance that is adapted to the distance. The diffuse reflection sensor 101 is provided with a protective shell to make it shockproof, waterproof, dustproof and oil-proof.

[0034] The diffuse reflection sensor 101 is the core execution unit of the detection module, and its selection and performance directly determine the reliability and adaptability of the entire detection system. This application preferably uses a PNP three-wire infrared switch with three leads: power, signal output, and ground. The output type is active high, facilitating compatibility with subsequent control circuits. The infrared beam emitted by this sensor has good directionality and anti-interference capabilities, enabling stable operation in the complex electromagnetic environment of the stamping workshop. Its detection distance can be adapted to the spatial dimensions of different mold scrap chutes, ensuring that the light effectively covers the chute exit area, avoiding false triggering due to insufficient distance and reducing sensitivity due to excessive distance. More importantly, the sensor is designed with a protective shell, possessing anti-vibration, waterproof, dustproof, and oil-proof characteristics, capable of withstanding severe vibrations, coolant splashes, metal dust, and lubricating grease generated during stamping, ensuring that its performance does not degrade or fail due to environmental factors during long-term operation. Furthermore, its non-contact detection method avoids physical modifications to the mold structure, achieving real-time and accurate sensing of the scrap status.

[0035] In some embodiments of this application, the control module is electrically connected to the detection module, including a terminal box 201. The terminal box 201 is provided with wiring terminals 204. The terminal box 201 is provided with a time relay 202 and an encoder 203. The time relay 202 is used to configure a preset time threshold, and the encoder 203 is used to set the mold code.

[0036] The control module is responsible for logically judging and processing the signals collected by the detection module, and executing corresponding control actions according to preset conditions. This module is electrically connected to the detection module, receives the raw signal from the diffuse reflection sensor 101, and achieves intelligent control through the internally integrated time relay 202 and encoder 203. Its core function is not simply to respond to signal interruptions, but to avoid malfunctions caused by brief obstructions (such as the momentary shading of light due to normal scrap sliding) by introducing time-dimensional judgment, thereby significantly improving the stability and accuracy of the system. The control module integrates internal components and connects to external components through the terminal box 201. The terminal box 201, as an electrical hub, not only houses the time relay 202 and encoder 203, but also provides standardized wiring terminals 204 for easy on-site installation, debugging, and maintenance. When the system determines that scrap blockage has reached a preset threshold, the control module sends a stop signal to the stamping equipment's control system through the terminal box 201, achieving active protection. This is a key link in the entire system's automated decision-making and execution.

[0037] In some embodiments of this application, the time relay 202 is a 24V DC relay. The time threshold is determined through software simulation based on the size of the waste chute space and the waste sliding method, adapting to the waste sliding speed under different stamping processes.

[0038] The time relay 202 is the core component of the control module for intelligent judgment. Its function is to introduce the key parameter of "time threshold," enabling the system to distinguish between normal operating conditions and abnormal blockages. In actual stamping processes, the scrap briefly blocks infrared light as it slides down. If the system stops immediately based solely on signal interruption, it will lead to frequent false alarms and unplanned shutdowns, severely impacting production efficiency. The time relay 202, by presetting a reasonable time threshold (e.g., 30 seconds), only determines a "real blockage" and triggers subsequent actions when the reflected signal is continuously blocked for more than this time. This time threshold can be predetermined through CATIA software simulation based on the scrap chute space size, scrap shape, and sliding speed of different molds, ensuring the system adapts to various stamping processes. This delayed judgment mechanism effectively filters out instantaneous interference and brief blockages during normal sliding, greatly improving detection accuracy and system robustness. It is a key technical design to avoid malfunctions and ensure production continuity.

[0039] In some embodiments of this application, the encoder 203 is a binary rotary switch disposed on the surface of the terminal box 201. By switching the switch state, an encoding corresponding one-to-one with the mold is set, enabling rapid identification when multiple molds are used together. When changing molds, only the state of the binary rotary switch needs to be switched to complete the device adaptation, without the need for rewiring.

[0040] The encoder 203 is a key component for enabling shared and rapid identification of multiple molds. Its function is to assign a unique electronic identifier to each mold, ensuring that the detection device can be switched between different molds without requiring rewiring or complex configuration. Since stamping workshops typically have multiple sets of molds, each with different scrap chute layouts and codes, rewiring or program adjustments every time a mold is changed would significantly reduce efficiency. The encoder 203 is mounted on the surface of the terminal box 201. By switching the binary state of the switch (e.g., setting mold code "18" to open switches 2 and 16), a code corresponding to the current mold can be quickly set. When a mold is changed, the operator only needs to rotate the switch to the corresponding code to complete the system adaptation. The control module then identifies the current mold and calls the corresponding detection logic or parameters. This design achieves "plug-and-play" functionality and standardized management of the detection device, significantly improving the system's flexibility and maintainability, and is a crucial guarantee for efficient application in multi-mold environments.

[0041] In some embodiments of this application, the connection module includes a multi-core connecting wire, which electrically connects the detection module and the control module, and electrically connects the control module and the control system of the stamping equipment.

[0042] In some embodiments of this application, the connection module further includes a connector assembly 304 and a connector assembly 302. The connector assembly 304 is used for quick plug-in connection between the terminal box 201 and the workbench of the stamping equipment. The connector assembly 302 has a 4-pin 4-hole structure and is adapted to the signal transmission of multi-core connecting wires.

[0043] The connection module is responsible for establishing stable and reliable electrical connections between various functional modules and between the detection device and external stamping equipment. This module consists of multi-core connecting cables (such as 4-core connecting cables 301 and 50-core connecting cables 303), connector assemblies 304, and connector assemblies 302, employing a standardized and modular design to ensure efficient signal and power transmission. The multi-core connecting cables (such as 4-core connecting cables 301) connect the detection module and the control module (terminal box 201), transmitting detection signals and power. Terminal blocks 204 provide safe and secure crimping points for easy on-site wiring and maintenance. Connector assemblies 304 enable quick-plug connections between the terminal box 201 and the stamping equipment workbench, achieving "plug and play" and significantly reducing installation and disassembly time. Connector assemblies 302 (4-pin, 4-hole structure) ensure stable and reliable signal transmission from the multi-core connecting cables and possess excellent waterproof, dustproof, and vibration-resistant properties. In addition, the connection module also includes quick-plug connectors 305. The design of the entire connection module takes into account both reliability and convenience, ensuring the integrity of signal transmission while supporting rapid deployment and maintenance, and forming the foundation for realizing system integration and engineering applications.

[0044] In some embodiments of this application, the fixing module includes a magnetic clamp 102 that detachably fixes the diffuse reflection sensor 101 to the mold waste inlet.

[0045] The fixing module is a key support structure for enabling rapid installation and reuse of the detection device, with its core component being the magnetic clamp 102. This clamp uses strong magnetic force to firmly fix the diffuse reflection sensor 101 to a preset position next to the mold scrap inlet, eliminating the need for drilling, welding, or bolt fixing, achieving true "non-destructive installation." This design simplifies the installation process; operators only need to place the sensor in place and clamp it to complete the fixation. More importantly, the magnetic strength of the magnetic clamp 102 is designed to be no less than a preset magnetic force threshold, ensuring that the sensor will not shift or fall off under the strong vibration environment generated during the operation of the stamping equipment, thus guaranteeing the stability of the detection. It can be easily disassembled and transferred to other locations for use, achieving "one machine for multiple uses" and cyclic switching, significantly reducing equipment investment costs and management complexity. This is a key innovation of this application in achieving low-cost and highly flexible applications.

[0046] In some embodiments of this application, the magnetic force of the magnetic clamp 102 is not lower than a preset magnetic force threshold, ensuring that the diffuse reflection sensor 101 has no displacement under the vibration environment of the stamping equipment and that the diffuse reflection sensor 101 is not damaged during disassembly.

[0047] Firstly, in the stamping production environment, equipment (especially large presses) generates severe periodic vibrations during operation, with vibration frequencies and accelerations far exceeding those of general industrial equipment. If the sensor experiences even a slight displacement or loosening during detection, it will directly cause a shift in the infrared light emission angle, potentially leading to the following serious consequences: First, the beam that should cover the slide outlet deviates from the target area, resulting in ineffective detection of waste material obstruction and "missed detections"; second, signal jitter due to beam instability triggers "false alarms"; third, long-term vibration causes metal fatigue or wear between the sensor and the mounting point, eventually leading to detachment. This design, by setting a "magnetic strength not lower than a preset magnetic threshold," quantifies the performance requirements of the magnetic clamp 102, ensuring that its adsorption force is sufficient to resist the vibration and impact of the stamping equipment under maximum operating load. This allows the sensor to remain in the preset installation position and angle during continuous operation for hours or even days, thus guaranteeing stable emission and reflection of the infrared beam and providing the most fundamental and crucial physical guarantee for the accuracy of the detection signal and the stability of the system operation.

[0048] Secondly, one of the core advantages of this application is "non-destructive installation," meaning no drilling, welding, or bolting is required. However, if the fixing method is unreliable, or if the sensor is damaged during disassembly, the meaning of "non-destructive" will be greatly diminished. This design not only emphasizes the reliability of "displacement-free" installation but also explicitly requires "no damage to the diffuse reflection sensor 101 during disassembly," reflecting consideration for the entire lifecycle management of the equipment. The magnetic strength of the magnetic clamp 102 is carefully designed to provide sufficient attraction to resist vibration without causing disassembly difficulties due to excessive magnetic force or damaging the sensor housing or connecting wires due to forced prying during disassembly. This "just the right amount of magnetic force" ensures that the sensor remains intact during frequent installation, disassembly, and switching, extending its service life, reducing maintenance costs, and truly achieving the economic goals of "multi-purpose use" and "cyclic switching."

[0049] Furthermore, stamping dies are made of various materials (such as cast iron and alloy steel) and have different surface conditions (such as oil stains, rust, and coatings), and the space for installation is limited. Installation conditions vary greatly depending on the die and the slide rail. This design ensures that the magnetic clamp 102 operates reliably under various typical working conditions by setting a minimum requirement of "not lower than the preset magnetic force threshold." This improves the system's adaptability to complex field environments, reduces the risk of failure due to unsatisfactory installation conditions, and enhances the versatility and robustness of the device, enabling its widespread application in stamping equipment and dies from different manufacturers, models, and eras.

[0050] In some embodiments of this application, when the reflected signal of the diffuse reflection sensor 101 is continuously blocked by the waste material for a period of time that reaches the preset time threshold of the time relay 202, the terminal box 201 of the control module sends a stop signal to the control system of the stamping equipment, controls the stamping equipment to stop working and triggers an alarm; the stop signal is transmitted through the multi-core connection line (such as the 50-core connection line 303) of the connection module to ensure that the stamping equipment stops in time before the waste material blockage expands, thus avoiding damage to the mold.

[0051] Traditionally, waste material blockage issues have relied primarily on manual inspections or post-incident detection, a typical "passive response" model. Intervention is only implemented after a fault occurs, often resulting in mold damage or mass scrap. This design, however, introduces a "time threshold" judgment mechanism, constructing an automated fault identification and response closed loop: once waste material is detected obscuring the infrared signal, the system starts timing; if the obscuring time exceeds a preset threshold (e.g., 30 seconds), it is determined to be a "real blockage" rather than a momentary disturbance, immediately triggering a shutdown and alarm. This mechanism proactively cuts off the production process in the early stages of a fault, before serious consequences arise, eliminating potential major accidents in their infancy. It fundamentally changes the fault response mode in stamping production, upgrading from "post-incident remediation" to "pre-incident prevention," significantly improving production safety.

[0052] During the stamping process, the scrap material briefly blocks infrared light as it slides down normally. If the system stops immediately based solely on signal interruption, it will lead to frequent malfunctions and unplanned shutdowns, severely impacting production cycle time and equipment OEE (Overall Equipment Effectiveness). This design cleverly solves this problem by introducing a delay-based judgment function into the time relay 202. The preset time threshold (e.g., 30 seconds) is much longer than the time required for the scrap material to slide down normally (usually only a few seconds). Therefore, the system can effectively filter out the momentary blocking signal when the scrap material passes through normally, responding only to continuous abnormal blockages. This "delay confirmation" mechanism significantly improves the accuracy of detection and the robustness of the system, avoiding false alarms caused by environmental interference, scrap material vibration, or brief jamming. It ensures that safety is guaranteed without sacrificing production efficiency, achieving a balance between safety and efficiency.

[0053] This design upgrades simple "present / absent" signal detection to a "continuous" judgment incorporating a time dimension, giving the system intelligent decision-making capabilities. The time threshold is not set arbitrarily, but is based on in-depth analysis of parameters such as the spatial structure of the waste chute, the shape and size of the waste, and its descent speed for different molds. It can be pre-optimized through software simulation and then fine-tuned based on actual on-site operating data. This precise setting based on process parameters allows the system to adapt to the complex working conditions of different molds and products, achieving personalized monitoring for each mold. For example, for molds with longer chutes and slower waste descent, the threshold can be appropriately extended; while for molds with compact spaces and prone to clogging, the threshold can be shortened to improve response sensitivity. This flexibility and adaptability demonstrate the system's level of intelligence.

[0054] This design not only achieves fault detection but also constructs a complete safety protection closed loop through two actions: "sending a stop signal" and "triggering an alarm." The stop signal is directly connected to the stamping equipment's control system (PLC), forcing the equipment to stop and physically cutting off the possibility of fault escalation. This prevents serious mechanical damage such as die tearing and punch breakage caused by abnormal closure of the upper and lower dies due to waste material accumulation. The alarm trigger notifies the operator through an audible and visual alarm, the equipment's HMI interface, or the MES system, enabling them to quickly locate and handle the fault. This dual mechanism of "automatic shutdown + manual response" ensures that faults can be handled promptly and effectively, minimizing downtime and maintenance costs.

[0055] If waste material blockage is not detected in time, it can lead to product rework at best, and severe mold damage at worst, with single repair costs potentially reaching hundreds of thousands of yuan, accompanied by prolonged production downtime. This design effectively avoids such major accidents through timely and accurate shutdown protection, directly reducing mold repair costs and economic losses caused by production stoppages. Furthermore, due to the system's low cost and simple maintenance, its investment is far lower than the potential losses, resulting in a very high return on investment. In addition, by reducing unplanned downtime, it indirectly improves equipment utilization and production delivery capacity, enhancing the company's market competitiveness.

[0056] This design combines low-cost sensor technology with time-based logic control, achieving complex safety monitoring functions with a minimalist hardware architecture. It represents a typical application of industrial automation and intelligent manufacturing concepts at the grassroots production unit level. It achieves real-time monitoring and intelligent decision-making for key process steps without relying on expensive AI vision systems or complex software platforms, providing a practical technical path for the digital and intelligent upgrading of traditional stamping workshops. Its modular and reusable design also facilitates plant-wide deployment, forming a standardized fault prevention system and driving the entire production system towards a higher level of automation and intelligence.

[0057] In conclusion, this technical design is not only the core innovation of this application, but also a technological breakthrough with significant engineering value and industry application implications. With extremely high reliability, precision, and economy, it solves the long-standing problem of waste material blockage in the stamping industry, achieving an optimal balance between safety, efficiency, and cost, and providing a solid technical guarantee for high-quality, high-efficiency, and high-reliability production in modern automobile manufacturing.

[0058] In some embodiments of this application, the device is suitable for the mold trimming process in which multiple waste materials share a cavity. By installing diffuse reflection sensors 101 next to the inlets of different waste material slides in the same mold, multi-channel synchronous detection can be achieved.

[0059] Firstly, in automotive stamping die design, especially in the trimming process of large body panels (such as side panels, floor panels, and door panels), due to the compact die structure, limited space, and cost control requirements, waste generated from multiple trimming stations is often designed to be discharged centrally through the same cavity chute. While this "multiple wastes sharing one cavity" design saves die space and manufacturing costs, it introduces a very high risk of blockage: wastes of different shapes, sizes, and weights are prone to interference, overlapping, and jamming during the sliding process. Especially under high-speed continuous stamping, the inconsistent sliding rhythm of wastes easily leads to "bridging" or "accumulation" phenomena in narrow sections of the chute. Traditional single-point monitoring struggles to cover all risk sources. This design, however, by installing independent diffuse reflection sensors 101 next to each waste chute inlet, achieves independent monitoring of each waste discharge channel, fundamentally solving the monitoring blind spot problem caused by "shared chute." It transforms the previously uncontrollable multi-factor superposition risk into an independent unit that can be monitored and managed individually, representing a precise strike against this persistent industry problem.

[0060] Secondly, by equipping each waste chute with an independent diffuse reflection sensor 101, the system can simultaneously monitor the discharge status of multiple wastes, forming a parallel monitoring network. This means that if any chute becomes blocked, the corresponding sensor will interrupt its signal due to the waste blocking the infrared light, thus triggering a delayed judgment by the time relay 202. This parallel architecture ensures full coverage of all potential blockage points, avoiding missed detections due to single sensor failure or insufficient monitoring points. Simultaneously, because the detection logic of each channel is independent and does not interfere with each other, the overall reliability of the system is significantly improved. Even if one channel experiences temporary interference due to environmental factors, other channels can still operate normally, and the system still possesses basic protection capabilities, exhibiting good fault tolerance and robustness.

[0061] Furthermore, the amount of waste generated and the layout of the slides vary greatly depending on the trimming process of different molds. Some molds have only 1-2 waste slides, while complex molds may have 5-6 or even more. This design adopts a modular and scalable architecture, allowing sensors to be installed next to any number of slide inlets according to actual needs without changing the core structure of the system. This flexibility enables the device to adapt to various mold types, from simple to complex, and it has strong versatility and adaptability. Users can selectively deploy sensors on high-risk slides based on the specific structure of the mold and historical fault data, achieving "on-demand configuration," which ensures monitoring effectiveness while avoiding unnecessary cost investment. This "plug-and-play" scalability is an important foundation for the system's engineering application and large-scale promotion.

[0062] Finally, when the system triggers a shutdown alarm, since each sensor corresponds to a specific waste chute, the control module can accurately locate the specific position of the blockage based on the signal source. Instead of checking each chute one by one, the operator can directly go to the fault point for cleaning and inspection, greatly shortening the fault diagnosis and recovery time. This "visualization of the fault point" ability significantly improves the on-site maintenance efficiency, reduces the unplanned downtime, and is of great significance for ensuring the production rhythm and OEE (Overall Equipment Effectiveness). At the same time, the alarm data accumulated over a long period for each channel can also be used to analyze the weak links of the die, providing data support for subsequent die optimization and process improvement.

[0063] In the scenario of "multiple wastes sharing one cavity", the blockage of one chute may trigger a chain reaction, resulting in the paralysis of the entire chute system. Through multi-channel synchronous detection, this design constructs a three-dimensional and all-round safety protection barrier. It can not only detect the blockage of a single chute in a timely manner but also provide a higher-level warning when multiple chutes show abnormalities simultaneously (such as identifying the interruption of multiple signals through the encoder 203 or the upper-level system), providing more comprehensive decision-making information for the operator. This multi-point linkage monitoring mode upgrades the system protection ability from "point" to "surface", significantly enhancing the ability to handle complex fault scenarios and effectively preventing small faults from evolving into major accidents.

[0064] It is worth noting that while achieving multi-channel monitoring, this design still maintains the low-cost feature of the system. The diffuse reflection sensor 101 is itself inexpensive and easy to install (through the magnetic wiring clip 102), and the control module (time relay 202, terminal box 201) can support multi-channel signal input without the need to configure an independent controller for each channel. This "one control for multiple transmissions" architecture maximally controls the hardware cost and system complexity while ensuring the functional integrity, perfectly fitting the core design concept of this application of "low cost, high efficiency, and easy installation". It proves that through ingenious system design and reasonable technology selection, it is completely possible to effectively monitor complex industrial scenarios without relying on expensive AI vision systems.

[0065] To sum up, this design is not only a technical response to the specific process problem of "multiple wastes sharing one cavity" but also a systematic innovation with broad applicability and far-reaching influence. Through multi-channel synchronous detection, it realizes the comprehensive, accurate, and real-time monitoring of the complex die waste discharge process, effectively solves the long-existing monitoring blind spots and chain fault risks in the industry, and significantly improves the safety, stability, and efficiency of stamping production. Its modular, scalable, and low-cost characteristics make it have extremely high engineering promotion value, providing a practical technical path for promoting the development of stamping automation to a higher level.

[0066] Secondly, refer to Figure 4 This application provides a method for detecting blockage of automotive stamping die scrap, applied to the aforementioned automotive stamping die scrap blockage detection device, including the following steps: Step S110: Fix the diffuse reflection sensor to a preset position next to the mold waste inlet using a magnetic clamp, so that the infrared light from the diffuse reflection sensor covers the outlet area of ​​the waste chute.

[0067] In step S110, the sensor is fixed to a preset position next to the mold waste inlet by using a magnetic clamp, which achieves "non-destructive installation" without drilling, welding or bolting the mold body. This fundamentally protects the structural integrity and surface accuracy of the expensive mold, avoids introducing new quality risks due to the installation of the detection device, and ensures that the diffuse reflection sensor can perform the monitoring task in the best posture and position.

[0068] More importantly, this step explicitly requires that the sensor's infrared beam must cover the exit area of ​​the waste chute, which directly determines the sensitivity and reliability of the detection. Incomplete coverage may prevent timely detection of early waste accumulation; if the beam is misaligned, it may cause continuous obstruction due to mis-illumination of the mold structure, leading to false alarms. Therefore, the precise "preset position" is determined based on a comprehensive analysis of the mold structure, the waste cascading trajectory, and the sensor's detection range, ensuring that the infrared beam can effectively penetrate the critical area of ​​the waste chute, providing an accurate and stable physical basis for subsequent signal acquisition. The "detachable" feature of this step also supports rapid switching and cyclical use of the sensor between different molds, significantly improving equipment utilization and economy.

[0069] Step S120: Electrically connect the control module to the diffuse reflection sensor and the control system of the stamping equipment via the connection module.

[0070] In step S120, a reliable electrical connection is established between the detection device and external equipment through a connection module (including multi-core connecting wires, terminals, connector assemblies, joint assemblies, and quick-plug devices). This step connects the detection module (diffuse reflection sensor) to the control module (terminal box, time relay, encoder), ensuring that the raw signals collected by the sensor can be transmitted to the control unit for processing without loss and with low latency. Simultaneously, the control module is connected to the control system of the stamping equipment (such as a PLC), providing a physical channel for subsequent sending of stop commands and alarm signals. This standardized and modular connection method not only ensures the stability and anti-interference capability of signal transmission (especially in the harsh environment of a stamping workshop with strong electromagnetic fields, oil stains, and vibrations), but also achieves rapid "plug-and-play" deployment. The application of industrial-grade interfaces such as connector assemblies and joint assemblies ensures the connection's waterproof, dustproof, and anti-loosening performance, maintaining reliable connection even under conditions of frequent equipment movement or vibration. This step is the foundation for realizing system integration and engineering applications, integrating dispersed hardware units into a fully functional automated monitoring system.

[0071] Step S130: Set the current mold code through the encoder of the control module, and preset the time threshold for judging waste blockage through the time relay.

[0072] In step S130, the system is parameterized using encoders and time relays to adapt to the specific needs of different molds. By setting a unique code for the current mold using an encoder (such as a binary rotary switch), rapid identification and matching in multi-mold environments is achieved, avoiding wiring confusion or program resets caused by mold changes, and supporting "one machine for multiple uses" and efficient switching. More importantly, by presetting a time threshold for waste blockage judgment using time relays, the system introduces a "delayed confirmation" mechanism, effectively distinguishing between momentary obstruction during normal waste sliding and true continuous blockage. This time threshold is not fixed but can be flexibly adjusted based on the waste slide length, angle, waste shape, and historical operating data of different molds (e.g., fine-tuning on-site after software simulation optimization) to ensure the accuracy of the judgment logic. This parameterized configuration gives the system a high level of adaptability and intelligence; it is no longer a simple "light / no light" switch but a "brain" capable of making intelligent decisions based on specific process conditions, a key guarantee for achieving high reliability and low false alarm rate.

[0073] In step S140, after starting the stamping equipment, the diffuse reflection sensor continuously emits infrared light and detects the reflection signal. When there is no blockage in the mold scrap chute, the infrared light is unobstructed and the reflection signal is normal; when the scrap is blocked, the scrap blocks the infrared light and the reflection signal is interrupted.

[0074] In step S140, continuous and dynamic sensing of the mold scrap discharge status is initiated and maintained. During the operation of the stamping equipment, the diffuse reflection sensor continuously emits infrared light and detects its reflection signal status in real time: when the scrap chute is unobstructed, the light undergoes diffuse reflection at the chute outlet or the metal surface below, the sensor receives a stable signal, and the system determines it to be "normal"; when scrap begins to block the chute due to jamming or accumulation, the accumulated metal scrap will block the propagation path of the infrared light, causing the reflection signal to be interrupted, and the system captures this "abnormal" state change. This non-contact, real-time, and continuous monitoring method can detect abnormalities at the first moment of a fault (the instant when scrap begins to accumulate), gaining valuable time for subsequent judgment and response. This step realizes the transformation from "static configuration" to "dynamic monitoring," marking the system's transition from "standby" to "working" state, and providing continuous and uninterrupted data flow support for the entire safety protection system.

[0075] In step S150, the duration of the interruption of the reflected signal is monitored in real time by the time relay. When the duration reaches the time threshold, the terminal box of the control module sends a stop signal to the control system of the stamping equipment, controls the stamping equipment to stop working immediately, and triggers an audible and visual alarm. When the reflected signal is restored, the time relay is reset and the detection process restarts.

[0076] In step S150, intelligent judgment based on real-time monitoring data and triggering corresponding safety protection actions is the final step in achieving "active protection." This step uses a time relay to monitor the duration of the reflected signal interruption in real time. When this time reaches a preset time threshold, it is determined to be a "real blockage" rather than a momentary interference. The terminal box of the control module immediately sends a stop signal to the control system of the stamping equipment, forcing the equipment to stop running and physically cutting off the possibility of the fault escalating, preventing serious damage to the mold due to waste accumulation. At the same time, an audible and visual alarm is triggered, notifying the operator to intervene quickly, forming a dual guarantee of "automatic shutdown + manual response." This mechanism effectively avoids unplanned shutdowns caused by malfunctions and prevents major accidents caused by missed detections, achieving a balance between safety and efficiency. In addition, when the blockage is cleared and the reflected signal is restored, the time relay automatically resets, and the system restarts the detection process, restoring normal operation without manual intervention, demonstrating the system's level of automation and intelligence. This step is the final manifestation of the closed-loop control of the entire detection method, ensuring that the system can reliably and decisively execute protection actions at critical moments, minimizing production risks and economic losses.

[0077] In summary, the automotive stamping part die waste blockage detection device and method provided in this application have the following technical effects.

[0078] First, this device achieves accurate identification of waste blockage by employing a collaborative mechanism between a diffuse reflection sensor and a time relay. The sensor monitors the infrared reflection signal at the waste chute outlet in real time using a non-contact method, and combines this with a time relay to make a delayed judgment based on a preset time threshold. This effectively distinguishes between the momentary obstruction caused by normal waste sliding and the continuous interruption caused by a true blockage, fundamentally solving the problems of high false alarm rate and slow response of traditional detection methods, and significantly improving the accuracy of detection and the stability of the system.

[0079] Secondly, the device employs magnetic clamps to achieve non-destructive installation and rapid disassembly of the sensor. This not only avoids any physical modification to the mold body, protecting the mold's precision and integrity, but also supports flexible switching and cyclic use between different molds, greatly improving the equipment's versatility and economy. The design, with a magnetic force strength not lower than a preset threshold, ensures long-term stable operation of the sensor under the severe vibration environment of the stamping equipment, without displacement or damage, guaranteeing continuous reliability of the detection.

[0080] Furthermore, by installing sensors at the inlets of different waste chutes within the same mold, multi-channel synchronous detection is achieved. This is particularly suitable for complex working conditions where multiple waste materials share a single cavity, comprehensively covering various blockage risk points, avoiding monitoring blind spots, and constructing a three-dimensional safety protection network. By using encoders (such as binary rotary switches) to set mold codes, rapid identification and parameter matching in multi-mold environments are achieved. System adaptation can be completed without rewiring, significantly improving on-site deployment and maintenance efficiency.

[0081] Furthermore, the device adopts a modular design, enabling quick plug-and-play connections through standardized interfaces such as connector assemblies and joint assemblies, simplifying the installation and commissioning process. The control module features an integrated design with clearly defined functions and easy maintenance. The entire system is vibration-proof, waterproof, dustproof, and oil-proof, enabling it to adapt to the harsh industrial environment of the stamping workshop and operate stably for extended periods.

[0082] Finally, when continuous blockage reaches a preset threshold, the system automatically sends a shutdown signal to the stamping equipment and triggers an audible and visual alarm, achieving proactive safety protection. This effectively prevents mold damage, batch scrap, and production accidents, ensuring equipment and personnel safety and reducing maintenance costs and downtime losses. The method has a clear process and rigorous logic, forming a complete closed loop from installation, configuration, monitoring to response. It is easy to operate and readily applicable.

[0083] In summary, this application provides a highly reliable, adaptable, and easy-to-maintain waste blockage solution with extremely low manufacturing costs and simple technical barriers. It effectively compensates for the deficiencies of existing technologies such as manual monitoring, mold optimization, and AI vision, and effectively improves the automation level, operational safety, and overall economic benefits of stamping production lines. It has outstanding practical value and broad prospects for promotion and application.

[0084] In some alternative embodiments, the functions / operations mentioned in the block diagrams may not occur in the order shown in the operation diagrams. For example, depending on the functions / operations involved, two consecutively shown blocks may actually be executed substantially simultaneously, or the blocks may sometimes be executed in reverse order. Furthermore, the embodiments presented and described in the flowcharts of this application are provided by way of example to provide a more comprehensive understanding of the technology. The disclosed methods are not limited to the operations and logic flows presented herein. Alternative embodiments are contemplated in which the order of various operations is changed and sub-operations described as part of a larger operation are executed independently.

[0085] Furthermore, although this application is described in the context of functional modules, it should be understood that, unless otherwise stated, one or more of the functions and / or features may be integrated into a single physical device and / or software module, or one or more functions and / or features may be implemented in a separate physical device or software module. It is also understood that a detailed discussion of the actual implementation of each module is unnecessary for understanding this application. Rather, given the properties, functions, and internal relationships of the various functional modules in the apparatus disclosed herein, the actual implementation of the module will be understood within the scope of ordinary skill of an engineer. Therefore, those skilled in the art can implement the application set forth in the claims using ordinary skill. It is also understood that the specific concepts disclosed are merely illustrative and are not intended to limit the scope of this application, which is determined by the full scope of the appended claims and their equivalents.

[0086] If a function is implemented as a software functional unit and sold or used as an independent product, it can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several programs to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods of the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0087] The logic and / or steps represented in the flowchart or otherwise described herein, for example, can be considered as a sequential list of executable programs for implementing logical functions, and can be embodied in any computer-readable medium for use by, or in conjunction with, a program execution system, apparatus, or device (such as a computer-based system, a processor-included system, or other system that can retrieve and execute a program from or in conjunction with such a program execution system, apparatus, or device). For the purposes of this specification, "computer-readable medium" can mean any means that can contain, store, communicate, propagate, or transmit a program for use by or in conjunction with a program execution system, apparatus, or device.

[0088] More specific examples (a non-exhaustive list) of computer-readable media include: electrical connections (electronic devices) having one or more wires, portable computer disk drives (magnetic devices), random access memory (RAM), read-only memory (ROM), erasable and editable read-only memory (EPROM or flash memory), fiber optic devices, and portable optical disc read-only memory (CDROM). Furthermore, computer-readable media can even be paper or other suitable media on which programs can be printed, because programs can be obtained electronically, for example, by optically scanning the paper or other media, followed by editing, interpreting, or, if necessary, processing in a suitable manner, and then stored in computer memory.

[0089] It should be understood that various parts of the present invention can be implemented in hardware, software, firmware, or a combination thereof. In the above embodiments, multiple steps or methods can be implemented in software or firmware stored in memory and executed by a suitable program execution system. For example, if implemented in hardware, as in another embodiment, it can be implemented using any one or a combination of the following techniques known in the art: discrete logic circuits having logic gates for implementing logical functions on data signals, application-specific integrated circuits (ASICs) having suitable combinational logic gates, programmable gate arrays (PGAs), field-programmable gate arrays (FPGAs), etc.

[0090] In the foregoing description of this specification, the reference to terms such as "one embodiment / implementation," "another embodiment / implementation," or "certain embodiments / implementations," etc., indicates that a specific feature, structure, material, or characteristic described in connection with an embodiment or example is included in an embodiment or example of the present invention. In this specification, the illustrative expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or characteristics described may be combined in any suitable manner in one or more embodiments or examples.

[0091] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

[0092] The above is a detailed description of the preferred embodiments of the present invention. However, the present invention is not limited to the embodiments. Those skilled in the art can make various equivalent modifications or substitutions without departing from the spirit of the present invention. All such equivalent modifications or substitutions are included within the scope defined by the claims of the present invention.

Claims

1. A device for detecting blockage of waste material in automotive stamping die, characterized in that, include: The detection module is used to detect the blockage status of waste in the mold waste chute. It includes at least one diffuse reflection sensor, which is installed next to the mold waste inlet and configured to emit infrared light and receive reflected signals. When the waste is blocked, the waste blocks the infrared light to cut off the reflected signal. The control module, electrically connected to the detection module, includes a terminal box; the terminal box has wiring terminals inside, and a time relay and an encoder are provided on the surface of the terminal box; the time relay is used to configure a preset time threshold, and the encoder is used to set the mold code. A connection module, including a multi-core connecting wire, electrically connects the detection module to the control module and electrically connects the control module to the control system of the stamping equipment; The fixing module includes a magnetic connector that detachably fixes the diffuse reflection sensor to the side of the mold waste inlet; When the reflected signal of the diffuse reflection sensor is continuously blocked by the waste material for a period of time that reaches the preset time threshold of the time relay, the terminal box sends a stop signal to the control system of the stamping equipment, controlling the stamping equipment to stop working and triggering an alarm.

2. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, Multi-channel synchronous detection is achieved by installing the diffuse reflection sensors next to the different waste chute inlets of the same mold.

3. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, The diffuse reflection sensor is a PNP three-line infrared switch, and the detection distance is adapted to the spatial dimensions of the mold waste slide.

4. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, The encoder is a binary rotary switch, which is set on the surface of the terminal box. By switching the switch state, a code corresponding to each mold is set, enabling rapid identification when multiple molds are used together. When changing molds, the device can be adapted simply by switching the state of the binary rotary switch, without the need for rewiring.

5. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, The connection module also includes a connector assembly and a connector assembly. The connector assembly is used for quick plug-in connection between the terminal box and the worktable of the stamping equipment. The connector assembly has a 4-pin 4-hole structure and is adapted to the signal transmission of the multi-core connection cable.

6. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, The time relay is a 24V DC relay; the time threshold is determined by software simulation based on the size of the waste chute space and the way the waste slides down, adapting to the waste sliding speed under different stamping processes.

7. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, The shutdown signal is transmitted through the multi-core connecting line to ensure that the stamping equipment stops in time before the waste blockage expands, thus avoiding damage to the mold.

8. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, The magnetic force of the magnetic clamp is not lower than the preset magnetic force threshold, ensuring that the diffuse reflection sensor does not shift under the vibration environment of the stamping equipment, and that the diffuse reflection sensor is not damaged during disassembly.

9. The automotive stamping part die scrap blockage detection device according to claim 1, characterized in that, The diffuse reflection sensor is equipped with a protective housing to make it shockproof, waterproof, dustproof and oil-proof.

10. A method for detecting blockage caused by scrap in automotive stamping dies, characterized in that, The device for detecting waste blockage in automotive stamping die as described in any one of claims 1 to 9 comprises the following steps: The diffuse reflection sensor is fixed at a preset position next to the mold waste inlet using a magnetic clamp, so that the infrared light of the diffuse reflection sensor covers the outlet area of ​​the waste chute. The control module is electrically connected to the diffuse reflection sensor and the control system of the stamping equipment via a connection module; The encoder of the control module sets the current mold code, and the time threshold for judging waste blockage is preset by the time relay; After the stamping equipment is started, the diffuse reflection sensor continuously emits infrared light and detects the reflected signal. When there is no blockage in the die scrap chute, the infrared light is unobstructed and the reflected signal is normal; when the scrap is blocked, the scrap blocks the infrared light and the reflected signal is interrupted. The duration of the interruption of the reflected signal is monitored in real time by the time relay. When the duration reaches the time threshold, the terminal box of the control module sends a stop signal to the control system of the stamping equipment, controlling the stamping equipment to stop working immediately and triggering an audible and visual alarm. When the reflected signal is restored, the time relay is reset and the detection process restarts.

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