Aug. 11, 2025 – Kistler has developed the KCA 400T analog controller to make even more efficient use of analog sensors in stamping: thanks to its large touch display, the modernized subsystem for monitoring systems on stamping machines enables simple implementation of double sheet detection using sensors integrated into the tool. The solution can also be implemented into older machines as a retrofit. Stamped and hybrid parts are standard equipment in demanding sectors such as the automotive, electronics and household appliance industries. Over the last few decades, not only has production evolved, as progressive dies enable the manufacture of complex parts.
Quality assurance has changed as well. Today, integrated sensor technology (optical, piezoelectric, inductive) combined with tool and process monitoring systems guarantees tight tolerances and high process reliability during stamping. Double sheet detection plays a crucial role here: if stamping waste is not completely discharged downwards, the tool may tilt; this is why it is referred to not only as double sheet detection but also as tilt detection. Kistler's analog inductive sensors have proven to be particularly helpful in detecting double sheets: in combination with the KCA 400T analog controller, these distance sensors detect even the smallest stamping waste in the tool and thus prevent component damage and possible tool breakage.
Intelligent stamping: No double sheet in the stamping tool
With the new KCA 400T from Kistler, analogue sensors installed in the stamping tool can be conveniently parameterized and connected to the stamping machine or its monitoring system respectively. The analog controller has four inputs for analog sensors (0 to 10 V) and a digital output (PNP). All sensors can be set with different tolerances (in the range 10 to 200 µm) via the large touch display. Error messages are now displayed in plain text and with additional explanations. Supported languages now include German, English, French, Italian, Chinese and Spanish.
In AUTOSET mode, the KCA 400T automatically reads the signals from the connected sensors. After starting the press, a comparison is made between the stored set values and the actual values determined during the run. If all actual values are within the set tolerance, a PNP output signal is sent to the downstream tool monitoring system. If one or more sensors exceed the set tolerance, no output signal is generated, and the tool monitoring system stops the press. Thus, the analog controller’s function is monitored with every stroke.
The corresponding error message is shown on the display. The double sheet control implemented with analog inductive sensors is more accurate than a setup with digital (switching) sensors, for example. It offers the possibility of achieving very high monitoring accuracy and therefore the highest quality in stamping, even for older stamping machines.
Best tool protection when stamping–also as a retrofit on older machines
The new KCA 400T can be combined with all tool and process monitoring systems available on the market, existing monitoring systems can be easily retrofitted. If more than four analog sensors are integrated into a stamping tool, several Kistler KCA 400Ts can be used in parallel. Each analog controller only occupies one input, so that one digital input of the monitoring system becomes four analog measurement inputs.
