Automotive

Fully automated assembly line for LED floodlight module

Initial situation / challenge

The customer needed a fully automated line to produce LED lighting modules with 5 variants for car floodlights, including space at the end for manual testing and packaging. Material is fed in by 3 tray loaders on one side and manually inserted into workpiece carriers on the other side

Industry: Automotive

What made the project unique:

Elaborate integration of 5 dosing processes and 10 technologies in one assembly line with collaboration between AWM and 3 technology partners [MRB, Proksys, Hella]
High-precision alignment in lower µm range

Challenges:

Various media need to be dosed (heat-conducting paste, spacer, silicone, UV adhesive), the UV adhesive has to be hardened and many technologies need to be integrated (mounting, riveting, bolting, compressed air cleaning, CO2 cleaning, protective film removal, weighing).

Lens alignment for the basic modules must be carried out in the lower µm range and therefore requires special axes with the highest precision. The alignment software is provided by the end customer and was integrated by our technology partner [MRB].

The modules need to be cleaned after every fundamental process step, 7x in total. At the critical point, after the protective film is removed, successful cleaning needs to be reviewed using special image processing.

Solution / Implementation

We developed and constructed a line with a total of 8 robots (some with triple grippers, some with automatic gripper change) and 6 handling systems that integrate all processes outlined above in a fully automated workflow.

A special image processing solution for detecting and counting particles in the range of 1/100 mm was developed and implemented.

The material flow relies on robotic transfer, handling system transfer, on the rotary table and using takeover conveyors with workpiece carriers.

Despite its compact design, the line is readily accessible for maintenance and repairs. All media are supplied from the outside without process interruptions.

Result for the customer

Managing a highly complex assembly and alignment technology in 24/7 operation.

The available assembly space was maintained, the challenging cycle time was achieved and the required technical availability was exceeded.

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The quality and reliability of our special equipment is primarily determined by the quality of our mechanical components. We are provide solutions for assembly and testing systems as well as sophisticated machines for plastic/metal-oriented parts and mechatronic systems up to a part weight of 10 kg.