Automotive

Fully automated assembly line for LED interior lighting

Initial situation / challenge

The customer needed a fully automated line to produce LED interior lighting with 8 variants. This line had to include all assembly steps between the depanelling system and the EOLT cell (end of line tester).

Industry: Automotive

What made the project unique:

Synchronised operation of 2 robots simultaneously for the same task;
4 mechanical engineers involved on the same line [Schunk depanelling system, AWM line, Seho soldering plant, Marquardt EOLT] and 1 technology partner [Proksys]

Challenges

Jumpers made of bundle wire need to be cut, bent and joined. The lighting modules are made of long slim plastic injection moulding parts. Neither of these are structurally stable, yet they have to be securely joined during manufacture.

The success of critical assembly steps has to be monitored via image processing.

Solution / Implementation

We developed and constructed an assembly line that met all the requirements outlined above.

The punching and bending cell for jumpers includes 2 robots that grip the jumpers simultaneously on both sides and insert them into the PCB using synchronised movements, where they are then soldered.

The final assembly cells include extremely large and complex grippers with up to 40 functional elements.

The material flow relies on conveyor sections with workpiece carriers which also involve large and complex design and functional elements.

Result for the customer

The challenging cycle time was achieved, and the required technical availability was exceeded.

The line is technically sophisticated and operates profitably for the customer

Do you have any questions?
We will resolve your issue.

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.