Development, construction and assembly of two single-purpose machines for the inspection of BMW E92LCI light tightness. These were new workstations where the operator tests light tightness with a standard halogen lamp and the other is used for testing lights with LED diode lamps.
The basic idea was to create a workstation where the operator would only insert finished floodlights into the testing station, perform testing and remove the floodlight from the station.
The requirements of the workers of Automotive Lighting were gradually added during the process of designing the station. ELVAC was required to flexibly respond in the stage of designing, projecting and implementing. We satisfied the customer also thanks to our flexible and adaptive system of order management.
Description of application
The station is equipped with a rotating table where two stations for clamping lights are located. The operator manually inserts the floodlight (glass up) to be tested and attaches is to the station. Then, the operator manually turns the rotating table to place the floodlight in the position where testing is done. Now, it is possible to start the control testing of the light tightness. The testing cycle is launched after the carousel is fixed in the working position. The automatic testing of one floodlight takes 20 seconds and is performed inside the machine. During the operation, the operator first removes the tested floodlight and then inserts and fixes another floodlight into the pallet on the rotating table of the station. The new light must be ready for the performance of the test. The machine registers the presence of the light. At the same time, the automatic test is performed on the other inserting pallet.
When the automatic cycle is complete, the operator is asked to start another cycle. The rotating table is turned manually and the role of the inserting pallets is exchanged.
The test of the floodlight tightness is done automatically. First, all openings are clogged and then the floodlight is pressurized. Decrease in pressure is monitored for a period of 8s.
The equipment assesses the measured quantities and the result is displayed on the screen of the control panel. All is done in an automatic mode. The customer required that the cycle length was below 30 seconds.
The equipment meets the requirement: the cycle length is under 15 seconds.
The following is done at the testing position
- Inspection of the completion of vulcanization
- Inspection of the presence of connecting clamps
- Inspection of the tightness of the floodlight according to the customer’s requirements
- Inspection of the barcode of the floodlight
- Inspection of the Matrix code
Used products and technologies
- The frame of the machine is made from the modular system of Al-sections by BOSCH Rexroth
- Bosch CL 200 control system and BT5 display unit with ZE 200 – DP process card, BT5 with Profibus DP, inputs and outputs with Profibus DP
- Rotating table with Al plate
- Inspection of tightness by Phönix pressure sensor
- FESTO pneumatic elements
- HIWIN linear shifts