22158 - Car headlight assembly line

The device is designed to automate the manual assembly process for lightbar-type lamps.

Purpose of the machine

The machine comprises four separate stations where the operator carries out the successive stages of lamp assembly. At the final stage of assembly, the component is removed from the line by a robot.

The conveyor operates by moving pallets in a closed loop, in a clockwise direction. The pallets move along two tracks: the upper track, where the sub-assembly of successive lamp components takes place sequentially, and the lower track, where empty pallets are returned to the start of the conveyor. At the ends of the conveyor there are lifts which raise and lower the pallets to a different level.

Description of the process

In order to assemble the lamp, it must travel along a conveyor belt through a series of stations where the operator carries out the following sub-assembly steps:

Lightguide test station;
Station 1 – assembly of the lamp housing, installation of the Lightguide;
Station 2 – installation of PCBs;
Station 3 – connecting the PCB plugs;
Station 4 – lamp assembly, scanning.

Once the work is complete, at the final station, the lamp is collected by a robot, and the empty pallet moves along the lower track back to the start of the conveyor.

Equipment design

LIGHTGUIDE INSPECTION STATION

The Lightguide inspection station allows the operator to check that the Lightguide is illuminating correctly. This is done by illuminating the component with an LED and visually checking the light transmission.

PALLET LIFT

The lifts are the first and final stages of pallet movement throughout the conveyor cycle, as well as stations for assembling lamp components. Their function is to transfer pallets to the upper or lower track. Lateral movement is achieved using a LIPRO conveyor. Vertical movement of the lift, however, is achieved using a ball screw. The module incorporates safety measures such as light curtains, a gravity gate and proximity switches to ensure the operator’s safety in the vicinity of moving mechanisms.

CENTRAL CONVEYOR

The central conveyor consists of two tracks: an upper assembly track and a lower return track, driven independently of one another. On these sections, the pallets move in only one direction (to the right on the upper track and to the left on the lower track). The central conveyor connects both lifts, forming a closed circuit for eight pallets. Within this section of the conveyor, there are three consecutive stations for assembling lamp components. They are also equipped with control buttons, emergency stop buttons and a pallet stopping mechanism.

ROLLER FEEDER

The roller feeder is a device located at the second station of the conveyor and is used to supply the components necessary for lamp assembly. Boxes containing components are loaded at the rear of the structure by simply dropping them onto the designated track. The operator uses a lever to remove the empty container and insert the next one.

SAFETY LEVEL

In accordance with the Customer’s guidelines and in compliance with the requirements of the PN-EN ISO 12100 standard, the machine is equipped (depending on the type of process being carried out) with a range of technical safety measures such as: an emergency stop switch, a light curtain, polycarbonate guards and pictograms.