Automation solutions from Festo for assembling LED headlights

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1 Automation solutions from Festo for assembling LED headlights Highlights Customer-specific Festo handling system: Ready-to-install three-axis handling with a performance guarantee and complete documentation Fast and precise movements Absorption of high lateral forces by using heavy-duty axes EGC-HD Connection to the higher-order controller via PROFIBUS Photo: GM Company Customer Requirements Solution End customer: Automotive supplier ZKW Group Customer (OEM): Vescon Systemtechnik GmbH in Austria Vescon implements a wide range of projects from automation and process engineering right up to power engineering and software development Project System for producing modern LED headlights Handling system for applying a two-component thermally conductive paste (dispensing) Handling system for moving and positioning a rivet head tool in the joining process (joining) Ready-to-install complete system Rapid, controlled application of the thermally conductive paste on all the required surfaces in the right quantity (note: there is only a small time frame in which the paste can be applied and components can be placed within it after that, it will have hardened too much) Rapid and precise positioning of the rivet head tool Absorption of high lateral forces during riveting Monitoring the complete system with its partially automated steps Precisely traceable manufacturing process for each headlight Three-axis handling system: Two toothed belt axis EGC form the basic axes in the x-direction The heavy-duty axis EGC-HD forms the y-axis The electric slide EGSL is the z-axis Motor controller CMMP-M with an integrated safety module Festo designs, builds and delivers complete ready-toinstall handling systems with a performance guarantee and documentation.

2 Automation solutions from Festo for assembling LED headlights Dispensing: Application of a heat transfer compound in the headlight assembly process. The thermally conductive paste ensures that the heat generated by the LED elements is dissipated from the headlight Hot riveting: A precisely set temperature deforms a plastic stud into a precise rivet head. It secures the printed circuit board and the cooling element to the reflector

3 Application of thermally conductive paste (dispensing) The process The headlight is already fully wired, has an adjustment system and the main beam module The cooling element is inserted into the station Fully-automatic application of the thermally conductive paste: a Festo handling system moves the K dosing system in the right path and positions it exactly in the right place at all times Positioning the printed circuit board with the five LEDS on the cooling element Attaching the reflectors Festo solution: three-axis handling system Basic axes: Two toothed belt axes EGC-0, stroke 50, synchronised via a connecting shaft and with a space-saving right-angle gear unit Y-axis: Heavy-duty axis EGC-HD60-TB Z-axis: Electric slide EGSL-BS-75, stroke Servo drive packages for all axes Controlledvia three motor controllers CMMP-MP Festo designs, builds and delivers everything as a ready-to-install system With a performance guarantee and documentation

4 Hot riveting (joining) of headlight parts The process A precisely set temperature deforms a plastic stud into a precise rivet head. The riveting head is positioned at the reflector. It must hold the reflector, the printed circuit board and the cooling element completely securely and reliably. Riveting must be so precise that the components are absolutely secure during shake tests and in actual use. A Festo handling solution is used to accurately position the hot riveting heads and to fasten the reflectors securely to the cooling element. Festo solution: three-axis handling system Basic axes: Two toothed belt axes EGC-80, synchronised via a connecting shaft and with a space-saving right-angle gear unit Y-axis: Heavy-duty axis EGC-HD60-BS Servo drive packages for all axes Final positioning of the rivet heads with compact cylinders ADN, actuated via valve terminal VTUG The pin length at the reflectors before riveting and the correct end position are checked using SMAT position sensors

5 Products and solutions Toothed belt and heavy-duty axes EGC Electric mini slide EGSL Motor controller range CMMx-AS Valve terminal VTUG Toothed belt or spindle axis Size Stroke length mm Forces N Optionally with a guide or as a heavy-duty version (EGC-HD) with two guide rails Maximum load capacity and rigidity Very short cycle times due to maximum dynamic response Modular product with flexible options Sizes 5, 5, 55, 75 Stroke lengths mm Force N Maximum performance for optimal machine cycle times and heavy-duty applications such as press-fitting and joining Simple and flexible installation in the machine Safe and reliable handling Efficient solution - outstanding value for money Servo motor controller CMMP-AS: Ideal for dynamic movements and electronic control of cam discs. Servo motor controller CMMS-AS: Strengths include standard applications and positioning tasks with I/O and fieldbus connection Servo motor double controller CMMD-AS: runs two servo motors independently of one another The safety function STO is integrated as standard: emergency stop requirements with safe stop SS up to category Up to valve positions in a fixed grid Available in sizes, up to,00 l/min Available as multi-pin or fieldbus valve terminal can be converted quickly and easily IO-Link Attractively priced Compact with high flow rate Suitable for use in a control cabinet