METHOD FOR AUTOMATED ASSEMBLY OF A LIGHT MODULE FOR A MOTOR VEHICLE HEADLIGHT

Description

[0001] The invention relates to a method for the automated assembly of a light module for a motor vehicle headlight by means of an assembly robot, the method comprising the following chronological steps: a) Providing the following components: a light-emitting assembly, comprising * a circuit board, * a light-emitting means for generating and emitting light, wherein the light-emitting means is arranged on the circuit board, * a carrier body on which the circuit board is arranged, wherein a first holding section is formed on the carrier body, wherein the first holding section is designed and configured to be picked up by a gripping device of an assembly robot, an optical device configured to form at least one light function from the light of the light-emitting means of the light-emitting assembly in an assembled state of the light module, wherein the optical device has at least one optically active element, which is accommodated in a housing of the optical device, for forming the at least one light function, wherein the housing has a light entry region,through which light emitted by the illuminant enters the interior of the housing and strikes the at least one optically active element and interacts with the at least one optically active element to form the at least one light function, wherein the housing has a light exit region from which the light forming the at least one light function emerges after its interaction with the at least one optically active element, a plug-in device which has a plug element and a mating plug element configured to correspond to the plug element, wherein the plug element is arranged on the light-emitting assembly and the mating plug element is arranged on the optical device, wherein the plug element can be brought into engagement with the mating plug element to fasten the light-emitting assembly to the optical device.

[0002] Methods for assembling light modules are known in the prior art. Unfortunately, these assembly methods require a large number of steps, which are typically performed partly automated and partly manually. If an automated step follows a manual one (or vice versa), process delays often occur. Document EP 3 301 351 A1 discloses a light signaling device that generates luminous pictograms using a matrix of micromirrors.

[0003] The object of the present invention is to alleviate or eliminate the disadvantages of the prior art. The invention therefore aims, in particular, to create an improved method for the automated assembly of a light module.

[0004] This object is achieved by a method having the features of claim 1.

[0005] Preferred embodiments are specified in the dependent claims.

[0006] According to the invention, the method comprises the further steps: b) Providing an assembly robot for the automated assembly of the light module, wherein the assembly robot has a gripping device, wherein the gripping device has a gripping portion configured to correspond to the first holding portion of the carrier body, c) Assembling the light module by attaching the light-emitting assembly to the optical device by the assembly robot, wherein the attachment comprises the following steps: * Picking up the light-emitting assembly with the gripping device by engaging the gripping portion of the gripping device with the first holding portion of the carrier body, * Positioning the picked up light-emitting assembly on the optical device such that the plug element of the light-emitting assembly can be engaged with the mating plug element of the optical device,* Plugging the plug-in device together by means of the assembly robot by engaging the plug element with the mating plug element, wherein during plugging the light-emitting assembly is held by the gripping device and moved along a plug-in direction, wherein in the plugged-in state of the plug-in device the plug element is arranged in an end position relative to the mating plug element, wherein the plug element and the mating plug element are designed and configured such that in the end position the engagement of the plug element with the mating plug element is such that the light-emitting assembly is secured against displacement counter to the plug-in direction, wherein the light module (1) has a control device (8) which is designed to control the at least one optically active element of the optical device (4) and the illuminant (2a) of the light-emitting assembly (2) to implement the at least one light function, wherein the plug element (5a) and the mating plug element (5b) each have electrical connection means which are designed to establish electrical contact between the light-emitting assembly (2) and the control device (8) when the plug device (5) is in the assembled state, wherein the control device (8) is electrically connected to the mating plug element (5b) via further electrical connection means in order to send control signals to the optical device (4) and the light-emitting assembly (2) when the light module (1) is in the assembled state.

[0007] This has the advantage that the mating of the plug element with the mating plug element (and thus the assembly of the light module) is automated and therefore particularly efficient. In particular, the plug device does not have to be mated manually and the secure connection does not have to be checked, which in turn saves time and money. It can be provided that an electrical connection that exists between the components of the light module in the assembled state of the light module is checked with a functional test. During this test, the function of the light-emitting element can also be checked. It can also be provided that after the plug device has been mated together, a fine adjustment is carried out to ensure optimal alignment of the light-emitting assembly relative to the optical device.After fine adjustment, the light-emitting assembly can be precisely positioned relative to the optical device, so that inaccuracies that may have arisen, for example, during the manufacturing process are compensated for by the precise positioning. It can be provided that the light-emitting assembly is fixed to the housing of the optical device by means of a fastening element. The fastening element can be, for example, a screw connection, a rivet connection, an adhesive connection, or similar. The optically active element can, for example, comprise a DMD element, which is designed to realize at least one, preferably several different lighting functions from the light of the illuminant. One element (ora surface of an element) is optically effective within the meaning of this disclosure in particular when the element changes the direction of the light which interacts with the element during intended use, with regard to its direction and / or its beam or bundle characteristics. In this disclosure, the assembled (or plugged together) state is the state in which the light-emitting module is connected to the optical device, this connection being made by the plugged together plug device. In the assembled state, the light module is in particular ready for use and configured to generate the at least one light function. In the assembled state, the light-emitting module is in particular fixed to the optical device orThe connection between the light-emitting assembly and the optical device is secured against loosening, whereby this securing is made possible by the engaged plug-in device. A printed circuit board within the meaning of this disclosure can also be understood in general terms as any circuit carrier.

[0008] It can be provided that the support body has a cooling element for cooling the illuminant, wherein the first holding section is arranged on the cooling element. The cooling element and the support body can, in particular, be formed integrally. This can simplify the structure of the light module.

[0009] It can be provided that the light entry area of ​​the housing is designed as a light entry opening which is designed to correspond to the light-emitting assembly in such a way that, when the light module is assembled with the illuminant, light emitted strikes the at least one optically active element through the light entry opening. It can be provided that the light exit area of ​​the housing is designed as a light exit opening, wherein the light (or the light beam) forming the lighting function exits the housing through the light exit opening. The light entry opening or the light entry area can be arranged on a first housing outer side, and the light exit opening or the light exit area can be arranged on a second housing outer side different from the first housing outer side.Preferably, the light entry region and the light exit region are arranged on the housing in such a way that, in the assembled state, a light beam entering the housing (which is emitted by the illuminant) and a light beam exiting the housing (which is emitted by the optically active element) have an acute angle to one another.

[0010] It can be provided that the circuit board of the light-emitting assembly has a top side and a bottom side opposite the top side, wherein the illuminant and the plug element are arranged on the top side and the carrier body is arranged on the bottom side. The carrier body can be designed as a cooling element, wherein preferably the illuminant and the plug element are arranged on the top side of the circuit board and the cooling element is arranged on the bottom side of the circuit board. It can be provided that a heat-conducting layer comprising a heat-conducting material is arranged between the cooling element and the bottom side of the circuit board, whereby the heat conduction between the circuit board and the cooling element is increased.

[0011] According to the invention, the light module has a control device which is designed to control the at least one optically active element of the optical device and the illuminant of the light-emitting assembly to form the at least one light function.

[0012] It can be provided that the control device comprises a further circuit board, which is in particular fastened to the housing of the optical device.

[0013] According to the invention, the plug element and the mating plug element each have electrical connection means configured to establish electrical contact between the light-emitting assembly and the control device when the plug device is plugged together. The control device is electrically connected to the mating plug element via further electrical connection means in order to send control signals to the optical device and the light-emitting assembly when the light module is assembled. The control signals are, in particular, signals that cause the optical device and the illuminant to implement the at least one lighting function.

[0014] It can be provided that the further electrical connection means are arranged within a cable receiving device, wherein the cable receiving device has a second holding portion configured and adapted to be brought into engagement with the gripping device of the assembly robot in order to pick up the cable receiving device with the gripping device. The first holding portion and the second holding portion can be configured (or shaped) similarly.

[0015] It can be provided that the cable receiving device is arranged on a housing outer side, in particular on a third housing outer side, of the housing.

[0016] It can be provided that the cable receiving device has a certain strength that can withstand a predetermined gripping force of the gripping device, so that the cable receiving device can be picked up with the gripping device under the action of the predetermined gripping force without damage. Preferably, the assembly robot is configured to assemble the picked-up cable receiving device to the housing by means of a fastening means. The fastening means can comprise a further plug device, wherein a further plug element of the further plug device can be brought into engagement with a further mating plug element of the further plug device in order to fasten the cable receiving device to the housing.It can be provided that the cable receiving device furthermore has a certain strength which not only withstands the predetermined gripping force of the gripping device, so that the cable receiving device can be picked up with the gripping device under the influence of the predetermined gripping force without damage, but also withstands the plug-in force which is applied by the gripping device in order to contact the cable receiving device by means of the plug-in device provided for this purpose, without damage.

[0017] It can be provided that the plug element has a first locking means and the mating plug element has a second locking means, wherein in the plugged-together state of the plug device, the first locking means interacts with the second locking means such that the position of the light-emitting assembly is fixed relative to the optical device.

[0018] It can be provided that the first locking means is designed as a latching lug and the second locking means as a latching lug receptacle, or the first locking means is designed as a latching lug receptacle and the second locking means as a latching lug, wherein in the plugged-together state of the plug-in device, the latching lug is received in the latching lug receptacle in order to fix the position of the light-emitting assembly relative to the optical device.

[0019] It can be provided that the locking lug of the first locking means or of the second locking means is pre-tensioned with a spring element in such a way that when the plug-in device is plugged together by the assembly robot, the plug element is plugged into the mating plug element against the spring force of the spring element, wherein in the plugged-together state the spring force of the spring element presses the locking lug into the locking lug receptacle.

[0020] It can be provided that after the light-emitting assembly has been positioned on the optical device and before the plug-in device has been plugged together by the assembly robot, the position of the light-emitting assembly relative to the optical device is checked with a checking device and, if the position deviates from a predetermined target position, the assembly robot changes the position in such a way that the target position is assumed.

[0021] In an embodiment not according to the invention, a motor vehicle headlight is provided, comprising a light module which has been assembled using a method for automated assembly.

[0022] For the purposes of this description, the terms "top", "bottom", "horizontal" and "vertical" are to be understood as indicating the orientation when the light module is arranged in the normal position of use after it has been installed in a motor vehicle headlamp.

[0023] The invention is further explained below using a preferred embodiment, to which, however, it is not intended to be limited. The drawings show: Fig. 1 a view of an embodiment of a light module before its assembly using a method according to the invention; Fig. 2 another view of the light module according to Fig. 1 ; Fig. 3 a view of the assembled light module according to Fig. 1 ; Fig. 4 a view of an optical device of the light module according to Fig. 1 ; Fig. 5 a view of a cable receiving device; and Fig. 6 another view of the cable holder.

[0024] Fig. 1 and Fig. 2 show different views of an unassembled light module 1. The assembly of the light module 1 is carried out by a method for the automated assembly of the light module 1 by means of an assembly robot (not shown). Fig. 1 and Fig. 2 show the unassembled state and Fig. 3 shows the assembled state.

[0025] The light module 1 comprises a light-emitting assembly 2. The light-emitting assembly 2 in turn comprises a circuit board 2a and a light-emitting means 2b for generating and emitting light, wherein the light-emitting means 2b is arranged on the circuit board 2a. The light module has a carrier body 2c on which the circuit board 2a is arranged, wherein a first holding section 3a is formed on the carrier body 2c. The first holding section 3a is designed and configured to be picked up by a gripping device of an assembly robot. In the exemplary embodiment shown, the carrier body 2c comprises a cooling element 2d for cooling the light-emitting means 2b, wherein the first holding section 3a is arranged on the cooling element 2d.

[0026] In the illustrated embodiment, the circuit board 2a of the light-emitting assembly 2 has a top side 7a and a bottom side 7b opposite the top side 7a. The illuminant 2b and the connector element 5a are arranged on the top side 7a, and the carrier body 2c (which has the cooling element 2d) is arranged on the bottom side 7b.

[0027] The light module 1 comprises an optical device 4, which is designed to generate a light source from the light of the illuminant 2b of the light-emitting assembly 2 in an assembled state of the light module (cf. Fig. 3) to form at least one lighting function. The lighting function can comprise a low beam, a high beam, a direction indicator light, a warning light, or similar. The optical device 4 has at least one optically active element (not shown) to form the at least one lighting function, which is accommodated in a housing 4a of the optical device 4. The housing 4a has a light entry region 4b through which light emitted by the illuminant 2b enters the interior of the housing 4a and strikes the at least one optically active element and interacts with the at least one optically active element to form the at least one lighting function. The housing 4a has a light exit region 4c from which the light forming the at least one lighting function exits after its interaction with the at least one optically active element.

[0028] The light module 1 comprises a plug-in device 5, which has a plug element 5a and a mating plug element 5b configured to correspond to the plug element 5a. In the illustrated embodiment, the plug element 5a is arranged on the light-emitting assembly 2, and the mating plug element 5b is arranged on the optical device 4. The plug element 5a can be engaged with the mating plug element 5b to fasten the light-emitting assembly 2 to the optical device 4.

[0029] The plug element 5a has a first locking means 10a and the mating plug element 5b has a second locking means 10b. In the mated state of the plug device 5a ( Fig. 3 ) the first locking means 10a cooperates with the second locking means 10b such that the position of the light-emitting assembly 2 is fixed relative to the optical device 4.

[0030] In the illustrated embodiment, the first locking means 10a is designed as a locking lug, and the second locking means 10b is designed as a locking lug receptacle. Alternatively, the first locking means 10a can be designed as a locking lug receptacle, and the second locking means 10b can be designed as a locking lug. In the plugged-together state of the plug-in device 5 (i.e., in the assembled state of the light module 1), the locking lug is received in the locking lug receptacle to fix the position of the light-emitting assembly 2 relative to the optical device 4.

[0031] The locking lug of the first locking means 10a or the second locking means 10b is preferably pre-tensioned with a spring element 11 such that when the plug-in device 5 is plugged together by the assembly robot, the plug element 5a is plugged into the mating plug element 5b against the spring force of the spring element, wherein in the plugged-together state the spring force of the spring element 11 presses the locking lug into the locking lug receptacle.

[0032] To assemble the light module 1 using the method according to the invention, an assembly robot (not shown) is provided for the automated assembly of the light module 1. The assembly robot has a gripping device, wherein the gripping device has a gripping section configured to correspond to the first holding section 3a of the carrier body 2c. It should be noted at this point that a person skilled in the field of automation technology is generally familiar with the design of assembly robots with gripping devices. Therefore, the technical description of the assembly robot is omitted.

[0033] The assembly of the light module 1 is carried out by attaching the light-emitting assembly 2 to the optical device 4 using the assembly robot. The attachment process involves the following steps: * Picking up the light-emitting assembly 2 with the gripping device by engaging the gripping portion of the gripping device with the first holding portion 3a of the carrier body 2c; * Positioning the picked up light-emitting assembly 2 on the optical device 4 such that the plug element 5a of the light-emitting assembly 2 can be engaged with the mating plug element 5b of the optical device 4 (this position is shown in the Fig. 1 and 2 shown); * Plugging together the plug device 5 by means of the assembly robot by engaging the plug element 5a with the mating plug element 5b.

[0034] During mating, the light-emitting assembly 2 is held by the gripping device and moved along an insertion direction 6. In the mated state of the plug device 5, the plug element 5a (or the light-emitting assembly 2) is arranged in a final position relative to the mating plug element 5b (or the optical device 4). The plug element 5a and the mating plug element 5b are designed and configured such that, in the final position, the engagement of the plug element 5a with the mating plug element 5b is such that the light-emitting assembly 2 is secured against displacement counter to the insertion direction 6.

[0035] As in Fig. 4As shown, in the exemplary embodiment shown, the light entry region 4b of the housing 4a is designed as a light entry opening, which is designed to correspond to the light-emitting assembly 2 in such a way that, in the assembled state of the light module 1 with the illuminant 2b, light emitted through the light entry opening strikes the at least one optically active element. The light exit region 4c is in turn designed as a light exit opening. The light module 1 has a control device 8, which is configured to control the at least one optically active element of the optical device 4 and the illuminant 2b of the light-emitting assembly 2 to implement the at least one lighting function. The control device 8 comprises a further printed circuit board, which is fastened in particular to the housing 4a of the optical device 4.

[0036] The plug element 5a and the mating plug element 5b each have electrical connection means configured to establish electrical contact between the light-emitting assembly 2 and the control device 8 in the assembled state. The control device 8 is electrically connected to the mating plug element 5b via further electrical connection means in order to send control signals to the optical device 4 and the light-emitting assembly 2 in the assembled state of the light module 1.

[0037] The further electrical connection means are arranged within a cable receiving device 9, wherein the cable receiving device 9 has a second holding section 3b, which is designed and configured to be engaged with the gripping device of the assembly robot in order to pick up the cable receiving device 9 with the gripping device. The cable receiving device 9 is arranged on an outer side of the housing 4a.

[0038] The Fig. 5 and Fig. 6 show detailed views of the cable holding device 9. In Fig. 5 the cable receiving device 9 is shown in an open state, so that the further electrical connecting means can be seen therein. Fig. 6 shows a closed state, in which state the assembly of the cable receiving device 9 can take place.

[0039] The cable receiving device 9 has a certain strength that can withstand a predetermined gripping force of the gripping device. This allows the cable receiving device 9 to be picked up by the gripping device without damage under the influence of the predetermined gripping force. The assembly robot is configured to assemble the picked-up cable receiving device 9 to the housing 4a using a fastening means 11. The fastening means 11 can be configured as an additional plug element (or mating plug element) of another plug device.

[0040] After positioning the light-emitting assembly 2 on the optical device 4 and before plugging the plug-in device 5 together by the assembly robot, in an optional step the position of the light-emitting assembly 2 relative to the optical device can be checked with a checking device, and if the position deviates from a predetermined target position, the assembly robot can change the position such that the target position is assumed.

Claims

1. Method for the automated assembly of a light module (1) for a motor vehicle headlight using an assembly robot, wherein the method comprises the following chronological steps: a) Providing the following components: - a light-emitting assembly (2) comprising * a printed circuit board (2a), * a light source (2b) for generating and emitting light, wherein the light source (2b) is arranged on the printed circuit board (2a), * a carrier body (2c) on which the printed circuit board (2a) is arranged, wherein a first holding section (3a) is formed on the carrier body (2c), wherein the first holding section (3a) is designed and arranged to be gripped by a gripping device of an assembly robot, - an optical device (4) which is designed to form at least one light function from the light of the light source (2b) of the light-emitting assembly (2) in an assembled state of the light module (1), wherein the optical device (4) for forming the at least one light function comprising at least one optically effective element which is accommodated in a housing (4a) of the optical device (4), wherein the housing (4a) has a light entry region (4b) through which light emitted by the light source (2b) enters the interior of the housing (4a) onto the at least one optically effective element and interacts with the at least one optically effective element to form the at least one light function, wherein the housing (4a) has a light exit area (4c) from which the light forming the at least one light function exits after its interaction with the at least one optically effective element, - a plug device (5) which has a plug element (5a) and a mating plug element (5b) designed to correspond to the plug element (5a), wherein the plug element (5a) is arranged on the light-emitting assembly (2) and the mating plug element (5b) is arranged on the optical device (4), wherein the plug element (5a) can be engaged with the mating plug element (5b) to secure the light-emitting assembly (2) to the optical device (4), characterized by b) providing an assembly robot for automated assembly of the light module (1), wherein the assembly robot has a gripping device, wherein the gripping device has a gripping section which is formed corresponding to the first holding section (3a) of the carrier body (2c), c) assembling the light module (1) by attaching the light-emitting assembly (2) to the optical device (4) by the assembly robot, wherein the attaching comprises the following steps: * grasping the light-emitting assembly (2) with the gripping device by engaging the gripping section of the gripping device with the first holding section (3a) of the carrier body (2c), * positioning the gripped light-emitting assembly (2) on the optical device (4) in such a way that the plug element (5a) of the light-emitting assembly (2) can be engaged with the mating plug element (5b) of the optical device (4), * assembly of the plug device (5) by means of the assembly robot by engaging the plug element (5a) with the mating plug element (5b), wherein during assembly the light-emitting assembly (2) is held by the gripping device and moved along an insertion direction (6), wherein in the assembled state of the plug device (5) the plug element (5a) is arranged in an end position relative to the mating plug element (5b), wherein the plug element (5a) and the mating plug element (5b) are designed and arranged such that, in the end position, the engagement of the plug element (5a) with the mating connector element (5b) is such that the light-emitting assembly (2) is secured against displacement in the opposite direction to the insertion direction (6), wherein the light module (1) has a control device (8) which is designed to control the at least one optically effective element of the optical device (4) and the light source (2a) of the light-emitting assembly (2) to form the at least one light function, wherein the plug element (5a) and the mating plug element (5b) each have electrical connection means which are arranged to establish electrical contact between the light-emitting assembly (2) and the control device (8) when the plug device (5) is plugged together, wherein the control device (8) is electrically connected to the mating plug element (5b) via further electrical connecting means in order to send control signals to the optical device (4) and the light-emitting assembly (2) when the light module (1) is assembled.

2. Method according to claim 1, wherein the carrier body (2c) has a cooling element (2d) for cooling the light source (2b), wherein the first retaining section (3a) is arranged on the cooling element (2d).

3. Method according to one of the preceding claims, wherein the light entry area (4b) of the housing (4a) is designed as a light entry opening which is formed to correspond to the light-emitting assembly (2) in such a way that, in the assembled state of the light module (1) with the light source (2b) passes through the light entry opening and strikes the at least one optically effective element.

4. Method according to one of the preceding claims, wherein the printed circuit board (2a) of the light-emitting assembly (2) has an upper side (7a) and a lower side (7b) opposite the upper side (7a), wherein the light source (2b) and the plug element (5a) are arranged on the upper side (7a) and the carrier body (2c) is arranged on the lower side (7b).

5. Method according to one of the preceding claims, wherein the control device (8) comprises a further printed circuit board which is attached in particular to the housing (4a) of the optical device (4).

6. Method according to one of the preceding claims, wherein the further electrical connection means are arranged within a cable receiving device (9), wherein the cable receiving device (9) has a second holding section (3b) which is designed and arranged to be engaged with the gripping device of the assembly robot in order to pick up the cable receiving device (9) with the gripping device.

7. Method according to claim 6, wherein the cable receiving device (9) is arranged on an outer side of the housing (4a).

8. Method according to claim 6 or 7, wherein the cable holding device (9) has a certain strength that can withstand a predetermined gripping force of the gripping device, so that the cable holding device (9) can be picked up without damage by the gripping device under the influence of the predetermined gripping force, wherein the assembly robot is preferably designed to assemble the gripped cable holding device (9) to the housing (4a) by means of a fastening device.

9. Method according to one of the preceding claims, wherein the plug element (5a) has a first locking means (10a) and the counter plug element (5b) has a second locking means (10b), wherein, in the connected state of the plug device (5a), the first locking means (10a) interacts with the second locking means (10b) in such a way that the position of the light-emitting assembly (2) relative to the optical device (4) is fixed.

10. Method according to claim 9, wherein the first locking means (10a) is designed as a locking tab and the second locking means (10b) is designed as a locking tab receptacle, or the first locking means (10a) is designed as a snap-in receptacle and the second locking means (10b) is designed as a snap-in tab, wherein, when the plug-in device (5) is in the plugged-in state, the snap-in tab is received in the snap-in receptacle in order to fix the position of the light-emitting assembly (2) relative to the optical device (4).

11. Method according to claim 10, wherein the locking nose of the first locking means (10a) or the second locking means (10b) is preloaded with a spring element (11) in such a way that, when the plug-in device (5) by the assembly robot, the plug element (5a) is inserted into the mating plug element (5b) against the spring force of the spring element, wherein, in the connected state, the spring force of the spring element (11) presses the locking tab into the locking tab receptacle.

12. Method according to one of the preceding claims, wherein, after positioning the light-emitting assembly (2) on the optical device (4) and before the plug-in device (5) is plugged in by the assembly robot, the position of the light-emitting assembly (2) relative to the optical device is checked using a checking device, and if the position deviates from a predetermined target position, the assembly robot changes the position so that the target position is reached.