Headlight Light Module Plug-In Assembly for Precise Robot Alignment
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Solution Overview
Problem
Existing methods for assembling light modules in motor vehicle headlights require a mix of automated and manual steps, leading to process delays and inefficiencies.
Innovation Solution
An automated assembly method using an assembly robot with a gripping device to securely attach a light-emitting assembly to an optical device via a plug-in mechanism, ensuring electrical connection and precise alignment, and optionally including a fastening element for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If automated assembly steps are combined with manual steps, then flexibility in assembly process is maintained, but process delays occur and productivity decreases
Solution Approach 1:
The patent combines the gripping function and electrical connection function into a single integrated plug-in device. The gripping device with gripping portion engages with the holding section to securely hold the light-emitting assembly, while simultaneously the plug element engages with the mating plug element to establish electrical connection. This merging of multiple functions into one operation eliminates the need for separate manual steps, thereby improving productivity while maintaining process flexibility.
Solution Approach 2:
The plug-in device serves multiple functions: it acts as a gripping mechanism to hold the light-emitting assembly during positioning, serves as a positioning aid to align the assembly with the optical device, and simultaneously establishes electrical connection through the plug element and mating plug element engagement. This multi-functionality allows a single automated operation to replace multiple manual steps, resolving the contradiction between flexibility and productivity.
2Manufacturing precision
If manual steps are used for plug-in device mating, then precise alignment can be achieved, but assembly time increases and costs rise
Solution Approach 1:
The plug-in device is designed to perform its own alignment and positioning functions during the automated plugging operation. The gripping device with gripping portion engages the holding section to automatically position the light-emitting assembly, and the plug element automatically aligns and engages with the mating plug element. This self-service capability ensures precise alignment without requiring manual intervention, thereby reducing assembly time and costs while maintaining manufacturing precision.
Solution Approach 2:
The plug-in device acts as an intermediary mechanism that facilitates precise alignment between the light-emitting assembly and the optical device. The gripping portion and holding section provide a mechanical interface for accurate positioning, while the plug element and mating plug element provide both mechanical engagement and electrical connection. This intermediary mechanism enables precise alignment to be achieved through automated means rather than manual operations.
3Ease of operation
If separate gripping and plugging operations are performed, then control over each step is improved, but process complexity increases
Solution Approach 1:
The patent merges the gripping operation and plugging operation into a single integrated action. The gripping device with gripping portion engages the holding section to hold the light-emitting assembly, and simultaneously the plug element engages with the mating plug element to establish electrical connection. This combining of operations reduces the number of discrete steps in the assembly process, thereby reducing process complexity while maintaining ease of operation through the unified automated action.
Data Source
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AI summary
A method for the automated assembly of a light module (1) for a motor vehicle headlight using an assembly robot, the method comprising the following steps: providing a light-emitting assembly (2) and an optical device (4) configured to generate at least one light function from the light of the light-emitting assembly (2) in an assembled state of the light module (1), providing a plug-in device (5) and an assembly robot for the automated assembly of the light module (1), 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: picking up the light-emitting assembly (2), positioning the picked-up light-emitting assembly (2) on the optical device (4), plugging the plug-in device (5) together using the assembly robot,so that the light-emitting assembly (2) is secured against displacement in the opposite direction of insertion (6).