Austrian plant engineering firm Vescon developed a solution for producing modern LED headlights for the Slovakian plant of well-known Tier 1 supplier. The focus was on efficient handling systems, the correct processing of time-critical production steps and end-to-end traceability. Specialists from Festo's Technical and Application Center, who were taking care of the turnkey handling systems, made up part of the team.
The headlight assembly system
The operator places the cooling element (with holes for insertion of the reflectors) in the station and the thermally conductive paste is applied automatically on both sides using the Festo handling system. It always brings the two-component dispensing system to exactly the right position on the right track. In the next step, the printed circuit board with the five LEDS is positioned in the paste on the cooling element. Then the reflectors, with their guide pins to ensure optimum positioning, are applied. Once this is done, the operator removes the complete cooling element and takes it to the next station, where a further Festo handling system takes care of the movement of the rivet head tool.
Here, there are two EGC-80 toothed belt axes with guide slides, synchronized via a connecting shaft and with a space-saving right-angle gear unit (x-axis). There is also a type EGC-HD-160-BS heavy-duty axis with sturdy double guide (y-axis) and a type PLFN flange gear. All axes are equipped with servo actuator packages with multi-turn encoders.
Project Manager Legat is delighted with the ready-to-install handling solutions: "We just gave details of the required characteristics, we defined the loads and the paths or tracks that had to be traveled and then we didn't have to give any more thought to this part. This simplified our work enormously as did being able to use the handling system CAD data that Festo provided us, with for the design of the complete system."