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In the context of the booming new energy vehicle market, the automotive lighting industry has also reached a turning point in its high-growth phase. The demand for product upgrades is increasing, and its role has far exceeded the traditional scope of lighting functions. As an indispensable exterior component of a vehicle, it not only ensures driving safety at night or in extreme weather but has also become a highlight in the exterior design competition among car manufacturers. Meanwhile, the production and assembly process of automotive lights is also keeping pace with the times, moving towards automation, intelligence, and flexibility.

Challenges and Responses in the Wave of Intelligent Assembly

Following the trend of intelligent manufacturing, the degree of automation in automotive light assembly is accelerating, with more collaborative robots gradually replacing manual operations. However, limited by the load capacity of robots, stricter lightweight requirements are imposed on assembly equipment. At the same time, the rapid iteration of automobiles has driven automotive light components towards small-batch, multi-variety development, which in turn demands higher flexibility and efficiency from assembly equipment.

Lightweight Tightening Equipment, Compatible with 5kg/7kg Collaborative Robots

Solution: The integrated module integrates the transmission mechanism, simplifies the pneumatic and electrical assembly procedures, and reduces the load requirements of the mobile mechanism. This brings more usable space, less installation and debugging time, and lower cost expenditure.

Additionally, quick-change nozzles are designed with a simple structure and convenient disassembly, allowing for tool-free quick replacement of bits. This flexibility meets the switching and tightening needs of different screw materials. The feed tube or the arm of the swing-arm nozzle can also be disassembled without tools, quickly resolving screw jamming issues at the nozzle.

Moreover, the Universal Module V3 version, through structural improvements and simplifications of the body and nozzle components, has a shorter length, lighter weight, and more compact size. This comprehensively reduces the load on collaborative robots and improves production beats.

Precise Solutions for Different Screw Types

In the assembly process of automotive lights, differentiated screws are used according to the diverse attributes of components to ensure assembly quality and performance. Specifically, for components with high vibration resistance and sealing requirements during operation, footed screws are specially selected. When dealing with thicker connecting parts, double-ended studs are flexibly used for connections. Additionally, with the gradual full plasticization of automotive lights, self-tapping small screws have become the mainstream choice and are widely used in the tightening operations of automotive light components.

The diversity of screw types also poses multiple challenges to the automated assembly of automotive lights, requiring precise matching of corresponding technical solutions to ensure stable performance.

Challenge 1: Footed Screws with Inconsistent Heights Due to Improper Washer Installation

Solution: A downward pressure structure design is adopted. Once the screw enters the track, it ensures that the screw head and washer are closely attached, reducing the occurrence of screw jams at the separation point and enhancing equipment stability. Additionally, the stepwise screw feeder, with its low screw jamming rate and high stability, ensures continuous production on the assembly line.

Challenge 2: Double-Ended Studs with Different Thread Lengths on Each Side

Solution: Combining a stepwise screw feeder with a vision system, the lengths of the threads are identified visually, and the materials are then blown to the tightening mechanism in a uniform orientation to ensure tightening quality. For hexagonal double-ended studs, the stepwise screw feeder is also used to avoid wear and debris generation, achieving clean feeding.

Challenge 3: Self-Tapping Screws in Plastic Components Prone to Stripping or Floating

Solution: Intelligent tightening tools are used, which have high precision with a standard deviation accuracy of ±2.5%, ensuring stable torque output within the full range. Additionally, these tools can monitor torque, angle, and time, enabling timely detection of stripping or floating issues. Moreover, tightening data can be synchronized to the MES system for quality traceability and management.