In 2015, a testing machine was developed for quality control of primary optics made of silicone, which are used in multibeam LED headlights for passenger cars. These optics are crucial for the light distribution in the headlight.
An operator loads two drawers with 20 optics each. An ABB robot removes these and places them on a rotary table, which guides them through several testing stations:
- Presence and height testing: Camera and confocal sensor check the position and height of the light guides.
- Light technical testing: The optics are darkened and illuminated from below. A light measurement camera evaluates the light transmission of each pin.
- Labeling: The optics are marked as 'Good' or 'Bad'.
- Sorting: OK parts go into the good drawer, NOK parts into the bad drawer.
I was responsible for the PLC programming with TIA Portal V14, the control of the rotary table, the design of the HMI interface, and the communication via Profinet. The commissioning at the customer included tests and final optimizations.