Headlight Production Line
Production Line Layout Diagram
Production Line Planning Guidelines
The production line occupies an area 11.5 meters long and 6 meters wide, comprising a total of 11 workstations (OP01–OP11); the pre-inspection station is located outside the production line.
Electrical Workbench
Standard electrical workbenches are the most commonly used assembly equipment on headlight assembly lines. These workbenches are equipped with a PLC control system, a human-machine interface, a quick-change tooling system, an anomaly alarm system, and optional features such as a screw tightening monitoring system, an electric screwdriver balancing system, an automatic screw feeding system, and an MES traceability system.
The standard electrical workbench is designed to handle the sub-assembly and final assembly of front and rear light components. When used with specialized fixtures, it facilitates complex assembly operations such as pressing, impact assembly, and flipping, thereby reducing cycle times and improving production quality.
Pressing Machine
Overview: The press machine is a machine designed to operate in conjunction with upper and lower tool assemblies. Standard configurations include a PLC control system, a human-machine interface (HMI), a quick-change tooling system, and an anomaly alarm system. Optional features include a screw tightening monitoring system, an electric screwdriver balancing system, an automatic screw feeding system, and an MES traceability system. Applications: The press machine is suitable for general-purpose equipment requiring the movement of upper and lower tooling.
Common applications include bonding mirror assemblies, pressing in dimming screws, and pull-out testing of lamp assemblies.
Vibration-based dust removal
Overview: This vibrating electrostatic dust removal equipment is designed to eliminate static electricity and remove foreign objects from lamp assemblies prior to their final assembly. The vibration table control system integrates an electrostatic elimination system, a vibration system, and a dust collection system.
Purpose: To remove static electricity and residual debris from the interior of the lamp housing before installing the front and rear lamp covers or welding,
and to inspect the product by powering it on after vibration testing to check for defects such as loose connections, incorrect connections, poor connections,
poor soldering, or abnormal filaments.
Adhesive Application and Joining Workstation
Overview: The standard electrical workstation is the most commonly used assembly equipment on automotive headlight assembly lines. It is equipped with a PLC control system, a human-machine interface (HMI), a quick-change tooling system, an anomaly alarm system, and optional features such as a screw tightening monitoring system, an electric screwdriver balancing system, an automatic screw feeding system, and an MES traceability system.
Application: The standard electrical workbench is designed to handle both sub-assembly and final assembly tasks for front and rear lighting components. By integrating with specialized tooling, it performs complex assembly operations such as pressing, impact, and flipping, thereby reducing cycle times and improving production quality.
Airtight Dimming Tester
Overview: The headlight airtightness and beam pattern testing machine is an integrated testing device that combines airtightness testing and beam pattern testing. Through multi-threaded task processing, beam pattern and airtightness testing are performed simultaneously without interfering with each other, thereby improving testing efficiency.
Application: The headlight airtightness and light pattern testing equipment uses an automatic light adjustment and airtightness testing fixture to automatically adjust the light pattern while simultaneously measuring parameters such as the sharpness and levelness of the cut-off line, luminous intensity, illuminance, color temperature, LED light guidance, and current.
Recirculating cooling tower
Overview: The recirculating cooling tower is equipped with 12 baskets, each holding a single product. Each basket operates for 60 seconds, and each lamp cures inside the tower for 12 minutes.
Purpose: Lamps coated with hot-melt adhesive undergo accelerated curing inside the cooling tower. The recirculating cooling tower effectively accelerates the cooling of the lamps, ensuring consistent product dimensions.
Comprehensive Testing Machine
Overview: The integrated inspection machine uses cameras positioned above and below to inspect LEDs on one side and check for missing components on the other.
Purpose: After production, the machine performs a comprehensive inspection of the product’s lighting and current performance, while simultaneously checking for missing accessories that are commonly overlooked, such as screws, venting membranes, venting caps, mounting brackets, and mounting clips.
Lamination Inspection Workstation
Overview: The electrical lamination workstation consists of an electrical system and an automatic film-cutting mechanism.
Purpose: This electrical lamination workstation is capable of performing product inspections, detecting missing components (via fixtures), applying protective film, and conducting manual visual inspections of products.
Material Rack/Material Cart
Overview: A variety of material racks and carts are used for material storage, handling, and transportation on the automotive lighting production line.
Rear Light Assembly Line
Machine tool fixtures
Welding Machine for Rear lighting
Equipment Overview
Description: The hot plate welding machine primarily uses a temperature controller to regulate the temperature of the heating plate (heating methods include hot plate heating and infrared heating). This process is used to weld plastic workpieces. The heating plate is positioned between two plastic workpieces. When the workpieces approach or come into contact with the heating plate, the plastic on both sides begins to heat up and melt. Once the preset melting depth and time are reached, the two plastic workpieces are separated, the heating plate retracts, and the two workpieces are then joined together. After reaching the curing depth, cooling and curing begin. Once the curing time is complete, the mold opens and the part is removed, completing the welding process.
Key Features: Depending on product requirements, the system can be driven by a servo motor or a pneumatic cylinder. Parameters such as welding temperature, heating time, cooling time, welding depth, pressure, and welding duration are all adjustable. Depending on the welding program requirements, either semi-automatic or fully automatic modes can be selected. The welding program can be adjusted to accommodate various materials, and mold changes are convenient thanks to a quick-change mechanism. Safety doors and safety light curtains are employed to fully ensure operator safety.
Servo-Driven Hot Plate Welding Machine
The upper and lower sections are guided by precision linear bearings, while the hot plate is guided by precision linear rails.
Servo motors provide the driving force, ensuring precise positioning and multi-speed operation. The upper die mounting plate is machined from high-quality steel plate that has undergone aging treatment. The machine is equipped with multi-point emergency stop switches and safety light curtains to ensure greater safety for operators. Standard machine die dimensions: 1000 × 800 × 660 mm / 1200 × 800 × 660 mm
Maximum stroke of the upper die: 500 mm
Maximum stroke of the lower die: 500 mm
Hot Plate Tooling
The hot plate is made of high-quality forged brass and is machined as a single piece to ensure a perfect fit with the machine. The upper and lower tooling components are machined from aluminum alloy to match the machine’s contours. Areas in contact with the surface parts have been mirror-polished to prevent indentations on the surface.
The hot plate heats up to operating temperature in less than 60 minutes.
A dedicated mold-changing cart enables quick and safe mold changes, thereby improving machine utilization.
Vibration welding
Equipment Overview
Features: This machine is equipped with a precision electronic scale to detect the position of the worktable and control the amount of material melting during the welding process, further enhancing welding accuracy and consistency.
Description: By transmitting linear vibration energy to the upper and lower contact surfaces of thermoplastic products under pressure, displacement friction is generated. The resulting frictional heat fuses the products together seamlessly. The vertical movement of the worktable is controlled by a hydraulic system or a servo motor.
Main Functions: The linear vibration friction
welding machine applies linear friction to the upper and lower contact surfaces of the products. The resulting frictional heat is determined by the melting depth, amplitude, and pressure applied to the upper and lower products, providing strong weld strength. It is widely used in industries such as automotive parts, home appliances, and medical devices.
Overall Dimensions: 2605 mm (L) × 1286 mm (W) × 2290 mm (H)
Upper Die Weight: 40 kg
Drive Plate Dimensions: 870 mm (L) × 440 mm (W)
Worktable Dimensions: 1300 mm (L) × 600 mm (W)
Welding Area: 200 cm²
Amplitude: 0.7–1.8 mm
Vibration Frequency: 190–240 Hz
Output Power: 18.5 kW
Multi-stage pressure control worktable stroke: 500 mm
Ultrasonic welding machine for automotive lighting
Jfortune also manufacture Synchronous laser welding equipment.
Aging rack introduction
Suitable for tail light and center tail light combinations, front position lights, standalone tail lights, standalone center tail lights, and front-center position lights.
- Configurations: Standard wired version, combination function version (wired, CAN, LIN)
- Input: AC 220V, power 1–3 kW.
- Output: Utilizes a 0-16V regulated power supply; each layer features an independent 0-16V adjustable, 0-50A adjustable regulated power supply.
- Output Modes: 6 channels/5A standard wire-controlled lights, 16 sets of CAN commands, 16 sets of LIN commands; messages are
- Current and Voltage Monitoring: Each light is equipped with a separate module; each module has current and voltage detection capabilities (resolution: 1 mA)
- Output Sequences: Multiple sequences can be programmed and executed in sequence.
- Recipe Function: Lighting sequences can be saved as recipes and recalled directly when needed; no need to re-edit sequences even if the lamp ages.
- Scanning Function: Each lamp has a separate control module with a unique module code. By scanning the product code followed by the module code, the product code and module code are bound together.
- Distributed Control: Modules are controlled via an RS485 bus using the standard MODBUS protocol. Each module can operate independently.
- Data Logging: Utilizes an industrial PC combined with a database to record information such as module codes, product codes, current, and voltage for each process. Storage capacity: 1 TB