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Robotic cell for automating testing, laser marking, and labelling of automotive lights
A technically advanced solution for a stable cycle time, higher productivity, and reliable quality in the automotive industry.
For a client in the automotive industry, we designed and built a dedicated robotic cell intended for the automated handling of existing process machines used for automotive lighting production. The cell integrates leak testing, laser marking, contacting, and labeling into a single, repeatable, and safe process. The solution is based on two industrial robots, specially designed grippers, transfer stations, and separate output conveyors for good and defective parts.
Initial challenge – The client faced challenges in achieving the required cycle time, high dependence on manual labor, and increased risk of errors and product damage during manual handling. The existing process required up to five operators, with efficiency heavily dependent on human factors. In addition, it was necessary to ensure reliable separation of good and defective parts and integrate existing machines into a single automated system.
Result – By robotizing the process, the client achieved a stable cycle time of 47 seconds per pair and increased productivity through continuous automated operation. The number of operators required was reduced from five to one, while product damage caused by manual handling was eliminated. The process became less sensitive to human error, and defective parts are reliably separated at an early stage of production.
Solution description
Robotic cell is built around three existing client machines:
- a system for automotive light leak testing,
- a laser marking machine,
- and a contacting device.
Parts are placed on a worktable with dedicated fixtures, and the operator simply confirms their presence by pressing a button. From that point, the cell runs fully automatically. Two industrial robots are synchronized via software, sharing tasks and workspace to maximize efficiency and throughput. At the end of the process, lights are sorted into good and defective parts using two separate output conveyors.
Designed with a modular approach, the system can be adapted for different types of lights, process changes, or the integration of additional operations in the future.
Light placement on the input worktable
Proces delovanja robotske celice
1. Operator places the automotive lights into the input fixtures on the dedicated worktable and confirms their presence by pressing a button.
2. Robot 1 picks up the lights from the fixtures and transfers them to Machine 1 for leak testing.
3. Once testing is complete, Robot 1 removes the lights from Machine 1 and moves them to a transfer station for re-gripping.
4. Robot 1 then transfers the appropriate lights to Machine 2 for laser marking.
5. Robot 2 takes over the process, picking up the lights from the laser machine and transferring them to Machine 3, where contacting and functional verification are performed.
6. After this operation, robot 2 moves the lights to the labeling station, where either an EOL label or a defective part label is applied.
7. Robot 2 sorts the lights into good and defective parts and places them on the corresponding output conveyors.
8. The cell immediately starts the next cycle without interruption.
Our solution includes
- two industrial robots,
- custom-designed robotic grippers,
- input worktable with dedicated fixtures,
- transfer stations for re-gripping parts,
- labeling system,
- output conveyor for good parts,
- output conveyor for defective parts,
- safety fence with access control,
- central control system with communication to existing machines.
This robotic cell is just one example of our custom solutions for the automotive industry. Explore other projects we have successfully delivered for clients in the automotive sector.
Custom robotic grippers
To ensure reliable and safe handling of automotive lights, we developed custom robotic grippers tailored to the geometry, weight, and sensitivity of the parts. The grippers provide stable handling throughout all stages of the process, preventing surface damage and ensuring high repeatability in positioning.
Gripper 1 combines mechanical and vacuum gripping, precisely positioning the part in plastic supports. A stable hold is maintained through vacuum suction cups and pneumatic mechanical components, ensuring reliable handling even in challenging orientations and during dynamic transfers between stations. Part presence is verified via photoelectric sensors for mechanical gripping and additionally monitored through vacuum control, significantly increasing process safety and preventing transfer errors.
Gripper 2 uses a mechanical pneumatic grip, designed for repeatable, stable holding and precise positioning of parts within the process machines. Part presence is monitored with photoelectric sensors, enabling reliable operation at production takt times and minimizing the risk of part misplacement or omission.
This gripper design ensures high process stability, short cycle times, and reliable operation in serial production, while providing flexibility for adaptation to different types of automotive lights.
The effects of automation in industrial processes are reflected not only in a more stable cycle time and higher product quality but also in clearly measurable economic indicators. Key factors in such projects typically include reduced dependence on manual labor, number of shifts, annual labor costs, and investment amortization.
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Automotive lighting robotic cell