Six-axis industrial robots simulate real operating processes and capture the haptic characteristics of the control elements. Simulation of real operating processes Capture of dynamic rotary movements Measurement of friction and actuation forces Assessment of resistance, smooth operation, and return behavior

Mechanical and Electrical Testing

Mechanical test methods and automatic contacting complement the haptic assessment of the components. Wobble circle testing to detect bent or misaligned pins Automatic contacting for functional testing Electrical signal feedback to verify switching points Results provided for quality assessment

Variants and Series Production

Interchangeable adapters and centralized line control support different product variants and repeatable series production. Drawer system with interchangeable adapters Testing of different product variants and types Central collection and visualization of test results Repeatable and efficient testing in series production

EOLT Systems

Multiple Haptic Component Testing

This end-of-line test line, with five stations and two robotic cells, tests the haptic, visual, and functional characteristics of automotive control panel bezels and switches

An intelligent, centralized network of the test cells flexibly controls and monitors all test processes and adapts them to different test specimens. The line combines robot-assisted haptic tests, dynamic force-displacement and torque measurements, and optical inspections (AOI) in one integrated test system. This ensures precise, repeatable, and efficient quality assurance in the end-of-line process.

Challenges and Concept

The end-of-line test line consists of three coordinated stations for comprehensive quality testing of automotive control panel bezels and switches. Two integrated robotic cells perform the haptic testing processes and ensure highly repeatable measurement results.

Blinker, Kamera, Heizung und Assistenzsysteme.

EOLT Systems

Außenspiegel

Multiple Haptic Component Testing

Automated EOL Test Line for Haptic Components

Six-axis industrial robots precisely capture and evaluate dynamic rotary actuation, friction forces, and force-displacement profiles. The setup is complemented by mechanical test methods such as wobble circle testing and electrical contacting to check component functionality.

The entire line is controlled centrally by an MCD-integrated line control system. Reject (NIO) parts are discharged via pneumatic chutes and monitored by a through-feed sensor. The graphical user interface, as well as visualization and evaluation of the test process, are provided via MCD tool monitors.

Test Line

3 stations

Robotic Cells

Robotics

6-axis industrial robots

Ein flexibler End-of-Line-Prüfstand

MCD entwickelte hierfür einen flexiblen End-of-Line-Prüfstand, der sämtliche Varianten innerhalb von weniger als 30 Sekunden prüft. Das System kombiniert optische, mechanische und elektrische Prüfverfahren zu einem durchgängigen Prüfkonzept.

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Produktvarianten

Über 30

Taktzeit pro Bauteil

Taktzeit pro Bauteil

Unter 30 s

Qualitätskontrolle vor Auslieferung

100 %

Testing and Functional Scope

The end-of-line test line performs repeatable testing of haptic components in automotive control panel bezels and switches as part of an automated production process:

EOL test station for haptic components

Overall view of the test station

Test cell with operator monitors

Open test station for haptic components

Front view of the test system

Test area and measurement technology

Six-axis industrial robots simulate real operating processes and capture the haptic characteristics of the control elements.

Simulation of real operating processes
Capture of dynamic rotary movements
Measurement of friction and actuation forces
Assessment of resistance, smooth operation, and return behavior

Force-displacement profiles and torque curves are captured and evaluated in real time.

Force-displacement measurements on push buttons and switches
Torque measurements on rotary switches
Real-time evaluation of measured values
Verification of switching points

Mechanical test methods and automatic contacting complement the haptic assessment of the components.

Wobble circle testing to detect bent or misaligned pins
Automatic contacting for functional testing
Electrical signal feedback to verify switching points
Results provided for quality assessment

Interchangeable adapters and centralized line control support different product variants and repeatable series production.

Drawer system with interchangeable adapters
Testing of different product variants and types
Central collection and visualization of test results
Repeatable and efficient testing in series production

Bauteilaufnahme im EOL-Prüfstand

Kamerasystem im EOL-Prüfstand

Multifunktionaler Außenspiegel · Symbolbild

Einblick in die MCD Prüflösung

Variantenspezifische Prüflogik

Der Prüfstand überprüft sämtliche vorhandenen Funktionen des Außenspiegels:

Spiegeleinstellungen

Kamerasysteme kontrollieren Lichtfunktionen und Spiegelstellungen, während Antriebe, Klappmechanismen und elektrische Funktionen automatisiert getestet werden.

Verstell- und Klappfunktion

Spiegelheizung

EC-Abblendglas

Lichtfunktionen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Blinker

Spurwechselassistent

Umfeldbeleuchtung

Kamerafunktion

Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Kamerafunktion

Länderspezifische Varianten

Auch das Nichtvorhandene zählt.

Die Negativprüfung stellt sicher, dass sich nicht verbaute Ausstattungsmerkmale nicht aktivieren lassen. Geprüft wird auch, was fehlen muss.

Integrated Line Control and NIO Ejection

The MCD-integrated line control system coordinates the test process across all three stations. Reject (NIO) parts are discharged pneumatically, and a through-feed sensor monitors the ejection process.

Test Methods and Results

Combining haptic, electrical, and visual testing enables precise and repeatable quality control of the control elements within the automated end-of-line test line.

Haptic Testing

Capture of torque profiles on rotary switches

Force-displacement curves for push buttons and switches

Assessment of haptic characteristics

Verification of switching points via electrical signal feedback

Visual Inspection

AOI testing of LED color and brightness

Assessment of LED position

Inspection of symbol quality and legibility

Automated testing of search, day, night, and functional lighting

Image Analysis and Test Technology

High-resolution cameras for visual inspection

Detailed image analysis with the MCD Vision ToolMonitor

Different gripping and actuation tools in the robotic cells

Central visualization and evaluation via MCD tool monitors

Process and Quality Assessment

Precise capture of haptic characteristics

Repeatable measurement results

Combined haptic, electrical, and visual quality control

Test results provided for quality assessment

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

Optische Prüfungen

Ein Kamerasystem erfasst Lichtfunktionen, Symbole und die Spiegelstellung.

Kamerabasierte Erkennung von Lichtfunktionen

Analyse von Spiegelstellungen

Kontrolle des Spiegelglases

Mechanische und elektrische Prüfungen

Antriebe und Klappmechanismen werden mechanisch geprüft, während Winkelpositionen bestimmt sowie Spannung und Stromaufnahme gemessen werden.

Bewegungsprüfung der Antriebe

Winkelmessung der Klappfunktion

Stromaufnahme der Motoren

Funktions- und Qualitätsbewertung

Eine besondere Herausforderung ist die hohe Variantenvielfalt der Außenspiegel. Unterschiedliche Ausstattungsmerkmale werden automatisch erkannt und gezielt geprüft.

Prüfung komplexer Ausstattungsvarianten

Sichere Erkennung von Fehlerbildern

Reproduzierbare Ergebnisse

FREQUENTLY ASKED QUESTIONS

FAQS

This EOL (end-of-line) test line is an automated testing system at the end of a production line. Within the robotic cells, visual, haptic, and functional tests are performed using gripping, probing, and contacting elements. This ensures consistent functionality and quality without the influence of human error.

This line combines multiple test methods: haptic tests such as torque, friction resistance, and force-displacement measurements; mechanical wobble circle tests; electrical current, voltage, or load measurements; and visual inspections of LEDs, symbols, and lighting.

The robots in the test cells perform precise and repeatable haptic testing. Six-axis articulated robots simulate real human operating movements while measuring component forces, torques, and mechanical resistance. Defective parts (NIO) are discharged and separated via monitored reject chutes.

Visual inspection is performed using an AOI (Automated Optical Inspection) system with specialist cameras. The test specimens are specifically illuminated in a darkened cell. LED color, brightness, symbol quality, and different lighting conditions are automatically captured and assessed against defined target parameters.

All captured measurement and test data is consolidated and visualized centrally via the MCD line control system. The system also coordinates the associated test sequences and centrally provides relevant process information. Linking the data to the test specimen’s unique UID enables complete traceability and documentation. Connected label printers can also provide relevant product and test data directly for shipment preparation.