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Automated Photometric Inspection Station — 4-Position Index Table

Machine Design Siemens S7-1200 Valeo 2022–2023

Led the Exxerpro team that designed, built and programmed a 4-position indexing photometric test station for Valeo Sistemas Eléctricos to automatically inspect three automotive headlamp models (LB Spot, LB Wide, HB) — including validating and correcting deficiencies in a design the client had already supplied.

Scope of Work

  • Mechanical design and fabrication of a 4-station index table with quick-disconnect nests and Dajac alignment.
  • Electrical panel design and assembly, plus the pneumatic clamping system.
  • PLC/HMI programming for manual and automatic sequencing.
  • Safety light-curtain and e-stop integration.

Architecture

The 4-position indexing table carries two part nests per station. Each position aligns the headlamp via Dajac sensors before photometric measurement; the PLC drives indexing, clamping and safety interlocks, with dedicated HMI screens for process, manual, alarms and I/O.

Technology

  • Siemens S7-1200, Simatic HMI
  • Safety light curtain, e-stops
  • Dajac alignment sensors, pneumatic clamping