Complete sunroof vehicle working condition simulation

Simulate all scenarios of full opening, half opening, anti-pinch protection, and limit power outage;

High-precision visual gap detection

Skylight sealing gap detection accuracy is ±0.01mm;

Anti-pinch force closed-loop precise control

Detects the anti-pinch triggering force with an accuracy of ±0.2N, which complies with the national skylight safety standards;

Vehicle model program database storage

Built-in electronic control test programs for sunroofs of various models, one-click switching;

Lightweight desktop structure

The whole machine occupies only 6 square meters and can be placed at any testing station in the workshop;

Automatically generate quality inspection reports from inspection data

Export IATF compliance PDF report with one click

Parameter items

Technical indicators

Adapted products

Panoramic sunroof and segmented sunroof electronic control assembly for fuel/new energy vehicles

Single unit detection rhythm

80s/set

control system

Siemens S7-1500 small PLC, 10-inch touch HMI

Anti-pinch detection accuracy

±0.2N, range 5~100N

Gap visual detection accuracy

±0.01mm

Simulation conditions

5 modes: fully open, half open, closed, anti-pinch trigger, and limit power-off

Traceability

The QR code of the sunroof assembly is bound to the electrical control, gap, and anti-pinch force detection data.

Equipment area

6㎡ desktop independent tooling

Full working condition simulation test of electric sunroof control

The inspection tool is connected to the sunroof motor, limiter, and anti-pinch sensor to automatically execute full-open, half-open, and close cycles, simulate foreign objects triggering anti-pinch protection, detect anti-pinch response speed, power-off limit accuracy, verify the safety logic of the sunroof electronic control module, and eliminate safety hazards such as the driving sunroof catching people and being unable to close.

Closed-loop accurate detection of sunroof anti-pinch strength

The servo outputs standard pressure to simulate the obstruction of foreign objects, collects the anti-pinch triggering force in real time, and automatically compares it with the national standard safety zone. If the force is too strong, it may pinch passengers, and if the force is too small, it may accidentally trigger the faulty part and automatically divert the faulty parts to ensure compliance with sunroof driving safety standards.

Visual inspection of skylight sealing gaps

The high-definition vision camera scans the assembly gap between the sunroof glass and the body frame, and automatically determines whether the gap meets the tolerances of the OEM's drawings. If the gap exceeds the tolerance, the workpiece is poorly marked to avoid water leakage and excessive wind noise in the vehicle.

Test reports are automatically generated and exported

After the inspection of each set of skylights is completed, the system automatically generates a PDF quality inspection report, which includes all values of electronic control response time, anti-pinch strength, and sealing gap. It can be directly used for second-party review by the OEM, eliminating the need to manually fill in inspection records.

Single piece quality traceability of sunroof parts

Each sunroof assembly is bound with an exclusive QR code, and electronic control, anti-pinch, and gap detection data are permanently stored. It is connected to MES to realize full-process quality traceability of sunroof interior parts.

Commercial value: After-sales failures such as sunroof anti-pinch failure, water leakage, and wind noise have been reduced by 89%, replacing 2 manual inspection personnel; desktop small tooling does not need to occupy a large area of ​​the factory, and each assembly line in the skylight parts factory can be equipped with a full inspection machine.

Multi-light environment simulation system

Simulate vehicle usage scenarios with strong daylight and low light at night;

High-precision imaging visual inspection

Identify micron-level projection black spots, chromatic aberration, and distortion defects;

Automatic correction and determination of optical path assembly deviation

Detect assembly deviation of lenses and projection modules;

W-HUD/AR-HUD dual product compatible

Switch between two types of HUD detection programs with one click;

Sealed light-shielding detection chamber

Isolate ambient light interference in the workshop to ensure stable detection accuracy;

Permanently archive inspection images

Each HUD projection screen is photographed and saved to facilitate quality review.

Parameter items

Technical indicators

Adapted products

Vehicle-mounted W-HUD, AR-HUD head-up display assembly

Single unit detection rhythm

100s/set

control system

Siemens S7-1500 small PLC, 12-inch industrial HMI

Lighting simulation interval

0~100000lux daylight strong light simulation, 0~500lux nighttime weak light

Visual imaging resolution

4K industrial camera, color difference detection accuracy ±1ΔE

Optical path deviation detection accuracy

±0.02mm, identify lens assembly deviation

Traceability

The HUD housing QR code binds projection image quality, light path detection images and data

Equipment area

8㎡ sealed light-shielding desktop workstation

Projection image quality testing in multiple lighting environments

The sealed light-shielding cavity isolates stray light in the workshop. The adjustable light source simulates noon daylight and night driving lighting in the tunnel. The HUD illuminates for projection imaging. The 4K industrial camera completely captures the projection image. The AI algorithm identifies black spots, scratches, color aberration, and image distortion defects, and defective products are automatically diverted for repair.

Optical path lens assembly accuracy inspection

Visually scans the assembly position of the projection lens and reflector inside the HUD to detect optical path deviation and lens tilt. If the optical path deviation exceeds tolerance, the workpiece will automatically be judged as defective to avoid deviation, blur, and ghosting of the vehicle's projection screen.

W-HUD/AR-HUD flexible program switching

It has a complete set of inspection process databases for two types of HUDs. The HUD of new models added by the OEM only needs to import drawing parameters to generate inspection programs. There is no need to re-develop tooling, and it is suitable for the rapid mass production introduction of new products.

Projection screen image archiving and traceability

When each HUD is inspected, a complete projection imaging photo is automatically taken, and the QR code is bound to the optical path deviation and color difference values for permanent storage. When a vehicle projection complaint occurs, the original factory inspection image can be retrieved to quickly determine defects at the production source.

HUD factory compliance quality inspection report output

The system automatically generates a PDF quality inspection report containing all indicators of illumination, color difference, and optical path deviation, meeting the IATF16949 audit requirements for automotive electronic components of the OEM.

Commercial value: after-sales faults such as blurred projection, chromatic aberration, and screen offset of the vehicle HUD have been reduced by 95%, completely eliminating the subjective error of artificial naked eye detection; the sealed light-shielding cavity is not affected by the light in the workshop, and the detection consistency is greatly improved, adapting to the strict quality standards of high-end new energy car companies' HUDs.