The project involved the full modernization of an outdated headlamp rain test system that no longer met current automotive industry requirements.

The mechanical washing enclosure was preserved, while the entire automation architecture was rebuilt, resulting in a modern, high-performance testing solution aligned with current industrial standards.

• Rain simulation testing for automotive headlamps

• Recipe-based test configuration per headlamp model

• Individual adjustment of process parameters

• Automatic recording of test data

• Full traceability of executed tests

Executed works included:

• Complete automation system reconstruction

• PLC integration

• Touchscreen HMI implementation

• Full electrical panel redesign and rewiring

• Integration of sensors for process parameter monitoring

Test parameters adjustable per recipe:

• Water temperature control

• Water pressure regulation

• Headlamp rotation speed control

• Washing time

• Drying time

• Model-specific custom parameters

All test data is:

• Automatically saved in XML format

• Accessible locally and via PC

• Recorded individually for each executed test

The operator selects the desired headlamp model and test recipe via the HMI interface.

The PLC controls the full test sequence, including water parameters, rotation, washing and drying cycles.

All parameters are monitored and recorded automatically, ensuring consistent performance and full traceability.

The project included complete electrical documentation update, PLC and HMI program backups, operator manual delivery, and calibration certificates for integrated sensors.

The system is currently operational within the laboratory of a major automotive industry company.