CN115945501A - Method for reproducing car lamp - Google Patents
Method for reproducing car lamp Download PDFInfo
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- CN115945501A CN115945501A CN202211604029.1A CN202211604029A CN115945501A CN 115945501 A CN115945501 A CN 115945501A CN 202211604029 A CN202211604029 A CN 202211604029A CN 115945501 A CN115945501 A CN 115945501A
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Abstract
The invention discloses a vehicle lamp reconstruction method, which relates to the technical field of vehicle lamp manufacturing, wherein recovered old vehicle lamps are classified according to vehicle types and light configurations and are disassembled into a bottom shell, a lamp shade, a large decorative ring and a decorative sheet, a far/near light lamp assembly, a steering lamp assembly, a wire harness, a light adjusting motor assembly, a light adjusting screw assembly, a wire clamp, screw hardware, a ventilating plug, ventilating cotton, a rear cover and a rubber sealing element in batches; by applying the remanufacturing method, the process technology and the professional facility equipment, the quality of the remanufactured automobile lamp product reaches the national standard, meets the requirements of industrial production technical specifications and the management system of automobile part remanufacturing enterprises, and meets the requirements of safety production and environmental protection regulations.
Description
Technical Field
The invention relates to the technical field of vehicle lamp manufacturing, in particular to a method for manufacturing a vehicle lamp.
Background
In the development history of automobiles for over one hundred years, the structure and functions of the lamps of initial oil gas lamps, incandescent lamps, halogen lamps, xenon lamps and LED lamps, and recently high-pixel LED projection headlamps and laser headlamps are also simplified, and the lamps are developed into richer, more integrated and more decorative functions.
During the daily running of an automobile, a headlamp is a main vulnerable part, and firstly, the headlamp is impacted by high temperature of an engine, sunlight, rain, storm wind, snow rain, sand and stone splashed during high-speed running, bumped, vibrated and damaged, so that plastics are naturally aged and yellowed, lamplight is darkened or broken, and secondly, the headlamp is damaged in automobile collision and scratch accidents.
In the prior art, after a vehicle lamp is damaged, a bulb is unloaded to be recycled as a spare part, and the damaged headlamp body is used for selling-changing treatment of waste articles, wherein a large number of parts with good quality in the interior are scrapped in advance to cause resource waste, and the reflector bowl of the high/low beam lamps made of BMC can only be used for dibbling treatment to occupy land as solid waste due to the fact that the reflector bowl can not be crushed to be sold and reused. The individual car lamp renovating workshop which is scattered and scattered is lack of production technology and professional facility equipment, the quality of renovated products of the individual car lamp renovating workshop far reaches the national standard requirements, the production technology does not meet the industrial specifications, the operation site is polluted greatly, and safety production and environmental protection regulations are violated, so that the individual car lamp renovating workshop is banned for the national regulation.
Disclosure of Invention
The present invention is directed to a method for manufacturing a vehicle lamp, so as to solve the problems of the prior art in the market.
In order to achieve the purpose, the invention provides the following technical scheme: a method for reconstructing a vehicle lamp, comprising the steps of:
s1: sorting and dismantling
Classifying the recycled old car lamps according to car types and light configurations, and disassembling the recycled old car lamps into a bottom shell, a lamp shade, a large decorative ring and decorative sheets, a far/near light lamp assembly, a steering lamp assembly, a wire harness, a light adjusting motor assembly, a light adjusting screw assembly, a wire clamp and screw hardware, a ventilating plug and ventilating cotton, a rear cover and a rubber sealing piece in batches;
s2: remanufacturing of bottom shells
The bottom shell is sequentially subjected to reverse engineering design, mold processing, mold testing, testing and inspection, injection molding processing is carried out after acceptance inspection is qualified, then inspection is carried out, inspection is qualified, warehousing is carried out, and after final assembly, the old bottom shell is classified and crushed according to materials and is used as a waste plastic raw material to be changed to be sold;
s3: remanufacturing of lamp shades
The method comprises the following steps of sequentially carrying out reverse engineering design, mold processing, mold testing, testing and inspection on a lampshade, carrying out injection molding processing after the lampshade is qualified, then inspecting, annealing after the lampshade is qualified, then carrying out UV paint spraying on the surface of the lamp and antifogging paint spraying in the lampshade, warehousing after the lampshade is qualified, and carrying out final assembly after the lampshade is crushed and is used as a waste plastic raw material for selling treatment;
s4: remanufacturing of large decorative ring and decorative sheet
Sequentially carrying out alcohol-dipping soft dust-free cloth wiping and static-removing ion air gun treatment on the large decorative ring and the decorative sheet, blowing clean by high-pressure air, and after the appearance is qualified, carrying out final assembly;
s5: remanufacturing of high/low beam light assemblies
S51: disassembly of high/low beam assembly
The high/low beam lamp assembly is disassembled into a high beam bulb clamp ring, a low beam lamp clamp ring, a high beam reflector bowl and a low beam reflector bowl.
S52: remanufacturing of far/near light bulb clamping ring
Soaking, neutral detergent → brush, washing → high pressure air blowing water beads → drying → inspection, qualified, ready to assemble; unqualified and scrapped, and the waste plastic is treated as the trade change of the waste plastic.
S53: remanufacturing of high/low beam reflecting bowl
Respectively checking the far/low light reflection bowls, and wiping the bowls with a fine soft cloth in running water, cleaning the bowls, blowing water beads with high-pressure air after the bowls are cleaned, drying, checking to be qualified, and waiting for assembly;
far/near light assembly: installing the bulb clamping ring on the far/near light reflection bowl seat by taking a new screw, inspecting, and waiting for final assembly;
s6: remanufacturing a turn signal assembly
S61: disassembly of the turn signal assembly
Disassembling the steering lamp assembly into a steering bulb, a steering lamp base and a steering lamp reflection bowl;
s7: remanufacturing of wire harnesses
Sequentially carrying out wire harness, cleaning, drying, appearance quality inspection and maintenance, maintenance and replacement of a new terminal shell, a plug, a contact pin and a lead, then carrying out appearance inspection and power-on test, warehousing after the inspection and the test are qualified, and waiting for final assembly;
s8: remanufacturing of lamplight adjusting motor assembly
The lamplight adjusting motor assembly is disassembled again and is disassembled into a motor body with a turbine, a motor driving plate, a turbine worm gear set, a push rod with a gear adjusting, a rubber sealing ring and an upper shell and a lower shell;
s81: remanufacturing of motor body with turbine
Wiping the motor body, checking the appearance of the motor, checking whether the plastic gear on the output shaft has broken teeth or broken teeth, measuring whether a motor coil is disconnected or not, judging whether a power-on test is normal or not, checking to be qualified, waiting for assembly, checking to be unqualified and scrapping;
s82: remanufacturing of motor drive plate
Cleaning a motor driving plate by dipping a brush in alcohol, checking the appearance quality, judging whether a power-on test is normal or not, checking to be qualified, waiting for assembly, checking to be unqualified, and scrapping;
s83: remanufacturing of turbine worm gear set
Cleaning the turbine worm gear set by the brush, checking whether the turbine has broken teeth or broken teeth, checking to be qualified, waiting for assembly, checking to be unqualified, and scrapping;
s84: remanufacturing of adjusting push rod with gear
Wiping the surface, checking the appearance quality of the push rod with the gear, checking whether the plastic gear has broken teeth or broken teeth, whether the push rod is bent or not, whether the screw thread on the surface of the push rod is deformed or rusted, checking to be qualified, waiting to assemble, checking to be unqualified and scrapping;
s85: remanufacturing of rubber sealing ring and upper and lower shells
Checking whether the sealing ring is deformed, aged and elastic loss, checking to be qualified, waiting for assembly, purchasing upper and lower shells, replacing a new shell, scrapping an old shell, and performing selling treatment as waste plastics;
s86: remanufacturing of lamplight adjusting motor assembly
Assembling remanufactured parts in S81, S82, S83, S84 and S85 into a lamplight adjusting motor assembly, paying attention to control assembly clearance of a turbine worm, checking whether a reduction gear set of the turbine worm is mutually occluded or not with clamping stagnation, electrifying to test functions of the remanufactured lamplight adjusting motor assembly, thrust moment, checking to be qualified, inspecting to be unqualified after final assembly, disassembling, and removing and scrapping unqualified parts;
s9: remanufacturing of light adjusting screw assembly
Cleaning the assembly by dipping the clean fine soft cloth in alcohol, checking the appearance quality of the universal joint ball bowl seat, the ball head adjusting rod, the screw and the sealing ring, checking to be qualified, checking to be unqualified after final assembly, scrapping, and classifying according to the material quality to be used as the selling of waste articles;
s10: remanufacturing of wire clamp and screw hardware
S101: remanufacturing of non-standard hardware such as wire clamps
Removing oil and dirt on the parts, spraying paint again, then inspecting, and waiting for final assembly;
s102: remanufacturing of standard hardware such as screw and nut
Purchasing and replacing new parts, and taking the deformed wire clamp and the old screw as scrap iron selling treatment;
s11: remanufacturing of breathable plug and breathable cotton
Purchasing new parts and scrapping old parts;
s12: remanufacturing of rear cover and rubber sealing element
S121: rear cover remanufacturing
Soaking, cleaning by using a neutral detergent, drying by using high-pressure air to blow dry water drops, finally performing appearance inspection, inspecting, and checking to be qualified, performing final assembly, inspecting unqualified products, scrapping, performing selling change treatment on the waste plastics, sequentially performing die sinking, injection molding and inspection on parts with insufficient manufacturing quantity of old rear covers, inspecting to be qualified, warehousing, and performing final assembly;
s12: rubber seal remanufacturing
Purchasing and replacing new parts, and scrapping old parts;
s13: assembly for remanufacturing vehicle lamp
The remanufactured ventilating plug, the lamplight adjusting screw assembly, the wire harness, the wire clamp, the lamplight adjusting motor assembly, the far/near light lamp assembly, the steering lamp assembly, the large decorative ring and the decorative sheet are respectively installed on a headlamp bottom shell by screws one by one, then the steering lamp assembly, the large decorative ring and the decorative sheet are clamped into a positioning tool, the surface of a groove of the bottom shell is automatically cleaned and activated by an atmospheric plasma cleaning manipulator, hot melt adhesive is automatically and uniformly injected into the groove of the bottom shell by an adhesive injection manipulator, lamp feet of a lamp shade are inserted into sealant of the groove of the bottom shell, the lamp shade is tightly attached to the bottom shell by pressing the lamp shade, the lamp shade is bonded and sealed with the bottom shell by the hot melt adhesive, the lamp shade is locked on the bottom shell by the screws to prevent the vibration, the hot melt adhesive is cooled and solidified, and the finished product is inspected and packaged.
Preferably, the appearance defective product in S4 is treated as follows:
discarding the obviously unqualified product with deep defect or coating layer scratch, classifying the product according to the material quality, and crushing the product to be sold as a waste plastic raw material;
the surface of the coating layer is foamed, falls off, discolors, fogs, yellows, scratches or scratches are carried out on slight defective products which do not damage the substrate, deplating, cleaning, high-pressure air blowing to remove water drops, drying, surface inspection, polishing, wiping, static electricity removing and air blowing, vacuum ion cleaning, UV primer spraying and vacuum coating are carried out in sequence, warehousing is carried out after the inspection is qualified, rejected treatment is carried out when final assembly is carried out, the defective products are classified according to the material quality, and the crushed products are used as the waste plastic raw material for selling change;
the method is characterized in that a large decorative ring and a decorative sheet which are high in breakage rate and insufficient in remanufacturing recycling amount are remanufactured, reverse engineering design, mold processing, mold testing, testing and inspection are sequentially carried out on the large decorative ring or the decorative sheet, batch injection molding processing, IPA (isopropyl alcohol) wiping, static electricity removing and air blowing by an ion air gun, vacuum ion cleaning and UV (ultraviolet) primer spraying are sequentially carried out after acceptance inspection is carried out, vacuum coating is carried out after quality inspection is qualified, warehousing is carried out after quality inspection is qualified, final assembly is carried out, unqualified products are scrapped, and waste plastic selling changing treatment is carried out by classifying and crushing according to materials.
Preferably, in S53, the appearance defective product is processed as follows:
scrapping unqualified products with deep damage, deformation and scratches, wherein the reflecting bowl made of BMC is delivered to an environmental protection company for landfill treatment, and the reflecting bowl made of iron is sold for disposal;
and (4) treating the slight defective products of the far/near reflection bowl with the coating layers which are blistered, fall off, discolored, fogged, yellowed, scratched or scratched and do not damage the substrate according to the deplating remanufacturing method in the step S4.
Preferably, in S6, the appearance of the turn signal lamp assembly is checked and treated as follows:
unqualified products with deep damage and obvious scratches are scrapped, a steering lamp reflecting bowl made of BMC is used as solid waste to be treated by an environmental protection company, and renewable plastics are classified and crushed according to the materials and used as waste plastics to be sold;
wiping and cleaning the qualified parts by using dustless fine soft cloth dipped with alcohol, then blowing the qualified parts by using high-pressure air of a static-ion removing air gun, and waiting for final assembly;
the reflector coating layer of the steering lamp changes color and yellows, bubbles, falls off, scratches or scratches do not damage the substrate, and the slightly unqualified product is processed according to the deplating remanufacturing method in S4.
Preferably, the step S13 of performing the product inspection includes:
and (4) functional test: installing a bulb, and respectively testing a dipped headlight, a high beam and a turn light to be qualified;
detecting the light distribution performance: turning on a low beam lamp and a high beam lamp, adjusting the light shape of the car lamp, and detecting the light distribution performance of the car lamp to be qualified;
and (3) air tightness testing: installing a sealing rubber ring and a rear cover on the headlamp, and testing the airtightness of the headlamp to be qualified;
and (3) carrying out appearance inspection on the headlamp: the front appearance quality of the headlamp is checked, and the lamp surface has no scratch, water thread, pattern, black spot, pinhole, pockmark, oil stain and fingerprint; no fingerprint, dust, screw and foreign matter of thread end exist in the lamp; the bottom shell has no scratch, white and oil stain; the socket and the wiring harness are correctly installed without defects; the racket has no abnormal sound; taking a hexagonal batch head to check whether the light adjusting mechanism is smooth or not, and correspondingly changing the high/low beam light assembly up and down; the rear cover is unscrewed to check the inner cavity, the wiring harness is firmly bound, the internal parts are not loosened, the hardware is bright and rustless, the wiring harness is qualified and labeled, the lamp surface is cleaned by using dust-free fine soft cloth to be stained with machine water, a protective film is pasted, and the packaging is carried out, the wiring harness is unqualified and reworked;
and (3) sheathing a rubber bag with a large lamp, putting a drying agent, a certificate and a product specification, tightening a bag opening, sheathing pearl cotton, filling the pearl cotton into a carton, sealing the carton, sticking an outer box label, warehousing, performing OQC sampling inspection, and finally leaving the finished product out of the factory.
Preferably, the disassembly in the S1 is carried out by adopting a far infrared heating furnace, the temperature is 110-120 ℃, and the baking time is 2-5 min.
Preferably, the drying temperature of the large decorative ring and the decorative sheet plastic part in S4 is 60-80 ℃, and the baking time is 4-6 h.
Preferably, the remanufacturing and deplating process for the large decorative rings and the decorative sheets in the S4, the S5 and the S6, the far/near light lamp assembly and the steering lamp assembly has the advantages that a coating layer of the remanufacturing and deplating process has bubbling, falling, color change, fogging, yellowing, scratching or scratches which do not damage a substrate and are slightly defective: 4 percent of sodium hydroxide is soaked in hot solution at 50-60 ℃ for 5-10 min.
Preferably, the bottom shell groove in S13 is activated by cleaning with atmospheric plasma.
Compared with the prior art, the invention has the beneficial effects that:
(1) By applying the remanufacturing method, the process technology and the professional facility equipment, the quality of the remanufactured automobile lamp product reaches the national standard, meets the requirements of industrial production technical specifications and the management system of automobile part remanufacturing enterprises, and meets the requirements of safety production and environmental protection regulations.
(2) The special equipment is used for inspection and detection, and the disassembled qualified parts are screened and then used, so that the use value of the parts is fully exerted, the service life is prolonged, the manufacturing cost is reduced, and the carbon emission is reduced.
(3) A large number of reflecting bowls, large decorative rings and decorative sheets with slightly poor surface coating layers are subjected to deplating remanufacturing, so that the utilization rate is greatly improved, particularly the reflecting bowls which are made of non-recyclable BMC (bulk molding compound) materials are subjected to remanufacturing, the generation amount of solid garbage is greatly reduced, and the occupation of dibble land resources is reduced.
(4) The scrapped parts are finely classified and crushed according to the material quality and then processed, so that the selling and utilization value of the waste articles is improved, and the method makes positive contribution to green, low-carbon, environment-friendly, energy-saving and renewable sustainable development.
Drawings
FIG. 1 is a flow chart of a method for remanufacturing a vehicle lamp according to the present invention.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
Referring to fig. 1, the present invention provides a technical solution: a method for reconstructing a vehicle lamp, comprising the steps of:
s1: sorting and dismantling
Classifying recycled old car lamps according to car types and configurations, putting the old car lamps into a large number of groups for disassembly, baking the old car lamps for 2-5 min at the temperature of 110-120 ℃ by using a far infrared hot blast stove, heating and melting sealant, inserting tools into the melted and softened sealant to pry a lampshade from a groove of a bottom shell, wearing heat-insulating gloves to break the lampshade from the bottom shell and remove the lampshade, and disassembling parts in a car lamp one by using tools such as an electric screwdriver, a nipper pliers, tweezers and the like into the bottom shell, the lampshade, a large decorative ring and a decorative sheet, a far/near light lamp assembly, a steering lamp assembly, a wire harness, a light adjusting motor assembly, a light adjusting screw assembly, a wire clamp and screw hardware, a ventilation plug and ventilation cotton, a rear cover and a rubber sealing element in a large number; wherein, the damage rate of the recycled used car lamp bottom shell and the lamp shade due to broken feet, cracking, breaking, scratching and the like is about 100 percent, the damage rate of the large decorative ring, the decorative sheet, the steering lamp assembly and the rear cover is about 30 to 40 percent, the damage rate of the far/near light assembly is about 20 to 30 percent, and the damage rate of other parts is less than or equal to 10 percent;
s2: remanufacturing of bottom shells
The bottom shell is sequentially subjected to reverse engineering design, mold processing, mold testing, testing and inspection, injection molding processing is carried out after acceptance inspection is qualified, then inspection is carried out, inspection is qualified, warehousing is carried out, and after final assembly, the old bottom shell is classified and crushed according to materials and is used as a waste plastic raw material to be changed to be sold;
s3: remanufacturing of lamp shades
The method comprises the following steps of sequentially carrying out reverse engineering design, mold processing, mold testing, testing and inspection on a lampshade, carrying out injection molding processing after the lampshade is qualified, then inspecting, annealing after the lampshade is qualified, then carrying out UV paint spraying on the surface of the lamp and antifogging paint spraying in the lampshade, warehousing after the lampshade is qualified, and carrying out final assembly after the lampshade is crushed and is used as a waste plastic raw material for selling treatment;
s4: remanufacturing of large decorative ring and decorative sheet
Sequentially carrying out alcohol soaking and light wiping on the dustless fine soft cloth and static ion removing air gun treatment on the large decorative ring and the decorative sheet, blowing clean under high pressure, and after the appearance is qualified, carrying out final assembly;
and in the S4, treating the appearance unqualified product according to the following conditions:
discarding the obviously unqualified product with deep defect or coating layer scratch, classifying the product according to the material quality, and crushing the product to be sold as a waste plastic raw material;
the slight defective products with blistering, falling, color changing, fogging, yellowing, scratching or scratching of the surface of the coating layer and without damaging the substrate are sequentially deplating, cleaning, high-pressure air blowing to remove water drops, drying, surface inspection, slight flaw polishing by 400-mesh abrasive paper, wiping, static removing and air blowing, vacuum ion cleaning, UV primer spraying and vacuum coating treatment, warehousing after passing inspection, and scrapping treatment after final assembly and defective products are classified according to material quality and crushed to be used as waste plastic raw materials for selling treatment;
aiming at the remanufacturing of a large decorative ring and a decorative sheet which have higher breakage rate and insufficient remanufacturing recycling amount, the large decorative ring or the decorative sheet is sequentially subjected to reverse engineering design, mold processing, mold testing, testing and inspection, after the quality is checked to be qualified, batch injection molding processing, IPA (isopropyl alcohol) wiping by dust-free thin soft cloth, static electricity removal and air blowing by an ion air gun, vacuum ion cleaning and UV (ultraviolet) primer spraying are sequentially performed, after the quality is checked to be qualified, vacuum coating is performed, after the quality is checked to be qualified, the large decorative ring or the decorative sheet is put in storage, after the assembly, unqualified products and scrapping are performed, and waste plastic selling processing is performed by classifying and crushing according to materials.
And S4, drying the large and medium decorative rings and the decorative sheet plastic parts at the temperature of 60-80 ℃ for 4-6 h.
S5: remanufacturing of high/low beam light assemblies
S51: disassembly of high/low beam assembly
The high/low beam lamp assembly is disassembled into a high beam bulb clamp ring, a low beam light clamp ring, a high beam reflection bowl and a low beam reflection bowl.
S52: remanufacturing of far/near light bulb clamping ring
Soaking, neutral detergent → brush, washing → high pressure air blowing water beads → drying → inspection, qualified, ready to assemble; unqualified and scrapped, and the waste plastic is treated as the trade change of the waste plastic.
S53: remanufacturing of high/low beam reflecting bowl
Respectively checking the far/low light reflection bowls, wherein the appearances are qualified, wiping the bowls with a fine soft cloth in running water, cleaning the bowls, blowing water drops off by high-pressure air, drying, checking to be qualified, and waiting for assembly;
far/near light assembly: installing the bulb clamping ring on the far/near light reflection bowl seat by taking a new screw, inspecting, and waiting for final assembly;
in the step S53, the appearance unqualified products are processed as follows:
rejected products with deep damage, deformation and scratches are scrapped, a reflecting bowl made of BMC is delivered to an environmental protection company for landfill treatment, and an iron reflecting bowl is delivered to a waste iron selling company for waste iron selling treatment;
and (4) treating the slight defective products of the far/near reflection bowl with the coating layers which are blistered, fall off, discolored, fogged, yellowed, scratched or scratched and do not damage the substrate according to the deplating remanufacturing method in the step S4.
S6: remanufacturing of a turn signal assembly
S61: disassembly of the turn signal assembly
Disassembling the steering lamp assembly into a steering bulb, a steering lamp base and a steering lamp reflection bowl;
in S6, the exterior of the turn signal assembly is checked and processed as follows:
scrapping unqualified products with deep and obvious damage and scratches, treating the steering lamp reflecting bowl made of BMC materials as solid wastes by an environmental protection company, and classifying and crushing renewable plastics according to the materials to treat the renewable plastics as waste plastics for sale change;
wiping and cleaning the qualified parts by using dustless fine soft cloth dipped with alcohol, then blowing the qualified parts by using high-pressure air of a static-ion removing air gun, and waiting for final assembly;
the color change, fogging, yellowing, bubbling, falling off, scratching or scratch of the coating layer of the reflector bowl of the steering lamp does not damage the slightly unqualified substrate, and the product is processed according to the deplating remanufacturing method in the S4.
The remanufacturing deplating process for the large decorative rings and the decorative sheets, the far/near light reflecting bowls and the steering lamp reflecting bowls in the S4, the S5 and the S6 comprises the following steps of: 4 percent of sodium hydroxide is soaked in hot solution at 50-60 ℃ for 5-10 min.
S7: remanufacturing of wire harnesses
Sequentially carrying out wire harness, cleaning, drying, appearance quality inspection and maintenance, maintenance and replacement of a new terminal shell, a plug, a contact pin and a lead, then carrying out appearance inspection and power-on test, warehousing after the inspection and the test are qualified, and waiting for final assembly;
s8: remanufacturing of lamplight adjusting motor assembly
The lamplight adjusting motor assembly is disassembled again and is disassembled into a motor body with a turbine, a motor driving plate, a turbine worm gear set, a push rod with a gear adjusting, a rubber sealing ring and an upper shell and a lower shell;
s81: remanufacturing of motor body with turbine
Wiping the motor body, checking the appearance of the motor, checking whether the plastic gear on the output shaft has broken teeth or broken teeth, measuring whether a motor coil is disconnected or not, judging whether a power-on test is normal or not, checking to be qualified, waiting for assembly, checking to be unqualified and scrapping;
s82: remanufacturing of motor drive plate
Cleaning a motor driving plate by dipping a brush in alcohol, checking the appearance quality, judging whether a power-on test is normal or not, checking to be qualified, waiting for assembly, checking to be unqualified, and scrapping;
s83: remanufacturing of turbine and worm gear set
Cleaning the turbine worm gear set by the brush, checking whether the turbine has broken teeth or broken teeth, checking to be qualified, waiting for assembly, checking to be unqualified, and scrapping;
s84: remanufacturing method of gear-adjusting push rod
Wiping the surface, checking the appearance quality of the adjusting push rod with the gear, checking whether the plastic gear has broken teeth or broken teeth, whether the push rod is bent or not, whether the screw thread on the surface of the push rod is deformed or rusted, checking to be qualified, waiting for assembly, checking to be unqualified and scrapping;
s85: remanufacturing of rubber sealing ring and upper and lower shells
Checking whether the sealing ring is deformed, aged and elastic loss, checking to be qualified, waiting for assembly, purchasing upper and lower shells, replacing a new shell, scrapping an old shell, and performing selling treatment as waste plastics;
s86: remanufacturing of lamplight adjusting motor assembly
Assembling remanufactured parts in S81, S82, S83, S84 and S85 into a lamplight adjusting motor assembly, paying attention to control assembly clearance of a turbine worm, checking whether a reduction gear set of the turbine worm is mutually occluded or not with clamping stagnation, electrifying to test functions of the remanufactured lamplight adjusting motor assembly, thrust moment, checking to be qualified, inspecting to be unqualified after final assembly, disassembling, and removing and scrapping unqualified parts;
s9: remanufacturing of light adjusting screw assembly
Cleaning the component by dipping the dustless fine soft cloth in alcohol, checking the appearance quality of a universal joint ball bowl seat, a ball head adjusting rod, a screw rod, a sealing ring and the like, checking the appearance quality to be qualified, carrying out final assembly, checking the appearance quality to be unqualified, carrying out scrapping treatment, and classifying the materials according to the materials to be used as the selling treatment of waste articles;
s10: remanufacturing of wire clamp and screw hardware
S101: remanufacturing of non-standard hardware such as wire clamps
Removing oil and dirt on the parts, spraying paint again, then inspecting, and waiting for final assembly;
s102: remanufacturing standard hardware such as screw and nut
Purchasing and replacing new parts, and taking the deformed wire clamp and the old screw as scrap iron selling treatment;
s11: remanufacturing of breathable plug and breathable cotton
Purchasing new parts and scrapping old parts;
s12: remanufacturing of rear cover and rubber sealing element
S121: rear cover remanufacturing
Soaking, cleaning by using a neutral detergent, drying by using high-pressure air to blow dry water drops, finally performing appearance inspection, inspecting, and checking to be qualified, performing final assembly, inspecting unqualified products, scrapping, performing selling change treatment on the waste plastics, sequentially performing die sinking, injection molding and inspection on parts with insufficient manufacturing quantity of old rear covers, inspecting to be qualified, warehousing, and performing final assembly;
s12: rubber seal remanufacturing
Purchasing and replacing new parts, and scrapping old parts;
s13: assembly for remanufactured vehicle lamp
The remanufactured ventilating plug, the lamplight adjusting screw assembly, the wiring harness, the wire clamp, the lamplight adjusting motor assembly, the far/near light lamp assembly, the steering lamp assembly, the large decorative ring and the decorative sheet are respectively installed on a headlamp bottom shell by screws one by one, then the steering lamp assembly, the large decorative ring and the decorative sheet are clamped into a positioning tool, the surface of a groove of the bottom shell is automatically cleaned and activated by an atmospheric plasma cleaning manipulator, hot melt adhesive is automatically and uniformly injected into the groove of the bottom shell by an adhesive injection manipulator, lamp feet of a lamp shade are inserted into sealant of the groove of the bottom shell, the lamp shade is tightly attached to the bottom shell by pressing the lamp shade, the lamp shade is bonded and sealed with the bottom shell by the hot melt adhesive, the lamp shade is locked on the bottom shell by the screws to prevent the bottom shell from being vibrated, the sealant is cooled and solidified, and the finished product is inspected and packaged.
The step S13 of checking the finished product comprises the following steps:
and (4) functional test: installing a bulb, and respectively testing a dipped headlight, a high beam and a steering lamp to be qualified;
detecting the light distribution performance: turning on a low beam lamp and a high beam lamp, adjusting the light shape of the car lamp, and detecting the light distribution performance of the car lamp to be qualified;
and (3) air tightness test: installing a sealing rubber ring and a rear cover on the headlamp, and testing the airtightness of the headlamp to be qualified;
and (3) carrying out appearance inspection on the headlamp: the front appearance quality of the headlamp is checked, and the lamp surface has no scratch, water thread, pattern, black spot, pinhole, pockmark, oil stain and fingerprint; the lamp has no fingerprint, dust, screw and thread foreign matter inside, and the bottom shell has no scratch, no white and no oil stain; the socket and the wiring harness are correctly installed without defects, and the racket has no abnormal sound; taking a hexagonal batch head to check whether the light adjusting mechanism is smooth or not, and correspondingly changing the high/low beam light assembly up and down; the rear cover is unscrewed to check the inner cavity, the wiring harness is firmly bound, the internal parts are not loosened, and the hardware is bright and is not rusted; labeling, cleaning the lamp surface by using dust-free fine soft cloth to be stained with machine water, sticking a protective film, turning to packaging, and reworking after disqualification;
and (3) sheathing a rubber bag with a large lamp, putting a drying agent, a certificate and a product specification, tightening a bag opening, sheathing pearl cotton, filling the pearl cotton into a carton, sealing the carton, sticking an outer box label, warehousing, performing OQC sampling inspection, and finally leaving the finished product out of the factory.
And in the S13, the bottom shell groove is cleaned and activated by using atmospheric plasma.
The invention relates to a remanufacturing method of a car lamp, which uses the method, the process technology and professional facility equipment to ensure that the quality of a remanufactured car lamp product reaches the national standard, meets the requirements of industrial production technical specifications and the management system of an automobile part remanufacturing enterprise, and meets the requirements of safety production and environmental protection laws and regulations; professional equipment is used for inspection and detection, and the disassembled qualified parts are screened and then used, so that the use value of the parts is fully exerted, the service life is prolonged, the manufacturing cost is reduced, and the carbon emission is reduced; a large number of reflecting bowls, large decorative rings and decorative sheets with slightly poor surface coating layers are remanufactured through deplating to greatly improve the utilization rate, particularly the reflecting bowls which are made of the BMC and cannot be recycled, the generation amount of solid garbage is greatly reduced through remanufacturing, and the occupation of land filling resources is reduced; the scrapped parts are finely classified and crushed according to the material quality and then processed, so that the selling and utilization value of the waste articles is improved, and the method makes positive contribution to green, low-carbon, environment-friendly, energy-saving and renewable sustainable development.
Although the present invention has been described in detail with reference to the foregoing embodiments, it will be apparent to those skilled in the art that various changes in the embodiments and/or modifications of the invention can be made, and equivalents and modifications of some features of the invention can be made without departing from the spirit and scope of the invention.
Claims (9)
1. A method for reconstructing a vehicle lamp is characterized in that: the method comprises the following steps:
s1: sorting and dismantling
Classifying the recycled old car lamps according to car types and lamp light configurations, and disassembling the recycled old car lamps into a bottom shell, a lampshade, a large decorative ring and decorative sheets, a far/near light lamp assembly, a steering lamp assembly, a wire harness, a lamp light adjusting motor assembly, a lamp light adjusting screw assembly, a wire clamp, screw hardware, a ventilating plug, ventilating cotton, a rear cover and a rubber sealing element in batches;
s2: remanufacturing of bottom shells
The bottom shell is sequentially subjected to reverse engineering design, mold processing, mold testing, testing and inspection, injection molding processing is carried out after acceptance inspection is qualified, then inspection is carried out, inspection is qualified, warehousing is carried out, and after final assembly, the old bottom shell is classified and crushed according to materials and is used as a waste plastic raw material to be changed to be sold;
s3: remanufacturing of lamp shades
The method comprises the following steps of sequentially carrying out reverse engineering design, mold processing, mold testing, testing and inspection on a lampshade, carrying out injection molding processing after the lampshade is qualified, then inspecting, annealing after the lampshade is qualified, then carrying out UV paint spraying on the surface of the lamp and antifogging paint spraying in the lampshade, warehousing after the lampshade is qualified, and carrying out final assembly after the lampshade is crushed and is used as a waste plastic raw material for selling treatment;
s4: remanufacturing of large decorative ring and decorative sheet
Sequentially carrying out alcohol soaking and light wiping on the dustless fine soft cloth and static ion removing air gun treatment on the large decorative ring and the decorative sheet, blowing clean under high pressure, and after the appearance is qualified, carrying out final assembly;
s5: remanufacturing of high/low beam light assemblies
S51: disassembly of high/low beam assembly
The high/low beam lamp assembly is disassembled into a high beam bulb clamp ring, a low beam light clamp ring, a high beam reflection bowl and a low beam reflection bowl.
S52: remanufacturing of far/near light bulb clamping ring
Soaking, neutral cleaning agent → brush, cleaning → high pressure air blowing water beads → drying → inspection, qualified, ready for assembly; unqualified and scrapped, and the waste plastic is treated as the trade change of the waste plastic.
S53: remanufacturing of high/low beam reflecting bowl
Respectively checking the far/low light reflection bowls, and wiping the bowls with a fine soft cloth in running water, cleaning the bowls, blowing water beads with high-pressure air after the bowls are cleaned, drying, checking to be qualified, and waiting for assembly;
far/near light assembly: installing the bulb clamping ring on the far/near light reflection bowl seat by taking a new screw, inspecting, and waiting for final assembly;
s6: remanufacturing of a turn signal assembly
S61: disassembly of the turn signal assembly
Disassembling the steering lamp assembly into a steering bulb, a steering lamp base and a steering lamp reflection bowl;
s7: remanufacturing of wire harnesses
Sequentially carrying out wire harness, cleaning, drying, appearance quality inspection and maintenance, maintenance and replacement of a new terminal shell, a plug, a contact pin and a lead, then carrying out appearance inspection and power-on test, warehousing after the inspection and test are qualified, and waiting for final assembly;
s8: remanufacturing of lamplight adjusting motor assembly
The lamplight adjusting motor assembly is disassembled again and is disassembled into a motor body with a turbine, a motor driving plate, a turbine worm gear set, a push rod with a gear adjusting, a rubber sealing ring and an upper shell and a lower shell;
s81: remanufacturing motor body with turbine
Wiping the motor body, checking the appearance of the motor, checking whether the plastic gear on the output shaft has broken teeth or broken teeth, measuring whether a motor coil is disconnected or not, judging whether a power-on test is normal or not, checking to be qualified, waiting for assembly, checking to be unqualified and scrapping;
s82: remanufacturing of motor drive plate
Cleaning a motor driving plate by dipping a brush in alcohol, checking the appearance quality, judging whether a power-on test is normal or not, checking to be qualified, waiting for assembly, checking to be unqualified, and scrapping;
s83: remanufacturing of turbine and worm gear set
Cleaning the turbine worm gear set by using a brush, checking whether the turbine has broken teeth or broken teeth, checking to be qualified, waiting to be assembled, checking to be unqualified, and scrapping;
s84: remanufacturing of adjusting push rod with gear
Wiping the surface, checking the appearance quality of the push rod with the gear, checking whether the plastic gear has broken teeth or broken teeth, whether the push rod is bent or not, whether the screw thread on the surface of the push rod is deformed or rusted, checking to be qualified, waiting to assemble, checking to be unqualified and scrapping;
s85: remanufacturing of rubber sealing ring and upper and lower shells
Checking whether the sealing ring is deformed, aged and has elastic loss, checking that the sealing ring is qualified, waiting for assembly, purchasing upper and lower shells, replacing a new shell, scrapping an old shell, and performing selling treatment as waste plastics;
s86: remanufacturing of lamplight adjusting motor assembly
Assembling remanufactured parts in S81, S82, S83, S84 and S85 into a lamplight adjusting motor assembly, paying attention to control assembly clearance of a turbine worm, checking whether a reduction gear set of the turbine worm is mutually occluded or not with clamping stagnation, electrifying to test functions of the remanufactured lamplight adjusting motor assembly, thrust moment, checking to be qualified, inspecting to be unqualified after final assembly, disassembling, and removing and scrapping unqualified parts;
s9: remanufacturing of light adjusting screw assembly
Cleaning the component by dipping the dustless fine soft cloth in alcohol, checking the appearance quality of a universal joint ball bowl seat, a ball head adjusting rod, a screw rod, a sealing ring and the like, checking the appearance quality to be qualified, carrying out final assembly, checking the appearance quality to be unqualified, carrying out scrapping treatment, and classifying the materials according to the materials to be used as the selling treatment of waste articles;
s10: remanufacturing of wire clamp and screw hardware
S101: remanufacturing of non-standard hardware such as wire clamps
Removing oil and dirt from the parts, re-spraying paint, inspecting, and waiting for final assembly;
s102: remanufacturing of standard hardware such as screw and nut
Purchasing and replacing new parts, and taking the deformed wire clamp and the old screw as scrap iron selling treatment;
s11: remanufacturing of breathable plug and breathable cotton
Purchasing new parts and scrapping old parts;
s12: remanufacturing of rear cover and rubber sealing element
S121: rear cover remanufacturing
Soaking, cleaning with a neutral detergent, drying with high-pressure air-dried water beads, performing appearance inspection, inspecting, checking to be qualified, performing final assembly, inspecting unqualified products, scrapping, performing selling change treatment on waste plastics, sequentially performing die sinking, injection molding and inspection on parts with insufficient quantity of old rear covers, inspecting to be qualified, warehousing, and performing final assembly;
s12: rubber seal remanufacturing
Purchasing and replacing new parts, and scrapping old parts;
s13: assembly for remanufacturing vehicle lamp
The remanufactured ventilating plug, the lamplight adjusting screw assembly, the wire harness, the wire clamp, the lamplight adjusting motor assembly, the far/near light lamp assembly, the steering lamp assembly, the large decorative ring and the decorative sheet are respectively installed on a headlamp bottom shell by screws one by one, then the steering lamp assembly, the large decorative ring and the decorative sheet are clamped into a positioning tool, the surface of a groove of the bottom shell is automatically cleaned and activated by an atmospheric plasma cleaning manipulator, hot melt adhesive is automatically and uniformly injected into the groove of the bottom shell by an adhesive injection manipulator, lamp feet of a lamp shade are inserted into sealant of the groove of the bottom shell, the lamp shade is tightly attached to the bottom shell by pressing the lamp shade, the lamp shade is bonded and sealed with the bottom shell by the hot melt adhesive, the lamp shade is locked on the bottom shell by the screws to prevent the vibration, the hot melt adhesive is cooled and solidified, and the finished product is inspected and packaged.
2. The remanufacturing method of a vehicle lamp according to claim 1, wherein: and S4, treating the appearance defective product according to the following conditions:
discarding the obviously unqualified product with deep defect or coating layer scratch, classifying the product according to the material quality, and crushing the product to be sold as a waste plastic raw material;
the surface of the coating layer is foamed, falls off, discolors, fogs, yellows, scratches or scratches are carried out on slight defective products which do not damage the substrate, deplating, cleaning, high-pressure air blowing to remove water drops, drying, surface inspection, polishing, wiping, static electricity removing and air blowing, vacuum ion cleaning, UV primer spraying and vacuum coating are carried out in sequence, warehousing is carried out after the inspection is qualified, rejected treatment is carried out when final assembly is carried out, the defective products are classified according to the material quality, and the crushed products are used as the waste plastic raw material for selling change;
the method is characterized in that a large decorative ring and a decorative sheet which are high in breakage rate and insufficient in remanufacturing recycling amount are remanufactured, reverse engineering design, mold processing, mold testing, testing and inspection are sequentially carried out on the large decorative ring or the decorative sheet, batch injection molding processing, IPA (isopropyl alcohol) wiping, static electricity removing and air blowing by an ion air gun, vacuum ion cleaning and UV (ultraviolet) primer spraying are sequentially carried out after acceptance inspection is carried out, vacuum coating is carried out after quality inspection is qualified, warehousing is carried out after quality inspection is qualified, final assembly is carried out, unqualified products are scrapped, and waste plastic selling changing treatment is carried out by classifying and crushing according to materials.
3. The remanufacturing method of a vehicular lamp according to claim 2, wherein: in the step S53, the appearance unqualified product is processed according to the following conditions:
scrapping unqualified products with deep damage, deformation and scratches, wherein the reflecting bowl made of BMC is delivered to an environmental protection company for landfill treatment, and the reflecting bowl made of iron is sold for disposal;
and (4) treating the slight defective products of the far/near reflection bowl coating layers which have blistering, falling, discoloring, fogging, yellowing, scratching or scratching but do not damage the substrate according to the deplating remanufacturing method in the step S4.
4. A method of remanufacturing a vehicle lamp according to claim 3, wherein: in S6, the exterior of the turn signal assembly is checked and processed as follows:
scrapping unqualified products with deep and obvious damage and scratches, treating the steering lamp reflecting bowl made of BMC materials as solid wastes by an environmental protection company, and classifying and crushing renewable plastics according to the materials to treat the renewable plastics as waste plastics for sale change;
wiping and cleaning the qualified parts by using dustless fine soft cloth dipped with alcohol, then blowing the qualified parts by using high-pressure air of a static-ion removing air gun, and waiting for final assembly;
the reflector coating layer of the steering lamp changes color and yellows, bubbles, falls off, scratches or scratches do not damage the substrate, and the slightly unqualified product is processed according to the deplating remanufacturing method in S4.
5. The remanufacturing method of a vehicular lamp according to claim 1, wherein: the step S13 of checking the finished product comprises the following steps:
and (4) functional test: installing a bulb, and respectively testing a dipped headlight, a high beam and a steering lamp to be qualified;
detecting the light distribution performance: turning on a low beam lamp and a high beam lamp, adjusting the light shape of the car lamp, and detecting the light distribution performance of the car lamp to be qualified;
and (3) air tightness test: installing a sealing rubber ring and a rear cover on the headlamp, and testing the airtightness of the headlamp to be qualified;
and (3) carrying out appearance inspection on the headlamp: the front appearance quality of the headlamp is checked, and the lamp surface has no scratch, water thread, pattern, black spot, pinhole, pockmark, oil stain and fingerprint; no fingerprint, dust, screw and foreign matter of thread end exist in the lamp; the bottom shell has no scratch, white and oil stain; the socket and the wiring harness are correctly installed without defects; the racket has no abnormal sound; taking a hexagonal batch head to check whether the light adjusting mechanism is smooth or not, and correspondingly changing the high/low beam light assembly up and down; the rear cover is unscrewed to check the inner cavity, the wiring harness is firmly bound, the internal parts are not loosened, the hardware is bright and rustless, the wiring harness is qualified and labeled, the lamp surface is cleaned by using dust-free fine soft cloth to be stained with machine water, a protective film is pasted, and the packaging is carried out, the wiring harness is unqualified and reworked;
covering a rubber bag with a large lamp, putting a drying agent, a certificate and a product specification, fastening a bag opening, covering pearl cotton, filling into a carton, sealing, sticking an outer box label, warehousing, performing OQC spot check, and finally leaving the finished product out of a factory.
6. The remanufacturing method of a vehicle lamp according to claim 1, wherein: and in the S1, a far infrared heating furnace is adopted for disassembly, the temperature is 110-120 ℃, and the baking time is 2-5 min.
7. The remanufacturing method of a vehicular lamp according to claim 1, wherein: and S4, drying the large and medium decorative rings and the decorative sheet plastic parts at the temperature of 60-80 ℃ for 4-6 h.
8. The remanufacturing method of a vehicle lamp according to claim 4, wherein: the remanufacturing deplating process for the large decorative rings and the decorative sheets, the far/near light reflecting bowls and the steering lamp reflecting bowls in the S4, the S5 and the S6 comprises the following steps of: 4 percent of sodium hydroxide is soaked in hot solution at 50-60 ℃ for 5-10 min.
9. The remanufacturing method of a vehicle lamp according to claim 1, wherein: and in the S13, the bottom shell groove is cleaned and activated by using atmospheric plasma.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211604029.1A CN115945501A (en) | 2022-12-13 | 2022-12-13 | Method for reproducing car lamp |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202211604029.1A CN115945501A (en) | 2022-12-13 | 2022-12-13 | Method for reproducing car lamp |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN115945501A true CN115945501A (en) | 2023-04-11 |
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ID=87290023
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202211604029.1A Pending CN115945501A (en) | 2022-12-13 | 2022-12-13 | Method for reproducing car lamp |
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| Country | Link |
|---|---|
| CN (1) | CN115945501A (en) |
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2022
- 2022-12-13 CN CN202211604029.1A patent/CN115945501A/en active Pending
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