NEXO Bumper Ultra
Application example:
Fast and reliable visual inspection of the
pedestrian protection hose with a cobot
Smart - Flexible - Time-saving
Cobot testing system for optical and electrical validation of front bumpers
Berghof developed and implemented a highly flexible testing system for comprehensive quality control of front bumpers for a well-known automotive customer in the luxury segment. The NEXO Bumper Ultra solution, which was designed, built, and tested entirely in-house, combines state-of-the-art electrical and optical testing technology, intelligent worker support, and seamless integration into the customer's MES systems.
The aim of the project was to test all safety- and function-related components of the bumper in an automated, reproducible, and clock-synchronized manner. The result is a scalable platform that meets the highest standards of precision, efficiency, and traceability.
Highlights of the application
Electrical testing
- Complete electrical validation of all sensors and actuators connected to the bumper wiring harness, including:
PDC, front camera, night vision camera, Bluetooth antenna, turn signals and parking lights/daytime running lights, side marker lights, pedestrian protection sensors, acceleration sensors, radar sensors. - Use of the NEXO Merlin Pro system as a central testing unit – including flexible signal distribution to any number of contact points.
- Future-proof, modular switch cabinet architecture in 19" format, easily expandable for additional models and series.
Efficiency & Worker Support
- Ergonomic worker guidance with intelligent component recognition.
- Parallel execution of all test tasks to reduce cycle times.
- Pick-by-light function for safe and intuitive contacting.
- Option for direct rework including repeat testing.
Visual inspection & robotics
- Visual inspection of the pedestrian protection hose to ensure correct installation in the bumper impactor.
- 3D measurement technology combined with a collaborative FANUC robot – the first FANUC cobot in use at Berghof.
- Photo documentation for quality assurance prior to delivery; modularly expandable.
Process integration & data management
- Connection to flexible customer guidance systems (RFID and MES) for automated order data transfer.
- Graphical visualization of all test results for quick identification of faulty or incorrect installations.
- Storage of all results both locally and in the MES system.
- Variant handling, parameterization, and system configuration via SQL-based data management.
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