17 August 2021
Sign up to our newsletterWant more news like this? Sign up to our newsletter.

Ultrasonic plastic welding of automotive interiors

Ultrasonic technology continues to be adopted as the process of choice for a growing number of plastic welding applications, many of which are within the automotive sector. The precise control, and resultant consistency in the process, makes it the ideal solution for joining and welding a wide range of polymer types and component variants, according to OEM Telsonic.

In a recent application by Poole-based Telsonic UK, “B” pillar products for the new Land Rover Defender are assembled using the company’s ultrasonic technology by KASAI Slovakia.

The system, designed and built by Telsonic UK and shipped to Slovakia, is used to weld left and right hand B pillar assemblies joining the seat belt cowls to the polypropylene pillars. Correct assembly is assured through the use of sensors to detect that all parts are in place, including the cowl, main pillar substrate and the airbag cover.

The machine also senses two colour variants of each of the three parts and also checks that metal clips and black felts are in position using a combination of inductive and camera sensors. Quality limits are also set for both weld delivery and collapse of the weld features.

The individual component parts are manually loaded into PU nests mounted onto an Indexing table, with the parts being secured within the nests by swing clamps.

The weld features are tubular staking pins and are formed to JLR weld specification by four Telsonic manufactured twin Titanium mother-daughter sonotrodes, fixed to four Telsonic 35kHzAC450 actuators complete with SE3512C converters including integrated cooling. The sonotrodes are powered concurrently by four TelsonicMAG3512E generators, selectable for Right or Left hand part only weld operation if necessary. Weld cycle time is 15 seconds per pair of “B” pillars.

The machine is guarded with Keyence light guards and painted and finished to Kasai Slovakia’s strict site requirements and specifications. In addition, the HMI and manuals are dual language.

Bar code labels are printed for left- and right-hand parts, only if all component parts are sensed as being present and the weld quality meets the pre-determined thresholds. A further check is then made to verify the position of the bar code label. The component parts are only released from the clamps if all of the above criteria are met.

Author
FAST magazine

Related Companies

Telsonic UK Ltd

Similar Articles

Weld purge plugs

For welding nickel alloy, titanium and stainless steel tubes and pipes, including stubs, elbows and tees, Huntingdon Fusion Techniques (HFT) has designed and developed clinically ...

SEAM WELDERS CONTROLLED BY PLC

Models in the Elena longitudinal seam welder range from Schnelldorfer Maschinenbau are available in several basic types, with special adaptations for varied applications.

Production machine takes

Altec Engineering's latest production automation system is used for the manufacture of tyre pressure sensors using laser technology from Rofin-Baasel to create a highly efficient ...

Automated plastic welding

Changes in the industrial landscape as a consequence of the pandemic, combined with renewed interest in re-shoring and shortening supply chains has opened up multiple new ...

Compound for laser welding

Laser transmission welding – also known as laser welding – is a method employed for joining plastic parts. Here FAST looks at a new range of compounds that have been specifically ...

Laser welding plastics

Requirements in the plastic industry are high: While manufacturing and production processes are accelerating, products are becoming ever more complex. All products should be ...

Hot Off The Press: New Fisnar

As a manufacturer of industry-leading fluid dispensing systems and equipment, Fisnar have an extensive range of products within their portfolio. The latest edition of their ...

tesa makes sure sound is no

When a leading global supplier of engineered noise control products and testing services experienced a problem in the manufacturing process of its sound-proof doors, tesa was ...

Nelweld N1500i Inverter- Light

From its launch the Nelweld N1500i Inverter Stud Welder has become the stud welder of choice across all industries. Weighing in at only 32Kg and with its capability of welding a ...