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Introduction In the global automotive industry, the quality of interior components is paramount for both aesthetic appeal and functional performance. Surface treatment is a critical process that ensures these components meet stringent OEM standards. This case study highlights how Huazhuo Automation's state-of-the-art vacuum plasma cleaning technology addresses the complex challenges of surface treatment for automotive interiors, delivering superior quality and performance on a global scale. Project Background A leading global automotive manufacturer faced significant challenges in achieving high surface energy and consistent quality for their automotive interior components, such as dashboards and interior panels. The requirements included: Surface treatment to achieve a surface energy of ≥38 dynes with a pass rate of over 99.9%. No deformation or damage to the components during the treatment process. Specific pull-off force requirements for different components to ensure durability and safety. Technical Challenges The project presented several technical challenges: Complex Geometries: The components had intricate shapes and sizes, making uniform treatment difficult. High-Quality Standards: The OEM standards demanded zero defects, which required precise control of the treatment process. Efficiency: The process needed to be efficient to meet high-volume production demands. Huazhuo Vacuum Plasma Cleaning Solution Huazhuo Automation proposed a comprehensive vacuum plasma cleaning solution tailored to meet these challenges. The system integrates advanced plasma technology with precise control mechanisms to ensure consistent and high-quality surface treatment. How It Works 1. Plasma Generation: The system uses a high-frequency power supply to ionize the process gases (Ar and O₂), creating a plasma state.2. Surface Activation: The plasma interacts with the surface of the components, breaking down contaminants and increasing surface energy.3. Controlled Environment: The process takes place in a vacuum chamber, ensuring uniform treatment and preventing contamination.4. Automated Process: The system is fully automated, with PLC control and touch screen interface for ease of operation. Key Technical Features Vacuum Chamber: 3000L capacity, made of military-grade aluminum, ensuring durability and airtightness.Process Gases: Ar and O₂, with the option to customize other gases.Flow Control: High-precision mass flow controllers for accurate gas flow management.Power Supply: 30KW medium-frequency power supply for stable plasma generation.Safety: Equipped with safety interlocks and emergency stop mechanisms. Advanced Technology Highlights Multi-Zone Vacuum Control: Ensures uniform treatment across complex geometries.Real-Time Monitoring: PLC control with real-time data logging for process optimization.Customizable Gas Mixtures: Tailored gas mixtures for specific material requirements.Non-Destructive Treatment: Ensures no deformation or damage to sensitive components. Results The implementation of Huazhuo's vacuum plasma cleaning solution yielded remarkable results: Surface Energy: Achieved a consistent surface energy of ≥38 dynes, exceeding the required standard.Quality: The pass rate for surface treatment reached 99.9%, with no deformation or damage to the components.Efficiency: The system significantly reduced the treatment time, enhancing overall production efficiency. Global Market Outlook Huazhuo's vacuum plasma cleaning technology is gaining significant traction globally: China: Widely adopted by Tier-1 suppliers for high-quality surface treatment.Europe: Recognized by premium OEMs for its precision and reliability.North America: Increasing demand in the automotive and aerospace industries.Southeast Asia: Growing adoption in emerging automotive markets.Middle East: Emerging markets for high-end automotive manufacturing. Why Choose Huazhuo? Proven Expertise: Over a decade of experience in vacuum plasma technology.Customization: Tailored solutions to meet specific client requirements.Global Support: Comprehensive after-sales service and technical support worldwide.Innovation: Continuous R&D to stay at the forefront of plasma cleaning technology. FAQs Q1: What is the advantage of vacuum plasma cleaning over traditional methods? A1: Vacuum plasma cleaning offers superior surface activation, uniform treatment, and zero contamination, making it ideal for high-precision applications. Q2: Can the system handle different types of components? A2: Yes, the system is highly flexible and can be customized to treat various types of automotive interior components. Q3: How does the system ensure consistent quality? A3: The system uses precise control mechanisms, including PLC control and high-precision flow controllers, to ensure consistent treatment results. Q4: What is the maintenance requirement for the system? A4: The system requires regular inspection of seals, vacuum pumps, and flow controllers to ensure optimal performance. Q5: Where can I get after-sales support? A5: Huazhuo provides comprehensive after-sales support globally.

Project Background Our client, a leading automotive manufacturer, required an advanced wrapping solution for instrument panel side covers, glove box side panels, and decorative trim parts. These components needed consistent quality, precision wrapping, and efficient cycle times to meet global OEM standards. Customer Requirements High precision wrapping for PVC and PU surface skins (0.8–1.0 mm). Consistent quality across multiple product layouts. Integration with existing automotive assembly processes. Minimized manual operations (manual corner wrapping only when necessary). Equipment designed to support long production runs with stable performance. Wrapping Principle (How It Works)   1.Skin Pre-heating: Infrared lamps or hot air evenly warm the PVC/PU skin to the activation window, avoiding gloss loss or surface defects.   2.Adhesive Activation: Hot water circulation (e.g., 35–40°C for upper mold, 85°C for lower mold) activates adhesives and softens skin edges.   3.Vacuum Positioning: Vacuum holes in the upper mold stabilize the skin; dowels and sensors position the substrate precisely.   4.Hot-Press Forming: Controlled pressure and dwell time close the mold; edge-folding blocks ensure tight wrap radii and uniform bonding.   5.Cooling & Release: Cooling circuits freeze the bond; Teflon-coated mold surfaces prevent sticking and ensure clean release. Defect Prevention Multi-zone thermal control avoids cold spots and overheating. Corner assist reduces wrinkling on thick skins. Teflon surfaces prevent sticking and print-through defects. Repeatability Controls PID thermocouples maintain precise temperature. Sensors verify vacuum levels and part presence. Recipe-controlled cycles ensure consistency across shifts. Process & Technical Analysis Product Placement & Positioning: Vacuum-assisted fixtures with clamps ensure alignment. Mold Design: Heated upper mold with vacuum holes; Teflon-coated lower mold with integrated cooling. Material Handling: Skin positioning blocks minimize operator error. Cycle Time: Optimized hot-press and folding cycle ensures high throughput with consistent surface quality. Equipment Solution Model: HZ-SFB2680 Automated Wrapping Machine Size & Weight: 3600 × 2700 × 2600 mm, ~7 tons Power Supply: 380V, 50Hz, three-phase Air Supply: >6 bar, >2000 L/min Thermal System: Upper mold hot water 35–40°C; lower mold hot water ~85°C; custom infrared preheating Flexible Layouts: Supports 1-out-1, 1-out-2, and 1-out-3 production layouts. Key Benefits for the Client ✅ Improved wrapping precision for complex automotive parts ✅ Reduced manual labor via automated positioning and forming ✅ Consistent quality compliant with OEM standards ✅ Optimized cycle time for mass production ✅ Flexible for multiple mold layouts and product types FAQs Q1: What defects does the system address?A1: Wrinkles at corners, gloss loss, insufficient bonding in cold spots, print-through, mold sticking, and misalignment from manual layup. Q2: Which interior parts are best suited?A2: Instrument panel side covers, glove box side panels, decorative trims, and door garnish components. Q3: How do you ensure edge quality on thick skins?A3: Localized IR preheat and corner assist blocks with controlled dwell; manual assist only for very thick stacks. Q4: Can the system integrate with upstream/downstream automation?A4: Yes, it supports robot loading, vision alignment, and downstream inspection or packaging. Q5: What is the recommended maintenance?A5: Regular cleaning of Teflon surfaces, IR lamp checks, vacuum system inspection, and calibration of thermocouples and pressure sensors. Conclusion Through advanced process design and automated wrapping technology, our solution helped the client achieve higher quality, efficiency, and consistency in interior part production. This project highlights Huazhuo’s expertise in plastic welding, hot pressing, and wrapping automation for global automotive manufacturers.

Pain Point: How to Improve Efficiency and Reliability in Plastic Welding? Manufacturers of plastic components face several challenges in their production processes: Complex geometries and large sizes of plastic parts make it difficult to achieve uniform welding. High production volumes require fast mold changes and consistent cycle times. Quality standards demand precise welding and reliable sealing to prevent leaks and ensure durability. Labor-intensive mold changes lead to increased downtime and reduced efficiency. To address these challenges, companies are increasingly turning to advanced ultrasonic welding solutions that offer high precision, efficiency, and flexibility. Engineering Solution: Dual-Station Ultrasonic Welding Machine by Huazhuo Automation Suzhou Huazhuo Automation Co., Ltd. offers a customized dual-station ultrasonic welding machine designed to meet the stringent requirements of plastic component manufacturing. This machine integrates advanced technology with a user-friendly interface, ensuring high-quality welding results and efficient production processes. Key Technical Features Dual-Station Design The machine features two independent workstations, allowing for continuous production and seamless mold changes. Each workstation is equipped with a servo motor for precise control and positioning. Precision Components Servo Motors: High-precision servo motors ensure repeatable positioning accuracy of ±0.02mm. Linear Guides: High-quality linear guides from Hiwin provide smooth and accurate movement. Ball Screws: Direct connection of ball screws and reducers ensures high precision and consistent welding quality. Advanced Control System PLC Control: Siemens PLC ensures reliable and stable operation. Touch Screen Interface: A user-friendly Siemens HMI touch screen allows for easy operation and programming. Safety Features: Safety light curtains and interlocks protect operators during operation. Efficient Mold Change System The machine includes a quick mold change system, allowing mold replacement within 2 minutes. The mold change process is automated, reducing downtime and increasing production efficiency. Welding Process The machine uses a 35KHz ultrasonic generator and transducers to deliver precise and consistent welding. The welding process is monitored and controlled in real-time, ensuring high-quality results. Technical Specifications Customize equipment and molds according to the product. Machine Dimensions: 2600mm × 2800mm × 2550mm Maximum Welding Size: 1100mm × 600mm × 250mm Workstation Stroke: Upper platen 500mm / Lower platen 500mm Middle Platen Stroke: 800mm Max Opening: 1400mm | Min Opening: 400mm Power Consumption: 86kW Voltage: 380V, 3-phase, 50Hz Air Pressure: >0.6MPa Cycle Time Results Implementing the dual-station ultrasonic welding machine has led to significant improvements for manufacturers: Increased Production Efficiency: The dual-station design allows for continuous production, reducing downtime and increasing output. Improved Welding Quality: High-precision components and advanced control systems ensure consistent and high-quality welding results. Reduced Labor Costs: Automated mold change system reduces the need for manual intervention, lowering labor costs. Enhanced Safety: Safety features protect operators, ensuring a safe working environment. Global Market Outlook Huazhuo Automation's dual-station ultrasonic welding machines are widely used in various industries, including automotive, consumer electronics, and medical devices. The machines are particularly popular in regions with high demand for precision plastic welding, such as: China: Large-scale applications in Tier-1 automotive suppliers. Southeast Asia: Rapid growth in automotive and electronics manufacturing in Malaysia, Thailand, and Vietnam. Europe: High demand from premium OEMs and suppliers in Germany and the Czech Republic. Americas: Export hubs for automotive and electronics components in Mexico and Brazil. Middle East: Emerging markets for plastic component manufacturing in Turkey and the UAE. Why Choose Huazhuo Automation Proven Engineering: Hundreds of successful installations in China. Technical Expertise: In-depth design for ultrasonic welding systems, mold alignment, and process control. Efficiency: Quick mold change, modular components, and minimized downtime. Global Service Network: On-site commissioning and remote troubleshooting.

Pain Point: How to Ensure Reliable Welding for Large Through-Type Automotive Lamps? Global automotive lighting manufacturers face growing challenges: Complex lamp geometries make it difficult to achieve uniform heating. Waterproofing and dustproofing standards require precise sealing. Large-size lamps (up to 1350mm) demand stable clamping and accurate positioning. High-volume production requires quick mold change and consistent cycle time. In Malaysia, a leading automotive lighting supplier encountered exactly these issues. Their vibration welding process could not guarantee the strength and sealing performance required by OEMs. Engineering Solution: Huazhuo Servo Hot Plate Welding Machine Suzhou Huazhuo Automation provided a customized hot plate welding system, proven in China and widely adopted by OEMs and Tier-1 suppliers. The system integrates servo precision, modular mold design, and advanced thermal control. Key Technical Features Servo Gear-Rack Transmission Independent servo motors for upper platen, lower platen, and hot plate movement. Repeat positioning accuracy up to ±0.02mm, eliminating vibration and misalignment. Multi-Zone Temperature Control 16 independent PID-controlled heating zones (up to 270℃). Split copper heating blocks ensure uniform thermal distribution. Embedded thermocouples detect internal mold temperature in real time. Auxiliary heating blocks prevent cold spots in “difficult-to-heat” lamp areas. Advanced Fixture & Mold Design Modular upper and lower mold assemblies with vacuum suction positioning. Multi-point clamping cylinders with automatic air–electric quick connectors. X/Y/Z reference positioning to prevent relative sliding of lamp components. Quick-change mold system allows fixture replacement within 2 minutes. Human-Machine Interface & Automation Siemens PLC + 12-inch Siemens HMI for intuitive operation. Automatic mold recognition (supports up to 24 sets). Safety doors and interlocks ensure operator protection. Technical Specifications Worktable Size: 1750mm × 600mm (Max lamp: 1350 × 200 × 150mm) Opening Stroke: Upper platen 500mm / Lower platen 500mm Middle Platen Stroke: 800mm Max Opening: 1400mm | Min Opening: 400mm Weight: ~7 tons Power Consumption: 86kW Voltage: 380V, 3-phase, 50Hz Air Pressure: >0.6MPa Results in Malaysia After commissioning, the customer achieved: Welding strength above OEM standards (no leakage, no cracking under vibration tests). Seamless sealing with improved waterproof and dustproof protection. 25% reduction in cycle time compared to vibration welding. Lower maintenance cost thanks to modular heating and fixture design. They confirmed the system’s flexibility for different lamp models and are planning to replicate the solution across multiple production lines. Global Market Outlook Huazhuo hot plate welding systems have been successfully applied to: Through-type tail lamps Rear lamp housings Headlamp assemblies with complex contours Regions with Strong Demand: China: Large-scale applications in Tier-1 automotive suppliers. Southeast Asia: Malaysia, Thailand, Vietnam – rapid automotive assembly growth. Europe: Germany, Czech Republic – premium OEM and lighting suppliers. Americas: Mexico, Brazil – export hubs for automotive components. Middle East: Turkey, UAE – emerging lamp assembly and re-export bases. Why Customers Choose Huazhuo Proven Engineering: Hundreds of successful installations in China. Technical Expertise: In-depth design for heating plates, fixture clamping, and mold alignment. Efficiency: Quick mold change, modular components, and minimized downtime. Global Service Network: On-site commissioning and remote troubleshooting. FAQ: Hot Plate Welding for Automotive Lamps Q1: Why choose hot plate welding over vibration welding?Because it ensures stronger bonding and sealing for large and complex automotive lamps. Q2: What components can be welded?Ideal for rear lamps, through-type tail lamps, headlamp housings, and other plastic automotive parts. Q3: Which materials are suitable?PP, ABS, PC, PA66+GF and other thermoplastics used in automotive lighting. Q4: How efficient is the process?±0.02mm precision, multi-zone heating, and quick mold change in 2 minutes improve efficiency by up to 25%. Q5: Where is it in demand?High adoption in China, and growing demand in Southeast Asia, Europe, Mexico, Brazil, and Turkey.

Case News: Huazhuo Delivers Automatic Robot Welding & Assembly Line for B-Pillar Production in Germany Huazhuo Group, a specialist in automotive plastic welding and assembly automation, has successfully deployed its Automatic Robot Welding and Assembly Production Line for B-pillar components in the German automotive industry. The solution integrates advanced robotics, ultrasonic welding, and intelligent assembly, meeting the high standards of German OEMs and Tier 1 suppliers. Project Background The B-pillar is a critical automotive structural and interior trim component that requires precise welding, foam bonding, and multiple clip installations to ensure durability, noise reduction, and safety. European automakers demanded a production line capable of: Consistent welding quality meeting VDA, ISO, and IATF16949 standards Flexible automation to handle different trim variations (left/right B-pillars, multiple foam pads, and clips) CE compliance, energy efficiency, and low noise operation Digital monitoring and traceability to support Industry 4.0 requirements Technical Solution System Layout Main Structure: Enclosed safety fence, central indexing turntable, two ultrasonic welding robots, and dual vibration bowl feeders. Overall Dimensions: 4100 × 4100 × 2200 mm Control System: PLC with servo drive Robots: ABB IRB 2600-20/1.65 six-axis robots, 20kg payload, 1.65m reach Process Workflow Manual Loading: Operators load B-pillar base components into the indexing turntable with positioning jigs. Foam & Boss Welding: Ultrasonic welding robots weld foam pads and BOSS pillars onto the B-pillar substrate. Clip Feeding & Assembly: Vibration bowl feeders automatically deliver POM Clip Typ 1 and Typ 3 to pick-up positions. Robots use quick-change tooling to pick clips and install them into pre-defined points. Each B-pillar side requires up to 7 ultrasonic weld points and 6 clips, depending on variant. Additional Component Integration: For some variants, the line also installs air outlets (Ausströmer) and air ducts (Luftkana). Vision Inspection: Integrated sensors and cameras verify weld quality, clip positions, and foam attachment. Finished Output: Parts are automatically unloaded for downstream processes. Key Specifications Voltage: AC 380V (customizable) Frequency: 50/60Hz Power Capacity: 22KW Cycle Time: 60s per part Automation Level: Fully automatic with manual loading Highlights for European Market High Precision & Consistency: Ultrasonic welding with servo control ensures stable weld strength and air-tightness. Flexible Manufacturing: Quick-change tooling and multi-variant jig design allow small-batch, multi-model production. Energy-Efficient & CE Certified: Low noise, reduced power consumption, and EU compliance. Industry 4.0 Integration: PLC-controlled traceability of weld parameters and clip installation data supports audits. Low TCO: Reduced labor, minimized rework, and faster ROI (1–2 years). Outcome The installation has significantly improved production efficiency, reducing cycle times while ensuring ±0.2mm assembly accuracy. German automotive manufacturers now benefit from: 35% higher throughput compared to semi-automatic systems Lower labor intensity through automation Full traceability of welding and assembly data for quality management About Huazhuo Group Huazhuo Group provides high-precision plastic welding, lamination, and assembly automation for automotive interior and exterior components. Trusted by global OEMs and Tier 1 suppliers, Huazhuo delivers flexible, sustainable, and Industry 4.0-ready automation solutions.

Customer Case Study – Vietnam Automotive Industry Vietnam Automotive Manufacturer Upgrades with Huazhuo’s Front & Rear Bumper Ultrasonic Punching and Welding Equipment In 2024, a leading automotive parts manufacturer in Vietnam purchased two customized ultrasonic punching and welding all-in-one machines from Suzhou Huazhuo Automation Equipment Co., Ltd. — one for front bumpers and one for rear bumpers. This investment was driven by Vietnam’s fast-growing automotive industry and the region’s increasing demand for high-quality, cost-effective plastic bumper assembly solutions. Market Needs in Vietnam & Southeast Asia Vietnam and other Southeast Asian countries are becoming key hubs for automotive manufacturing. However, the industry faces unique challenges: Hot and humid tropical climate requires equipment with stable heat dissipation and continuous operation capability. High-volume production for both domestic and export markets, demanding 24/7 reliable automation equipment. Customer requirements from global OEMs for stronger welding strength, defect reduction, and international quality compliance. Cost reduction & efficiency improvement, as labor costs in the region continue to rise. Our Solution: Ultrasonic Punching & Welding All-in-One Equipment Huazhuo delivered two durable 380V ultrasonic punching and welding automation machines tailored for front and rear bumpers: Welding & Punching Integration: Radar hole punching and radar bracket ultrasonic welding completed in one cycle. High Stability in Hot Climates: Optimized cooling system ensures stable ultrasonic frequency and power output, suitable for Vietnam’s high-temperature environment. Precision & Quality: Ultrasonic punching achieves clean, burr-free holes without damaging the paint surface. Radar brackets are welded firmly without bulging on the bumper’s backside. 24-Hour Continuous Production: Designed for uninterrupted operation, with PLC control, real-time monitoring, and multiple protection features (light grid, abnormal alarm, data recording). Durability & Reliability: Built with stainless steel base plates, forged copper molds, and high-temperature resistant components to ensure long life and consistent performance. After installation and stable mass production, the Vietnamese customer reported: High output and high utilization, supporting large-volume production. Improved welding strength and consistency, fully meeting international automotive standards. Substantial cost savings from shorter welding cycles, reduced labor, and lower defect/rework rates. Estimated payback period of just one year, thanks to efficiency gains and material savings. Reliable performance under tropical conditions, ensuring continuous operation without overheating. The customer was highly satisfied and recognized Huazhuo’s equipment as a key enabler in their manufacturing upgrade, cost reduction, and efficiency improvement. Why Huazhuo for Southeast Asia? Proven experience in Vietnam & Southeast Asian automotive markets. Equipment designed for hot and humid climates, ensuring durability and stable performance. Strong after-sales service: one-year warranty, online technical support, video guidance. Trusted by OEM and Tier 1 suppliers for bumper welding automation. Huazhuo Automation Group continues to support Southeast Asia’s automotive manufacturing industry, providing advanced ultrasonic welding automation solutions that enable local manufacturers to achieve global competitiveness.

How Indian Car Manufacturers Cut Costs and Improve Quality with Robot Ultrasonic Bumper Welding Machine? Customer Case – India Market Successful Delivery of Dual-Station Robot Ultrasonic Welding Machine for Car Bumper in India. Huazhuo Automation Group exported a Flexible Dual-Station Robot Ultrasonic Punching and Welding Machine to a leading automotive parts manufacturer in India. The customer required a high-precision and cost-effective solution for plastic bumper welding, aiming to improve production efficiency and upgrade their manufacturing process. Customer Needs in the Indian Market The Indian automotive industry is experiencing rapid growth, with strong demand for lightweight, durable, and precisely assembled plastic components such as bumpers, air outlets, and headlamp housings. Local manufacturers are under pressure to: Reduce production costs while maintaining consistent welding quality. Upgrade automation levels to keep pace with global OEM standards. Ensure flexibility in production with equipment that can handle different bumper models. Our Solution: Dual-Station Robot Ultrasonic Welding Machine Huazhuo provided a customized robot ultrasonic welding system designed specifically for plastic bumpers: Welding Method: Imported 35KC ultrasonic welding system from Europe, ensuring stable and strong welds. Dual-Station Design: While one station is welding, the operator can load/unload the other station, achieving continuous production and reducing cycle time. Precision Adjustment: The welding head positions (front, back, left, right, up, down) can be easily adjusted, simplifying mold alignment and reducing setup time. High Accuracy Structure: CNC-machined spherical vibrator holder with fine-tooth screws allows horizontal micro-adjustments, ensuring higher leveling accuracy. Robotic Integration: Equipped with a 6-axis ABB robot, supporting complex welding paths and flexible applications. Results & Customer Feedback Customer Feedback After Stable Mass Production The customer reported high output and excellent equipment utilization. Thanks to shorter welding cycles and reduced labor costs, the investment is expected to achieve payback within one year. Welding strength and consistency have significantly improved, reducing defects and rework while fully meeting international automotive industry standards. The resulting savings in material waste and rework costs over the course of a year are also substantial. Fast mold adjustment and simple operation have greatly minimized downtime, further enhancing overall production efficiency.