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• Automotive
• Medical
• Industrial
• Consulting

Mechatronic Receives 'Top Marques' From Leading Automotive Supplier

The Client’s Challenge

One of the world’s largest first tier automotive suppliers approached Mechatronic to design and manufacture an assembly cell to weld ultrasonically the major components on a left or right handed 4 × 4 instrument panel.

The Client’s Specific Needs

The design, build and delivery of a flexible cell to weld air ducts to reinforce a foam covered and skinned top moulding, then to join the sub assembly to a polypropylene lower moulding.

The machines had to produce a completed assembly within 120 seconds while meeting strict crash test requirements. The lower moulding was to be made from polypropylene, which was incompatible with the Dylark of the topper and therefore led to the development of a specialist ultrasonic staking head to form a mechanical joint between the two materials.

The Mechatronic Solution

Mechatronic designed and built two stand-alone work stations; the first to ultrasonically weld the air duct to the underside of the topper, the second comprised three robot-mounted ultrasonic stakers which could be automatically reprogrammed.

The need to keep labour to a minimum led Mechatronic to supply an automatic off-load gantry to transport the finished assembly to an external inspection station. To avoid squeak and rattle while maintaining maximum strength Mechatronic designed and developed a special energy director on the moulding.

The Results

The completed cell is now in production and has consistently exceeded expectations. Mechatronic’s robust design and understanding have led to a very reliable production cell for a safety critical component in a prestige car.

For more information, please contact Luke Fedden, applications engineer, on 0121 742 7206