Telsonic Match Technology to Volumes
Having already supplied an ultrasonic
welding system to produce cup holders for the mainstream and higher volume
variants of the latest generation Range Rover, Telsonic UK were asked to
develop a system for a more complex cup holder arrangement, fitted to higher
specification vehicles.
The original system, currently in full
production, manufactures a cup holder assembly comprising of 2 components, base
moulding & bezel, that are joined using the company’s ultrasonic technology.
This variant of cup holder, produced at the rate of one every 12 seconds, is
fitted to the majority of vehicles in the range.
The challenge was to provide a cost
effective solution for the assembly of the 4 individual component parts that
make up this higher specification version of cup holder, allowing for lower
volume and cycle rates, and enabling one part to be made every 45 seconds.
An ultrasonic system could be used to
successfully join the components of the new cup holder, however the fast cycle
times associated with the technology are not required. The solution offered by Telsonic
was therefore based upon Hot Air Cold Staking (HACS) technology.
The machine, designed and manufactured by
Telsonic at their Poole facility, uses a motorised fixture table to transfer the
components between the operator load / unload position, heating area and
staking station. The assembly comprises of 3 ABS moulded components, an
elasticated mesh pocket and retaining clips. The presence of each component is
confirmed using sensors before each cycle begins. There are a total of 15
staking points on the assembly, 2 of which are used to secure the elasticated
strap of the mesh pocket to the “B” surface of the component.
Individual controllers are used to monitor
and maintain the correct temperature profile within the system to ensure
consistent results for each weld staking point and for each machine cycle. Operator
safety is assured by the use of light guards at the load/unload station.
As for all systems and solutions from
Telsonic UK, prototype trials were conducted at the concept stage. In this instance
the trials were used to ensure no negative effects of heat on the soft flock
material used on the “A” surface of the part or on the elasticated mesh strap staked
into position on the B side.
Now in full production at Lear, this compact
machine is providing an efficient and cost effective solution to the
application. The decision by Lear to use Telsonic UK for this project was based
upon a number of factors including: Telsonics’ proven track record on the previous
Cup Holder assembly system, customer references and a partnership approach to
determining the optimum solution.
Telsonic UK offer a comprehensive range of
ultrasonic modules and systems for a variety of welding, sealing, food cutting,
textile cutting, metal welding and cleaning applications.