Production requirement

How the system addresses it

Large-part support

Contoured nest controls datum and local stiffness across the exterior component.

Multi-plane access

Adjustable modules reach side walls, return flanges and curved bracket positions.

Cosmetic control

Support, horn contact and sequence are validated against Class-A appearance criteria.

Program control

Correct fixture, part variant and recipe are verified before the automatic cycle.

Application

Typical joining requirement

Bumper

Sensor brackets, reinforcements, guides and mounting features.

Radiator grille

Decorative and structural subcomponents joined without visible fasteners.

Spoiler

Upper/lower shells, brackets and internal supports.

Rocker / wheel-arch trim

Localized bracket and clip-carrier attachment.

Exterior garnish

Decorative carriers and functional attachments with surface protection.

Configuration

Architecture

Best fit

Upper head array

Heads approach from one primary direction

Suitable for accessible weld maps.

Opposed / side modules

Heads placed on several planes

For deep return flanges or side-wall brackets.

Shuttle fixture

Part loaded outside weld zone

Supports ergonomics and large-part handling.

Dual fixture

Alternate product or left/right variant

Used when common head envelope is feasible.

Line integration

Robot/conveyor loading

For high-volume exterior assembly lines.

Parameter

Reference value

Engineering note

Part envelope

Project-specific

Based on bumper/grille/spoiler geometry

Weld-point quantity

Project-specific

Single, grouped or multi-head firing

Head orientation

Multi-axis adjustable

Reference stops for repeat setup

Frequency

20 or 35 kHz typical

Final by joint and tool design

Power

Selected per head/application

Validated with representative parts

Actuation

Pneumatic or servo

By force, position and data requirement

Fixture

Contoured, surface-protective support

Quick-change option

Loading

Manual, shuttle or automated

Ergonomic study required

Cycle time

Project-specific

Depends on point count and firing strategy

Quality data

Optional point/group result storage

Controller-dependent

Parameter

Engineering purpose

Frequency and acoustic tuning

Matches the horn, booster, converter and application; confirmed after acoustic design and trials.

Amplitude

Controls vibration displacement and heat generation; stored by recipe where the generator supports it.

Trigger force or trigger position

Defines when ultrasonic energy starts and reduces variation from part loading.

Weld mode

Time, energy, peak power, collapse/distance or absolute position, depending on controller and validation plan.

Weld force / air pressure

Influences interface contact, melt flow and final joint formation.

Hold time and hold force

Stabilizes the joint before the horn retracts.

Peak power and energy windows

Useful indicators for detecting missing parts, poor contact, tool wear or material variation.

Collapse or final position

Optional measured characteristic for applications requiring dimensional control.

Control element

Available project function

Recipe and access control

Named part programs, controlled editing rights and change history where required.

Cycle result

Pass/fail result based on agreed parameter limits, with clear alarm and recovery logic.

Process data

Time, energy, peak power, amplitude, force/pressure and position values available according to controller scope.

Part identification

Barcode, QR, RFID or manual selection options to prevent recipe/variant mismatch.

Tool and fixture status

Presence, home-position and service-life counters can be included in the control plan.

Line interface

Dry contacts, industrial Ethernet or customer-defined protocol; MES exchange is optional, not standard.

Class-A check

Agreed surface zone and master samples define acceptable read-through or marking.

Bracket presence

Sensors or vision confirm every required bracket before welding.

Fixture deflection

Design and validation control movement under multiple simultaneous heads.

Head alignment

Mechanical references and setup checks maintain perpendicular horn contact.

Material or design factor

Application guidance

ABS, PC/ABS, PC, PS

Common ultrasonic candidates when joint geometry and cosmetics are suitable.

PP, PE and other semi-crystalline resins

Feasibility depends strongly on near/far-field distance, stiffness, joint design and fillers.

PA and filled engineering resins

Moisture, reinforcement level and horn wear must be reviewed during trials.

TPE/TPU or soft components

Often challenging; test the exact grade, thickness and support condition.

Dissimilar materials

Do not approve from generic resin names; validate chemical compatibility and melt behavior.

Option

Project scope

Head quantity and sequence

Sized to the weld map, local part stiffness and takt.

Surface-contact materials

Selected for painted, textured or high-gloss exterior surfaces.

Fixture change

Quick-change base, coded connectors, tool cart and recipe interlock.

Bracket verification

Presence sensors, camera, tray poka-yoke or automated feed.

Dimensional check

Gauge, camera or customer-defined datum measurement.

Noise control

Acoustic enclosure and plant-specific noise assessment.

Poka-yoke

Part presence, orientation, variant, insert, fixture and tool verification.

Traceability

Barcode/QR/RFID, cycle-result storage and customer-defined data fields as an option.

Inspection

Vision, displacement, force, leak, pressure, flow or dimensional checks according to the CTQ plan.

Line communication

Signals or industrial network interface; MES connection only when explicitly included.

Safety

Interlocked guarding, safety doors/light curtains, emergency stops and safe reset concept to destination requirements.

Service package

Training, recommended spares, preventive-maintenance plan, remote support and optional on-site support.

Acceptance activity

Typical evidence

Documented scope review

Approved specification, layout, utilities, interfaces, cycle definition and exclusions.

Tool and datum verification

Part location, clamp support, tool identity and changeover checks.

Process-window trials

Representative production parts across agreed material and dimensional variation.

Quality checks

Agreed visual, dimensional, strength, leak, burst or functional test with defined limits.

Repeatability run

Quantity, run duration, operator conditions and acceptance method agreed before FAT.

Safety validation

Guarding, interlocks, emergency stops, reset behavior and maintenance access.

Data and alarm test

Recipes, access levels, pass/fail windows, alarms, identifiers and interface signals.

Training and handover

Operation, changeover, maintenance, backup/restore and agreed documentation.

Stage

Main input or activity

Output / decision

1. Application review

Parts, materials, joint, CTQs, takt and plant standards

Feasibility risks and missing inputs

2. Concept and quotation

Process choice, layout, tooling, controls, interfaces and exclusions

Approved technical and commercial scope

3. Trials and samples

Production-equivalent parts and agreed test method

Process window and sample evidence

4. Detailed engineering

3D design, risk review, I/O, safety and documentation plan

Customer design approval

5. Build and debug

Machine, tooling, programs and internal run-off

Ready-for-FAT review

6. FAT

Agreed parts, run quantity, quality checks, takt and documents

Punch list and shipment release

7. Installation and SAT

Utilities, setup, training and site acceptance run

Production handover by agreed scope

Please provide

Why it is needed

Exterior part 3D and datum drawing

Used to check envelope, datums, access, tooling and machine layout.

Bracket and weld-point map

Required to complete the technical concept and remove quotation assumptions.

Class-A zones and appearance standard

Defines destination compliance, controls and responsibility boundaries.

Part variants and changeover target

Used to check envelope, datums, access, tooling and machine layout.

Required weld strength

Defines measurable trial, FAT and SAT acceptance criteria.

Takt and loading method

Used to size stations, automation, changeover and capacity.

Question

Answer

How is this page different from the interior multi-head machine?

The exterior system emphasizes large flexible parts, multi-plane access and strict protection of painted or high-gloss Class-A surfaces.

Can it weld bumper radar brackets?

Yes, if the bracket geometry, stake design, fixture support and access suit fixed ultrasonic heads. A robot may be better when positions or variants change frequently.

Can several heads weld at once?

Yes, after confirming power capacity, fixture stiffness, part movement and surface quality with actual parts.

How is changeover error prevented?

Tool ID, coded connectors, part verification and recipe interlocks can prevent a mismatched fixture or program from entering automatic mode.

What information is required for an application review?

Please send part 3D data and drawings, exact resin grades, joint or stake details, production-equivalent samples if available, CTQ and test requirements, takt, annual volume, variant mix, utilities and plant standards.

Can Dizo Sonics test our real parts before quotation?

Yes. An application review and representative-part trials are recommended when feasibility, tooling concept or cycle assumptions need evidence. Trial scope, sample quantity and test method are agreed before testing.

How is the final cycle time confirmed?

The committed cycle is based on trials and a complete sequence study including loading, clamping, joining, cooling, inspection, data handling and unloading. Published reference cycles are not universal guarantees.

Which plastic materials can be processed?

Suitability is approved at exact-grade level. Resin chemistry, fillers, moisture, additives, color, recycled content, molded-part variation and joint design can all change the process window.

What documents are supplied with the machine?

The project handover package can include the approved specification and layout, electrical and pneumatic documentation, manuals, maintenance plan, spare-parts list, parameter backup, inspection records and FAT documents according to the contract.

Do you support FAT, installation and SAT?

Yes. FAT and SAT activities are defined in the project plan. Installation, training and on-site support depend on destination, responsibility split and the commercial scope.