Production requirement

How the system addresses it

Fast multi-point cycle

Simultaneous or grouped firing reduces motion between fixed weld locations.

Dedicated alignment

Each module and fixture support is set to the approved part geometry.

Stable visible surfaces

Controlled support and sequencing protect customer-facing interior areas.

Maintainable layout

Head access, connectors, reference stops and service positions are engineered into the station.

Application

Typical joining requirement

Door panel

Map pocket, speaker grille, decorative carrier, clips and bracket attachment.

Instrument panel

Ducts, supports, bezels and internal reinforcement components.

Center console

Localized weld points for carriers, guides and cosmetic subassemblies.

Pillar trim

Brackets, energy absorbers and secondary trim components.

Seat / trunk trim

Plastic supports, covers and functional attachments.

Configuration

Architecture

Best fit

Vertical press

Upper moving head array

Common for flat or moderately contoured assemblies.

Multi-plane modules

Heads arranged at different angles

For three-dimensional parts with side access.

Shuttle station

Load outside the weld zone

Improves ergonomics and separates operator from moving heads.

Rotary index

Two or more stations

Supports load, weld and optional inspection in parallel.

Integrated line

Conveyor or transfer connection

For automated handling and line-level identification.

Parameter

Reference value

Engineering note

Welding head quantity

Project-specific

Defined by weld map and process balance

Head adjustment

Multi-axis / 360-degree mechanical adjustment

With reference stops where required

Firing strategy

Simultaneous, grouped or sequential

Validated for part behavior and power demand

Frequency

20 or 35 kHz typical

Selected per joint and horn design

Power per head

Application-specific

Confirmed by trials and acoustic design

Actuation

Pneumatic or servo

Selected by control and data requirements

Fixture

Dedicated contoured support

Quick-change option available

Controls

PLC/HMI with recipes and head status

Brand by customer standard

Cycle time

Project-specific

Includes load, clamp, weld, hold and unload

Data interface

Optional

Point or group results according to controller

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.

Head-ready matrix

All required generators, actuators and cooling conditions must be ready before cycle start.

Grouped result

Pass/fail status retained for each head or firing group according to the control architecture.

Part verification

Sensors confirm the main part and selected inserts before clamping.

Service counters

Cycle and horn/tool service counters support preventive maintenance.

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 architecture

Fixed modular heads with independent adjustment and mechanical reference stops.

Drive

Pneumatic for robust standard control or servo for position/force profiles and richer data.

Station layout

Single, shuttle, rotary index or line-integrated configuration.

Tooling

Quick-change fixture with coded connectors and recipe interlock.

Noise management

Acoustic enclosure or guarding selected from plant noise requirements.

Inspection

Stake-height, presence, vision or manual master-sample checks.

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

Assembly 3D data and weld map

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

Resin grade and molded-part condition

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

Required weld/stake strength

Defines measurable trial, FAT and SAT acceptance criteria.

Visible-surface limitations

Required to complete the technical concept and remove quotation assumptions.

Takt and shift pattern

Used to size stations, automation, changeover and capacity.

Head-level traceability requirement

Required to complete the technical concept and remove quotation assumptions.

Question

Answer

How many ultrasonic heads can be installed?

Head count is project-specific. The practical number depends on the weld map, part support, available space, acoustic interaction, power and required takt.

Do all heads fire at the same time?

They may fire simultaneously, in groups or sequentially. Dizo Sonics validates the sequence to control power demand, part movement and weld consistency.

Can the fixture be changed for another part?

Yes, when the machine envelope and head arrangement support the second product. Tool ID and recipe interlocks are recommended for changeover.

How are visible surfaces protected?

The fixture supports the part near each joint and uses approved contact materials. Trials confirm that force, sequence and horn contact do not create unacceptable read-through.

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.