Production requirement

How the system addresses it

3D accessibility

Robot motion reaches distributed weld points on contoured plastic parts.

Program flexibility

Paths and recipes can be revised within the validated work envelope.

Scalable takt

Single/dual robot and one/two station layouts support different capacity targets.

Controlled release

Part, tool, safety and weld results are checked before the cell releases the assembly.

Application

Typical joining requirement

Front bumper

Radar or sensor bracket welding with one or two robots.

Rear bumper

Distributed bracket and support welds on a large curved component.

Automotive spoiler

Single-robot, dual-station concept for alternating load and weld.

Interior trim

Door panel, instrument panel, console and pillar assemblies.

Large industrial plastic part

Multiple localized weld points that are accessible to a robot end-effector.

Configuration

Architecture

Best fit

Single robot / single station

Compact dedicated cell

Moderate weld count or takt; lowest system complexity.

Single robot / dual station

Alternating load and weld

Improves robot utilization where manual loading is significant.

Dual robot / single station

Parallel weld sequence

High weld count or tight cycle with shared large fixture.

Dual robot / dual station

Maximum parallel flexibility

High-volume programs; requires careful safety and balance study.

Tool changing

Fixed EOAT or automatic tool changer

Needed when frequencies, horn types or processes differ.

Parameter

Reference value

Engineering note

Robot quantity

1 or 2

Selected by reach, weld map and takt

Workstation quantity

1 or 2

Manual or automated loading concept

Robot reference

ABB IRB4600-40/2.55 or IRB4600-60/2.05

Project reference; equivalent options available

Ultrasonic frequency

20 or 35 kHz typical

Final by part and acoustic design

Ultrasonic power

Application-specific

35 kHz / 1200 W reference on defined projects

Compliant axis

Pneumatic or servo option

Controls horn approach and trigger condition

Fixture

Dedicated quick-change fixture

Datum, support and clamp plan by part

Controls

PLC/HMI plus robot controller

Siemens reference where specified

Power

Destination-specific

380 V, 3-phase reference; transformer if required

Traceability

Optional

MES is not standard unless included

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.

Point-by-point result

Each programmed weld stores its own time, energy, power and other available result fields.

Robot position interlock

Weld enable only inside the approved zone and after fixture confirmation.

End-effector status

Horn, compliant-axis, cooling and tool-ID checks according to the risk plan.

Recovery logic

Controlled restart avoids skipped or double-welded points after a fault.

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

Robot brand

ABB reference; other approved robot platforms can be evaluated for regional service or plant standards.

Robot quantity

Single or dual robot with cycle simulation before concept release.

Stations

One or two fixture stations; fixed, shuttle or index arrangement.

End-effector

Single acoustic stack, multi-tool turret or automatic tool changer.

Seventh axis

External linear or rotary axis when reach and access require it.

Offline programming

Simulation and reach/collision study based on approved 3D data.

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

Complete assembly 3D data

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

Weld-point coordinates and bracket drawings

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

Required weld strength or stake-head criteria

Defines measurable trial, FAT and SAT acceptance criteria.

Takt and annual volume

Used to size stations, automation, changeover and capacity.

Preferred robot/PLC plant standards

Defines destination compliance, controls and responsibility boundaries.

Loading, station and changeover concept

Required to complete the technical concept and remove quotation assumptions.

Question

Answer

When is a robot better than a multi-head machine?

A robot is attractive when weld points are widely distributed, geometry may change, or access benefits from programmable motion. A multi-head system is often faster when many fixed points can be welded simultaneously.

Can one robot use several ultrasonic tools?

Yes. A tool changer or multi-tool end-effector can be evaluated, but added mass, acoustic cables, cycle time and validation must be considered.

Can the cell use two fixtures?

Yes. A dual-station concept can let the operator load one station while the robot welds the other, subject to the safety design.

Is MES included?

No. MES is not standard. The required data fields, protocol, server responsibility and acceptance test must be defined as an option.

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.