Bumper applications for ultrasonic welding

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For technical solutions to be optimised and operate most effectively, it is preferable that both the technology manufacturer and the end user work together closely and communicate clearly and concisely. This is certainly true for ultrasonics, where the greatest benefits will be realised when the ultrasonic specialist and the customer work together in the early stages of the project. It can lead to the incorporation of design features that could aid production processes.

Ultrasonic technology is becoming increasingly recognised as both a reliable and cost-effective process for joining (and cutting) lightweight automotive components. The introduction of ultrasonic technology has transformed a number of manufacturing processes across many industries, including the Russian automotive sector for assembly operations on door panels, spoilers and the mounting of sensor brackets on thin-walled bumpers.

One example of the technology in action is on the front bumpers of the ┼ákoda Karoq and ┼ákoda Rapid models, which are manufactured using Telsonic’s ultrasonic welding and cutting equipment supplied by Windeq TC Telsonic’s Russian partner headquartered near Moscow. The company is the first Russian system manufacturer to design and produce semi-automatic ultrasonic systems for the automotive manufacturer, and Windeq TC has also been recognised as an official supplier to Magna Russia since 2019. Other applications where ultrasonic technology is a key process include the manufacture of the front and rear spoilers, and reflector mounts for the VW 316 Tarek.

Lada also use ultrasonic systems to attach the structures used for electric window guides, and brackets for interior door panel storage compartments. In this application it was possible to use dual sonotrodes, as these joining processes require welding to take place at particular spots and along seams. This is a distinct advantage in areas where the welding points on the seams are close together. With two blades, a dual sonotrode is able to produce two welds at the same time whilst only requiring one converter and booster to apply mechanical vibrations. As the use of lightweight plastics continues to proliferate in automotive design, it is likely that more applications than ever before will involve ultrasonic cutting or joining at some point in the design and production processes.

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