The Linecross Group (www.linecross.co.uk) — a Tier One automotive supplier — has invested in an automated ultrasonic welding cell at its Cannock facility to boost productivity, process repeatability and flexibility in the production of automotive components.

A general uplift in business levels and an increase in component volumes were the main reasons behind this decision to invest in automation.

The proven track record of the ultrasonic process, along with an increase in the use of this technology for welding and joining applications, was also a consideration.

The new cell features a Kuka six-axis robot and two workstations with ‘intelligent’ workpiece fixturing, which allows a range of different component types to be processed — simultaneous with loading/unloading.

Mounted to the robot’s wrist are the sonotrode (a tool that creates the ultrasonic vibration) and the Telsonic converter (www.telsonic.com).

Linecross will use the new cell to produce a variety of automotive components such as consoles, seat frames and under-trays, mainly in glass filled nylon.

The consistency of the ultrasonic process, plus the fact that the robot will never miss a weld, guarantees quality and consistency on all parts.

The project was led by Leicestershire-based DB-Automation.

It worked alongside Telsonic, which offers a comprehensive range of ultrasonic modules and systems for a variety of plastic and metal welding, cutting and sealing applications in a wide range of industries.