Suzhou Huazhuo automation equipment Co., Ltd

Introduction In the global automotive industry, the quality of interior components is paramount for both aesthetic appeal and functional performance. Surface treatment is a critical process that ensures these components meet stringent OEM standards. This case study highlights how Huazhuo Automation's state-of-the-art vacuum plasma cleaning technology addresses the complex challenges of surface treatment for automotive interiors, delivering superior quality and performance on a global scale. Project Background A leading global automotive manufacturer faced significant challenges in achieving high surface energy and consistent quality for their automotive interior components, such as dashboards and interior panels. The requirements included: Surface treatment to achieve a surface energy of ≥38 dynes with a pass rate of over 99.9%. No deformation or damage to the components during the treatment process. Specific pull-off force requirements for different components to ensure durability and safety. Technical Challenges The project presented several technical challenges: Complex Geometries: The components had intricate shapes and sizes, making uniform treatment difficult. High-Quality Standards: The OEM standards demanded zero defects, which required precise control of the treatment process. Efficiency: The process needed to be efficient to meet high-volume production demands. Huazhuo Vacuum Plasma Cleaning Solution Huazhuo Automation proposed a comprehensive vacuum plasma cleaning solution tailored to meet these challenges. The system integrates advanced plasma technology with precise control mechanisms to ensure consistent and high-quality surface treatment. How It Works 1. Plasma Generation: The system uses a high-frequency power supply to ionize the process gases (Ar and O₂), creating a plasma state.2. Surface Activation: The plasma interacts with the surface of the components, breaking down contaminants and increasing surface energy.3. Controlled Environment: The process takes place in a vacuum chamber, ensuring uniform treatment and preventing contamination.4. Automated Process: The system is fully automated, with PLC control and touch screen interface for ease of operation. Key Technical Features Vacuum Chamber: 3000L capacity, made of military-grade aluminum, ensuring durability and airtightness.Process Gases: Ar and O₂, with the option to customize other gases.Flow Control: High-precision mass flow controllers for accurate gas flow management.Power Supply: 30KW medium-frequency power supply for stable plasma generation.Safety: Equipped with safety interlocks and emergency stop mechanisms. Advanced Technology Highlights Multi-Zone Vacuum Control: Ensures uniform treatment across complex geometries.Real-Time Monitoring: PLC control with real-time data logging for process optimization.Customizable Gas Mixtures: Tailored gas mixtures for specific material requirements.Non-Destructive Treatment: Ensures no deformation or damage to sensitive components. Results The implementation of Huazhuo's vacuum plasma cleaning solution yielded remarkable results: Surface Energy: Achieved a consistent surface energy of ≥38 dynes, exceeding the required standard.Quality: The pass rate for surface treatment reached 99.9%, with no deformation or damage to the components.Efficiency: The system significantly reduced the treatment time, enhancing overall production efficiency. Global Market Outlook Huazhuo's vacuum plasma cleaning technology is gaining significant traction globally: China: Widely adopted by Tier-1 suppliers for high-quality surface treatment.Europe: Recognized by premium OEMs for its precision and reliability.North America: Increasing demand in the automotive and aerospace industries.Southeast Asia: Growing adoption in emerging automotive markets.Middle East: Emerging markets for high-end automotive manufacturing. Why Choose Huazhuo? Proven Expertise: Over a decade of experience in vacuum plasma technology.Customization: Tailored solutions to meet specific client requirements.Global Support: Comprehensive after-sales service and technical support worldwide.Innovation: Continuous R&D to stay at the forefront of plasma cleaning technology. FAQs Q1: What is the advantage of vacuum plasma cleaning over traditional methods? A1: Vacuum plasma cleaning offers superior surface activation, uniform treatment, and zero contamination, making it ideal for high-precision applications. Q2: Can the system handle different types of components? A2: Yes, the system is highly flexible and can be customized to treat various types of automotive interior components. Q3: How does the system ensure consistent quality? A3: The system uses precise control mechanisms, including PLC control and high-precision flow controllers, to ensure consistent treatment results. Q4: What is the maintenance requirement for the system? A4: The system requires regular inspection of seals, vacuum pumps, and flow controllers to ensure optimal performance. Q5: Where can I get after-sales support? A5: Huazhuo provides comprehensive after-sales support globally.

Project Background Our client, a leading automotive manufacturer, required an advanced wrapping solution for instrument panel side covers, glove box side panels, and decorative trim parts. These components needed consistent quality, precision wrapping, and efficient cycle times to meet global OEM standards. Customer Requirements High precision wrapping for PVC and PU surface skins (0.8–1.0 mm). Consistent quality across multiple product layouts. Integration with existing automotive assembly processes. Minimized manual operations (manual corner wrapping only when necessary). Equipment designed to support long production runs with stable performance. Wrapping Principle (How It Works)   1.Skin Pre-heating: Infrared lamps or hot air evenly warm the PVC/PU skin to the activation window, avoiding gloss loss or surface defects.   2.Adhesive Activation: Hot water circulation (e.g., 35–40°C for upper mold, 85°C for lower mold) activates adhesives and softens skin edges.   3.Vacuum Positioning: Vacuum holes in the upper mold stabilize the skin; dowels and sensors position the substrate precisely.   4.Hot-Press Forming: Controlled pressure and dwell time close the mold; edge-folding blocks ensure tight wrap radii and uniform bonding.   5.Cooling & Release: Cooling circuits freeze the bond; Teflon-coated mold surfaces prevent sticking and ensure clean release. Defect Prevention Multi-zone thermal control avoids cold spots and overheating. Corner assist reduces wrinkling on thick skins. Teflon surfaces prevent sticking and print-through defects. Repeatability Controls PID thermocouples maintain precise temperature. Sensors verify vacuum levels and part presence. Recipe-controlled cycles ensure consistency across shifts. Process & Technical Analysis Product Placement & Positioning: Vacuum-assisted fixtures with clamps ensure alignment. Mold Design: Heated upper mold with vacuum holes; Teflon-coated lower mold with integrated cooling. Material Handling: Skin positioning blocks minimize operator error. Cycle Time: Optimized hot-press and folding cycle ensures high throughput with consistent surface quality. Equipment Solution Model: HZ-SFB2680 Automated Wrapping Machine Size & Weight: 3600 × 2700 × 2600 mm, ~7 tons Power Supply: 380V, 50Hz, three-phase Air Supply: >6 bar, >2000 L/min Thermal System: Upper mold hot water 35–40°C; lower mold hot water ~85°C; custom infrared preheating Flexible Layouts: Supports 1-out-1, 1-out-2, and 1-out-3 production layouts. Key Benefits for the Client ✅ Improved wrapping precision for complex automotive parts ✅ Reduced manual labor via automated positioning and forming ✅ Consistent quality compliant with OEM standards ✅ Optimized cycle time for mass production ✅ Flexible for multiple mold layouts and product types FAQs Q1: What defects does the system address?A1: Wrinkles at corners, gloss loss, insufficient bonding in cold spots, print-through, mold sticking, and misalignment from manual layup. Q2: Which interior parts are best suited?A2: Instrument panel side covers, glove box side panels, decorative trims, and door garnish components. Q3: How do you ensure edge quality on thick skins?A3: Localized IR preheat and corner assist blocks with controlled dwell; manual assist only for very thick stacks. Q4: Can the system integrate with upstream/downstream automation?A4: Yes, it supports robot loading, vision alignment, and downstream inspection or packaging. Q5: What is the recommended maintenance?A5: Regular cleaning of Teflon surfaces, IR lamp checks, vacuum system inspection, and calibration of thermocouples and pressure sensors. Conclusion Through advanced process design and automated wrapping technology, our solution helped the client achieve higher quality, efficiency, and consistency in interior part production. This project highlights Huazhuo’s expertise in plastic welding, hot pressing, and wrapping automation for global automotive manufacturers.

Pain Point: How to Improve Efficiency and Reliability in Plastic Welding? Manufacturers of plastic components face several challenges in their production processes: Complex geometries and large sizes of plastic parts make it difficult to achieve uniform welding. High production volumes require fast mold changes and consistent cycle times. Quality standards demand precise welding and reliable sealing to prevent leaks and ensure durability. Labor-intensive mold changes lead to increased downtime and reduced efficiency. To address these challenges, companies are increasingly turning to advanced ultrasonic welding solutions that offer high precision, efficiency, and flexibility. Engineering Solution: Dual-Station Ultrasonic Welding Machine by Huazhuo Automation Suzhou Huazhuo Automation Co., Ltd. offers a customized dual-station ultrasonic welding machine designed to meet the stringent requirements of plastic component manufacturing. This machine integrates advanced technology with a user-friendly interface, ensuring high-quality welding results and efficient production processes. Key Technical Features Dual-Station Design The machine features two independent workstations, allowing for continuous production and seamless mold changes. Each workstation is equipped with a servo motor for precise control and positioning. Precision Components Servo Motors: High-precision servo motors ensure repeatable positioning accuracy of ±0.02mm. Linear Guides: High-quality linear guides from Hiwin provide smooth and accurate movement. Ball Screws: Direct connection of ball screws and reducers ensures high precision and consistent welding quality. Advanced Control System PLC Control: Siemens PLC ensures reliable and stable operation. Touch Screen Interface: A user-friendly Siemens HMI touch screen allows for easy operation and programming. Safety Features: Safety light curtains and interlocks protect operators during operation. Efficient Mold Change System The machine includes a quick mold change system, allowing mold replacement within 2 minutes. The mold change process is automated, reducing downtime and increasing production efficiency. Welding Process The machine uses a 35KHz ultrasonic generator and transducers to deliver precise and consistent welding. The welding process is monitored and controlled in real-time, ensuring high-quality results. Technical Specifications Customize equipment and molds according to the product. Machine Dimensions: 2600mm × 2800mm × 2550mm Maximum Welding Size: 1100mm × 600mm × 250mm Workstation Stroke: Upper platen 500mm / Lower platen 500mm Middle Platen Stroke: 800mm Max Opening: 1400mm | Min Opening: 400mm Power Consumption: 86kW Voltage: 380V, 3-phase, 50Hz Air Pressure: >0.6MPa Cycle Time Results Implementing the dual-station ultrasonic welding machine has led to significant improvements for manufacturers: Increased Production Efficiency: The dual-station design allows for continuous production, reducing downtime and increasing output. Improved Welding Quality: High-precision components and advanced control systems ensure consistent and high-quality welding results. Reduced Labor Costs: Automated mold change system reduces the need for manual intervention, lowering labor costs. Enhanced Safety: Safety features protect operators, ensuring a safe working environment. Global Market Outlook Huazhuo Automation's dual-station ultrasonic welding machines are widely used in various industries, including automotive, consumer electronics, and medical devices. The machines are particularly popular in regions with high demand for precision plastic welding, such as: China: Large-scale applications in Tier-1 automotive suppliers. Southeast Asia: Rapid growth in automotive and electronics manufacturing in Malaysia, Thailand, and Vietnam. Europe: High demand from premium OEMs and suppliers in Germany and the Czech Republic. Americas: Export hubs for automotive and electronics components in Mexico and Brazil. Middle East: Emerging markets for plastic component manufacturing in Turkey and the UAE. Why Choose Huazhuo Automation Proven Engineering: Hundreds of successful installations in China. Technical Expertise: In-depth design for ultrasonic welding systems, mold alignment, and process control. Efficiency: Quick mold change, modular components, and minimized downtime. Global Service Network: On-site commissioning and remote troubleshooting.