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Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System

Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System

2025-08-27

Case News: Huazhuo Delivers Automatic Robot Welding & Assembly Line for B-Pillar Production in Germany

Huazhuo Group, a specialist in automotive plastic welding and assembly automation, has successfully deployed its Automatic Robot Welding and Assembly Production Line for B-pillar components in the German automotive industry. The solution integrates advanced robotics, ultrasonic welding, and intelligent assembly, meeting the high standards of German OEMs and Tier 1 suppliers.

latest company case about Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System  0

Project Background

The B-pillar is a critical automotive structural and interior trim component that requires precise welding, foam bonding, and multiple clip installations to ensure durability, noise reduction, and safety. European automakers demanded a production line capable of:

  • Consistent welding quality meeting VDA, ISO, and IATF16949 standards

  • Flexible automation to handle different trim variations (left/right B-pillars, multiple foam pads, and clips)

  • CE compliance, energy efficiency, and low noise operation

  • Digital monitoring and traceability to support Industry 4.0 requirements


Technical Solution

System Layout

  • Main Structure: Enclosed safety fence, central indexing turntable, two ultrasonic welding robots, and dual vibration bowl feeders.

  • Overall Dimensions: 4100 × 4100 × 2200 mm

  • Control System: PLC with servo drive

  • Robots: ABB IRB 2600-20/1.65 six-axis robots, 20kg payload, 1.65m reach

Process Workflow

  1. Manual Loading: Operators load B-pillar base components into the indexing turntable with positioning jigs.

  2. Foam & Boss Welding: Ultrasonic welding robots weld foam pads and BOSS pillars onto the B-pillar substrate.

  3. Clip Feeding & Assembly:

    • Vibration bowl feeders automatically deliver POM Clip Typ 1 and Typ 3 to pick-up positions.

    • Robots use quick-change tooling to pick clips and install them into pre-defined points.

    • Each B-pillar side requires up to 7 ultrasonic weld points and 6 clips, depending on variant.

  4. Additional Component Integration: For some variants, the line also installs air outlets (Ausströmer) and air ducts (Luftkana).

  5. Vision Inspection: Integrated sensors and cameras verify weld quality, clip positions, and foam attachment.

  6. Finished Output: Parts are automatically unloaded for downstream processes.


Key Specifications

  • Voltage: AC 380V (customizable)

  • Frequency: 50/60Hz

  • Power Capacity: 22KW

  • Cycle Time: 60s per part

  • Automation Level: Fully automatic with manual loading

latest company case about Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System  1

Highlights for European Market

  • High Precision & Consistency: Ultrasonic welding with servo control ensures stable weld strength and air-tightness.

  • Flexible Manufacturing: Quick-change tooling and multi-variant jig design allow small-batch, multi-model production.

  • Energy-Efficient & CE Certified: Low noise, reduced power consumption, and EU compliance.

  • Industry 4.0 Integration: PLC-controlled traceability of weld parameters and clip installation data supports audits.

  • Low TCO: Reduced labor, minimized rework, and faster ROI (1–2 years).


Outcome

The installation has significantly improved production efficiency, reducing cycle times while ensuring ±0.2mm assembly accuracy. German automotive manufacturers now benefit from:

  • 35% higher throughput compared to semi-automatic systems

  • Lower labor intensity through automation

  • Full traceability of welding and assembly data for quality management


About Huazhuo Group

Huazhuo Group provides high-precision plastic welding, lamination, and assembly automation for automotive interior and exterior components. Trusted by global OEMs and Tier 1 suppliers, Huazhuo delivers flexible, sustainable, and Industry 4.0-ready automation solutions.



latest company case about Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System  2

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Solutions Details
Created with Pixso. Home Created with Pixso. solutions Created with Pixso.

Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System

Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System

Case News: Huazhuo Delivers Automatic Robot Welding & Assembly Line for B-Pillar Production in Germany

Huazhuo Group, a specialist in automotive plastic welding and assembly automation, has successfully deployed its Automatic Robot Welding and Assembly Production Line for B-pillar components in the German automotive industry. The solution integrates advanced robotics, ultrasonic welding, and intelligent assembly, meeting the high standards of German OEMs and Tier 1 suppliers.

latest company case about Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System  0

Project Background

The B-pillar is a critical automotive structural and interior trim component that requires precise welding, foam bonding, and multiple clip installations to ensure durability, noise reduction, and safety. European automakers demanded a production line capable of:

  • Consistent welding quality meeting VDA, ISO, and IATF16949 standards

  • Flexible automation to handle different trim variations (left/right B-pillars, multiple foam pads, and clips)

  • CE compliance, energy efficiency, and low noise operation

  • Digital monitoring and traceability to support Industry 4.0 requirements


Technical Solution

System Layout

  • Main Structure: Enclosed safety fence, central indexing turntable, two ultrasonic welding robots, and dual vibration bowl feeders.

  • Overall Dimensions: 4100 × 4100 × 2200 mm

  • Control System: PLC with servo drive

  • Robots: ABB IRB 2600-20/1.65 six-axis robots, 20kg payload, 1.65m reach

Process Workflow

  1. Manual Loading: Operators load B-pillar base components into the indexing turntable with positioning jigs.

  2. Foam & Boss Welding: Ultrasonic welding robots weld foam pads and BOSS pillars onto the B-pillar substrate.

  3. Clip Feeding & Assembly:

    • Vibration bowl feeders automatically deliver POM Clip Typ 1 and Typ 3 to pick-up positions.

    • Robots use quick-change tooling to pick clips and install them into pre-defined points.

    • Each B-pillar side requires up to 7 ultrasonic weld points and 6 clips, depending on variant.

  4. Additional Component Integration: For some variants, the line also installs air outlets (Ausströmer) and air ducts (Luftkana).

  5. Vision Inspection: Integrated sensors and cameras verify weld quality, clip positions, and foam attachment.

  6. Finished Output: Parts are automatically unloaded for downstream processes.


Key Specifications

  • Voltage: AC 380V (customizable)

  • Frequency: 50/60Hz

  • Power Capacity: 22KW

  • Cycle Time: 60s per part

  • Automation Level: Fully automatic with manual loading

latest company case about Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System  1

Highlights for European Market

  • High Precision & Consistency: Ultrasonic welding with servo control ensures stable weld strength and air-tightness.

  • Flexible Manufacturing: Quick-change tooling and multi-variant jig design allow small-batch, multi-model production.

  • Energy-Efficient & CE Certified: Low noise, reduced power consumption, and EU compliance.

  • Industry 4.0 Integration: PLC-controlled traceability of weld parameters and clip installation data supports audits.

  • Low TCO: Reduced labor, minimized rework, and faster ROI (1–2 years).


Outcome

The installation has significantly improved production efficiency, reducing cycle times while ensuring ±0.2mm assembly accuracy. German automotive manufacturers now benefit from:

  • 35% higher throughput compared to semi-automatic systems

  • Lower labor intensity through automation

  • Full traceability of welding and assembly data for quality management


About Huazhuo Group

Huazhuo Group provides high-precision plastic welding, lamination, and assembly automation for automotive interior and exterior components. Trusted by global OEMs and Tier 1 suppliers, Huazhuo delivers flexible, sustainable, and Industry 4.0-ready automation solutions.



latest company case about Automatic Robot Welding and Assembly Line for Automotive B-Pillars | CE-Certified Plastic Welding System  2