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.
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
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
Manual Loading: Operators load B-pillar base components into the indexing turntable with positioning jigs.
Foam & Boss Welding: Ultrasonic welding robots weld foam pads and BOSS pillars onto the B-pillar substrate.
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.
Additional Component Integration: For some variants, the line also installs air outlets (Ausströmer) and air ducts (Luftkana).
Vision Inspection: Integrated sensors and cameras verify weld quality, clip positions, and foam attachment.
Finished Output: Parts are automatically unloaded for downstream processes.
Voltage: AC 380V (customizable)
Frequency: 50/60Hz
Power Capacity: 22KW
Cycle Time: 60s per part
Automation Level: Fully automatic with manual loading
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).
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
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.
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.
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
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
Manual Loading: Operators load B-pillar base components into the indexing turntable with positioning jigs.
Foam & Boss Welding: Ultrasonic welding robots weld foam pads and BOSS pillars onto the B-pillar substrate.
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.
Additional Component Integration: For some variants, the line also installs air outlets (Ausströmer) and air ducts (Luftkana).
Vision Inspection: Integrated sensors and cameras verify weld quality, clip positions, and foam attachment.
Finished Output: Parts are automatically unloaded for downstream processes.
Voltage: AC 380V (customizable)
Frequency: 50/60Hz
Power Capacity: 22KW
Cycle Time: 60s per part
Automation Level: Fully automatic with manual loading
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).
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
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.