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.