How Indian Car Manufacturers Cut Costs and Improve Quality with Robot Ultrasonic Bumper Welding Machine?

Customer Case – India Market

Successful Delivery of Dual-Station Robot Ultrasonic Welding Machine for Car Bumper in India.

Huazhuo Automation Group exported a Flexible Dual-Station Robot Ultrasonic Punching and Welding Machine to a leading automotive parts manufacturer in India. The customer required a high-precision and cost-effective solution for plastic bumper welding, aiming to improve production efficiency and upgrade their manufacturing process.

Customer Needs in the Indian Market

The Indian automotive industry is experiencing rapid growth, with strong demand for lightweight, durable, and precisely assembled plastic components such as bumpers, air outlets, and headlamp housings. Local manufacturers are under pressure to:

• Reduce production costs while maintaining consistent welding quality.

• Upgrade automation levels to keep pace with global OEM standards.

• Ensure flexibility in production with equipment that can handle different bumper models.

Our Solution: Dual-Station Robot Ultrasonic Welding Machine

Huazhuo provided a customized robot ultrasonic welding system designed specifically for plastic bumpers:

• Welding Method: Imported 35KC ultrasonic welding system from Europe, ensuring stable and strong welds.

• Dual-Station Design: While one station is welding, the operator can load/unload the other station, achieving continuous production and reducing cycle time.

• Precision Adjustment: The welding head positions (front, back, left, right, up, down) can be easily adjusted, simplifying mold alignment and reducing setup time.

• High Accuracy Structure: CNC-machined spherical vibrator holder with fine-tooth screws allows horizontal micro-adjustments, ensuring higher leveling accuracy.

• Robotic Integration: Equipped with a 6-axis ABB robot, supporting complex welding paths and flexible applications.

Results & Customer Feedback

Customer Feedback After Stable Mass Production

• The customer reported high output and excellent equipment utilization. Thanks to shorter welding cycles and reduced labor costs, the investment is expected to achieve payback within one year.

• Welding strength and consistency have significantly improved, reducing defects and rework while fully meeting international automotive industry standards. The resulting savings in material waste and rework costs over the course of a year are also substantial.

• Fast mold adjustment and simple operation have greatly minimized downtime, further enhancing overall production efficiency.