Pain Point: How to Ensure Reliable Welding for Large Through-Type Automotive Lamps?

Global automotive lighting manufacturers face growing challenges:

• Complex lamp geometries make it difficult to achieve uniform heating.

• Waterproofing and dustproofing standards require precise sealing.

• Large-size lamps (up to 1350mm) demand stable clamping and accurate positioning.

• High-volume production requires quick mold change and consistent cycle time.

In Malaysia, a leading automotive lighting supplier encountered exactly these issues. Their vibration welding process could not guarantee the strength and sealing performance required by OEMs.

Engineering Solution: Huazhuo Servo Hot Plate Welding Machine

Suzhou Huazhuo Automation provided a customized hot plate welding system, proven in China and widely adopted by OEMs and Tier-1 suppliers. The system integrates servo precision, modular mold design, and advanced thermal control.

Key Technical Features

1. Servo Gear-Rack Transmission

   • Independent servo motors for upper platen, lower platen, and hot plate movement.

   • Repeat positioning accuracy up to ±0.02mm, eliminating vibration and misalignment.

2. Multi-Zone Temperature Control

   • 16 independent PID-controlled heating zones (up to 270℃).

   • Split copper heating blocks ensure uniform thermal distribution.

   • Embedded thermocouples detect internal mold temperature in real time.

   • Auxiliary heating blocks prevent cold spots in “difficult-to-heat” lamp areas.

3. Advanced Fixture & Mold Design

   • Modular upper and lower mold assemblies with vacuum suction positioning.

   • Multi-point clamping cylinders with automatic air–electric quick connectors.

   • X/Y/Z reference positioning to prevent relative sliding of lamp components.

   • Quick-change mold system allows fixture replacement within 2 minutes.

4. Human-Machine Interface & Automation

   • Siemens PLC + 12-inch Siemens HMI for intuitive operation.

   • Automatic mold recognition (supports up to 24 sets).

   • Safety doors and interlocks ensure operator protection.

Technical Specifications

• Worktable Size: 1750mm × 600mm (Max lamp: 1350 × 200 × 150mm)

• Opening Stroke: Upper platen 500mm / Lower platen 500mm

• Middle Platen Stroke: 800mm

• Max Opening: 1400mm | Min Opening: 400mm

• Weight: ~7 tons

• Power Consumption: 86kW

• Voltage: 380V, 3-phase, 50Hz

• Air Pressure: >0.6MPa

Results in Malaysia

After commissioning, the customer achieved:

• Welding strength above OEM standards (no leakage, no cracking under vibration tests).

• Seamless sealing with improved waterproof and dustproof protection.

• 25% reduction in cycle time compared to vibration welding.

• Lower maintenance cost thanks to modular heating and fixture design.

They confirmed the system’s flexibility for different lamp models and are planning to replicate the solution across multiple production lines.

Global Market Outlook

Huazhuo hot plate welding systems have been successfully applied to:

• Through-type tail lamps

• Rear lamp housings

• Headlamp assemblies with complex contours

Regions with Strong Demand:

• China: Large-scale applications in Tier-1 automotive suppliers.

• Southeast Asia: Malaysia, Thailand, Vietnam – rapid automotive assembly growth.

• Europe: Germany, Czech Republic – premium OEM and lighting suppliers.

• Americas: Mexico, Brazil – export hubs for automotive components.

• Middle East: Turkey, UAE – emerging lamp assembly and re-export bases.

Why Customers Choose Huazhuo

• Proven Engineering: Hundreds of successful installations in China.

• Technical Expertise: In-depth design for heating plates, fixture clamping, and mold alignment.

• Efficiency: Quick mold change, modular components, and minimized downtime.

• Global Service Network: On-site commissioning and remote troubleshooting.

  
  

FAQ: Hot Plate Welding for Automotive Lamps

Q1: Why choose hot plate welding over vibration welding?
Because it ensures stronger bonding and sealing for large and complex automotive lamps.

Q2: What components can be welded?
Ideal for rear lamps, through-type tail lamps, headlamp housings, and other plastic automotive parts.

Q3: Which materials are suitable?
PP, ABS, PC, PA66+GF and other thermoplastics used in automotive lighting.

Q4: How efficient is the process?
±0.02mm precision, multi-zone heating, and quick mold change in 2 minutes improve efficiency by up to 25%.

Q5: Where is it in demand?
High adoption in China, and growing demand in Southeast Asia, Europe, Mexico, Brazil, and Turkey.