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JLR sticks with HACS for seatback assembly

08 March 2015

Having already supplied both ultrasonic and HACS (hot air cold staking) welding systems to Jaguar Land Rover (JLR), Telsonic UK was again selected to deliver a machine that produces seat back assemblies for the company's new Range Rover and Jaguar lines.

A seat back assembly comprises four main components: a polypropylene backboard, map pocket, anti-squeak pad and carpet panel. The individual items are assembled and secured with twenty one separate stake points within the floor-standing machine, which is used to produce both left hand and right hand seat variants.

The fully automatic system, designed and manufactured by Telsonic at its Poole facility, uses a motorised fixture table to transfer the seat back components between the operator load/unload position, heating area and staking station. The presence of each component is confirmed using sensors before each cycle begins, in order to verify that the correct hand of seat has been loaded and that the correct number of metal clips are present.

Each hot air unit has its own separate temperature controller, ensuring a consistent heat profile across the twenty one separate staking points and hence a repeatable result for each part. The machine operates on a fifty-second cycle, providing an effective method of balancing production volumes, number of stake points and capital cost.

Machine control, including the setting and adjustment of the temperature for the individual heat units, is achieved via a touchscreen unit, and operator safety is assured by light guards at the load/unload station.

Now in full production, this compact machine is proving to be both efficient and cost effective. The decision to go with Telsonic UK for this project was based upon a number of factors, including the company's proven track record on the previous HACS assembly system, customer references and its willingness to work in partnership with the customer through all stages of the project.

Telsonic UK offers a range of ultrasonic modules and systems for a variety of plastic welding, sealing, food cutting, textile cutting, metal welding and cleaning applications.

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