Automatic Loading and Unloading Ultrasonic Welding Line

Introduction

This automatic loading and unloading ultrasonic welding line is designed for integrated 

production conveyor systems. It combines robotic pick-and-place, vision inspection, 

NG rejection, ultrasonic welding, and automatic unloading into one complete automation solution.

The system automatically picks products from the conveyor and transfers them to the vision inspection

position. The camera inspection system checks whether the previous manual assembly process has been

completed correctly. If the product is not assembled properly, the mechanism places it into the NG area 

for operator removal.

Qualified products are then transferred to the ultrasonic welding station. After welding is completed, 

another unloading mechanism places the finished product back onto the conveyor, which transports it

 to the next production process.

This type of conveyor-integrated automation line is especially suitable for factories that already have 

a manual or semi-automatic assembly process before ultrasonic welding. By adding automatic transfer, 

vision inspection, NG separation, and welding into one production flow, the system helps reduce manual handling 

while keeping each process step more consistent.

Production Line Running Video

Watch automatic ultrasonic welding line with conveyor integration, automatic transfer, vision inspection, 

and ultrasonic welding process in operation.

Key Features

• Automatic loading and unloading from conveyor line

• Vision inspection for previous assembly accuracy

• Automatic NG product rejection

• Ultrasonic welding process integration

• Finished product transfer back to conveyor

• PLC-controlled full automation process

• Suitable for production line integration

• Custom design based on customer products

  

For products that require accurate positioning before welding, the loading mechanism, inspection camera, 

welding fixture, and unloading mechanism can be designed according to the actual product shape and 

conveyor layout. This allows the ultrasonic welding process to be connected smoothly with the customer’s 

existing production line.

Safety Features

• Emergency stop button

• Three-color warning tower light

• Safety door interlock system

• Protective acrylic safety doors

• Stable PLC control system

Main Components

• SMC pneumatic cylinders

• Schneider power components

• Mitsubishi PLC and HMI

• Clearly labeled electrical wiring

• Reliable pneumatic and electrical configuration

Customization Options

• Electronic components can be customized according to customer requirements

• Network connection available for production data reading and storage

• Machine color can be customized

• Acrylic safety doors can be customized

• Fixtures, inspection system, welding tooling, and conveyor connection can be customized

In many customized automation projects, the inspection method, fixture structure, welding tooling, 

and conveyor connection are adjusted based on the customer’s production process. For example, 

some parts require visual confirmation before welding, while others may need automatic sorting,

marking, or data collection after assembly.

Applications

This system is suitable for automated plastic welding production lines where products need to 

be transferred, checked, welded, and returned to the conveyor automatically. It can be used for

automotive plastic components, appliance parts, consumer product assemblies, electronic housings,

and industrial plastic parts that require stable vision inspection and ultrasonic welding integration.

For automotive applications, similar ultrasonic welding automation concepts can also be used in

end cap and felt welding projects where stable positioning, repeatable welding quality, and efficient 

material handling are important.

Discuss Your Automation Project

Share your current process and the steps you would like to automate. Helpful details include:

• Part photos or drawings and product variations

• Assembly, welding or trimming sequence

• How parts arrive and how finished parts should leave

• Target output and inspection requirements

A short video of the existing process is useful for an initial review. Include any space constraints 

or connections to other equipment.

Use the inquiry form below or contact us on WhatsApp: +86 159 8954 1416.