Wednesday, February 24, 2016

A Success Story about Team Work and Tenacity - Vibration Welding Toyota Tonneau Cover

Dukane feeling honored and proud to be part of this award winning team for Tonneau cover assembly on the 2016 Toyota Tacoma pickup. This winning team in eleven months designed and created a Tonneau cover that is not only flexible and light weight but also provides the required strength and security to the end user. All these unique features have made the Tonneau cover a winner in Parts Competition in Exterior Trim Category at 2015 SPE TPO Automotive Engineered Polyolefins Conference.   

SPE Trophy for the winning team 
New Toyota Tonneau cover has a trifold design, which can be easily secured or removed from the vehicle. Thermoplastic polyolefins is injection molded to form the upper and lower panel of these three folds. Injection molding was the choice, to get consistent thin wall and dimensional stability.  Further these panels are trimmed for additional weight savings. Aluminum bars, “T” nuts and nut plates are placed on the panels for required strength.  All the three panels have more weld area on the right and left side to prevent the use of a crow bar to pick up or pry open the assembly and provides security from theft.

Initially, leading suppliers of Vibration Welding technology from the plastic welding industry, including Dukane, felt that this application was a low frequency weld application. Due to the high cost of the low frequency Vibration Welders and the extra expense required to build the larger tooling, it was evident that using low frequency equipment would be a very expensive way to weld these panels.  However, Dukane’s technical experts kept an open mind and tested the application using both high and low frequency Vibration Welders, proving it could be done by a high frequency welder.  Finally, Dukane built a standard 240 Hz Dukane Vibration Welding machine and kept the cost to a minimum.

Two versions of the assemblies were designed one for short bed truck and another for long bed truck. Dukane built three panels per version which means six vibration tools to weld the six individual parts. Dukane’s customer Nyloncraft, welds these parts in batches. The quick tool change feature of Dukane’s Vibration Welders allow Nyloncraft to weld all the three panels of bed cover using the same welder. Tools are typically changed in less than ½ an hour much less than the changing of the mold tools.

Inductive part sensing capabilities of Dukane’s Vibration Welders are used to make sure that all aluminum bars, “T” nuts and nut plates are placed securely before welding the upper and lower parts. Dukane’s proprietary HMI software is programmed to look for upto 15 parts before welding the upper and lower molds of the cover panels. There is somewhere between 55 and 70 square inches of weld area on each assembly.  Some panels are larger so they are closer to the 70 square inches of weld.

Initial challenges on this project were met with team work, persistence and clear vision. The result is an award winning product that helps Toyota meet stringent CAFÉ (Corporate Average Fuel Economy) standards for mpg of fleet vehicles.

For more information on Dukane's Vibration Welding technology visit http://www.dukane.com/us/PVI_VibeWeld.htm or call 630-797-4902

1 comment: