EuroWire March 2020

Technology News

Boxing clever with spot-welded assembly for storage tray

WILLIAM Hughes has come to the aid of an automotive seat manufacturer, providing a spot-welded grid assembly to complete an under-seat storage unit for a city van. The intricate part had to meet stringent criteria for robustness and aesthetics, while assuring ease of integration into the under-seat structure. The seat manufacturer had no problem forming the tray base and three of the sides as part of the larger welded structure, but the fourth side proved more intricate, so the company subcontracted the assembly to a third party. William Hughes was able to demonstrate its capability in the area. The part comprises three mild steel wires running horizontally from one end of the storage tray to the other, with two U-shaped bent wires welded across them to complete the grid structure and form a robust fourth side to the storage tray. The grid assembly is spot-welded in two processes: the straight wires and the bent wires are first positioned into what will be the finished grid, loaded into a jig on a trolley and wheeled into the spot welder. William Hughes constructed the jig especially for the project, assuring consistency in appearance and performance of the finished part. As the assembly is only required in relatively low volumes, the grid is welded manually. Spot welding was chosen in preference to other welding techniques as it provides a cleaner finish and the operator can carry out a visual check on the quality of the weld. With the grid assembly complete, end brackets are spot welded to the grid in the second process.

▲ ▲ A custom-made spot-welded assembly for storage tray fromWilliam Hughes

Once complete, William Hughes coats the grid assembly on a KTL black electrophoretic paint line, which deposits a shiny black coating just a few microns thick. This coating technology is used extensively within automotive applications, combining an aesthetically appealing finish with protection against challenging environmental conditions. Because the coating is so thin, it does not interfere with the functionality of a part. William Hughes Ltd www.wmhughes.co.uk

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March 2020