New automated ultrasonic work cells from Dukane Corp., St. Charles, Ill., can handle entire automotive door assemblies and are built with open guarding so the welding process remains visible. A one-touch cycle initiator retracts the slide tray, and pneumatic clamps accurately position the parts. Sensors ensure that all door clips are in place, and light curtains protect the operator during welding. A single ultrasonic generator with a multi-point controller provides independent control of all five probes and monitors the time, energy, and amplitude of each weld. The five thrusters are mounted on a solid structural bridge to ensure precise weld placement without “walking” or side deflection of the horn. Each thruster has hydraulic speed control to match its down speed to the melt viscosity of the plastic. The work cell can also be adapted for spin welding, heat welding, or a combination of processes.