Automobile manufacturer's badges in the steering wheels are ultrasonic welded. The badges have small protrusions at the back for insertion into holes in the steering wheels. These are then welded ultrasonically to the steering wheel. Only a certain length of the protrusion needs to be welded. If the weld is short then the badge becomes loose during hard braking or front end collisions and injures the driver. If the weld is more it creates the same problem. A maskant is used for ensuring the weld does not overshoot the required length. Accuracy required is+/-0.05mm. A simple wirecut fixture was used to hold the badge, fixture+badge slid on rails and was picked by a simple pneumatic pick and place system. The fixture with badge was placed over a pump+pipes+tank circuit. The fixture ensures the badge is coated only to the required level. Another pick and place system removes the fixture+badge and places a it on the output rails. A drying circuit pumps hot air over the maskant for drying. 
