Compact Footprint, Space Saving
The carousel structure is arranged radially and compact, which is particularly suitable for production environments with limited plant area.
Efficient Mold Circulation
The mold runs continuously around the central axis to ensure efficient connection of processes such as infusion, foaming, and cooling, and improve production rhythm.
High Degree Of Automation
It can integrate functions such as automatic infusion and automatic demoulding to reduce manual operations and improve product consistency and production efficiency.
Carousel Car Seat Production Line
The carousel polyurethane car seat production line is an efficient and compact solution designed for high-volume continuous molding of polyurethane car seat cushions. The system adopts a turntable structure to achieve seamless mold circulation, automatic injection molding, and synchronous operation of multiple stations. It is ideal for medium and large manufacturers seeking to optimize space, improve production efficiency, and maintain stable foam quality.
Specification Of Carousel Car Seat Production Line
Turntable cable diameter | Customizable |
Number of Workstations | Within 80 stations |
Height of the turntable line from the ground | 400 mm _ |
support wheel | 20 |
running speed | Adjustable from 4 to 12 minutes per revolution |
driving mode | Reduction unit |
Reducer power | 5.5 kilowatts |
Load capacity of the center support | 3 0 t |
Disk loading | 3 0 t |
Thickness of rotating line steel plate | 6mm |
Wire skeleton of a turntable | 10 mm I-beam (national standard) |
steel track plate | 16 mm steel plate |
Components Of Carousel Car Seat Production Line
Mold Bases
The pneumatic formwork system consists primarily of the lower mold base, support plate, upper mold base, mold opening cylinder, clamping pin, clamping cylinder, clamping air bag, guide rod, safety pin cylinder, compression spring, pneumatic control valve, connecting shaft, and other components, as well as an electrical control box. The main body of the formwork system is machined and formed by section steel welding, making it both firm and beautiful.
| Loading template size | left and right 800 mm Front and rear 900 mm |
| Closed mold height | to be determined |
| Clamping force | up to 4000kgf |
| Airbag stroke | 30 mm |
| Air source pressure | cylinder air source 0.6-0.8Mpa |
| Air bag air source | 0.2- 0.3Mpa |
| Solenoid valve control voltage | DC24V |
Polyurethane Car Seat Molds
Polyurethane car seat molds are precision-engineered tools used in the production of automotive seat cushions and backrests through foam-in-place technology. These molds are typically constructed from high-strength aluminum or steel, designed to withstand high pressures and repeated thermal cycles during the foaming process.
Each mold is custom-designed to match the ergonomic shape and comfort specifications of specific vehicle models. Integrated with advanced features such as automatic mold temperature control, robotic demolding systems, and in-mold release agent spraying, these molds ensure consistent foam density, perfect surface finish, and dimensional accuracy.
By combining durability, precision, and automation, polyurethane seat molds play a critical role in achieving high-quality, comfortable, and safety-compliant seating systems for modern vehicles.
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Robotic Arm
The robot arm is equipped with high-precision servo motors and intelligent control systems, with excellent repeatability and accuracy, which can significantly reduce human errors and ensure consistent product quality. Its flexibility enables it to be easily reprogrammed for different seat models, making it an ideal choice for mass production and customized production. The robot arm integrates sensors and safety systems, which not only improves operational safety, but also helps reduce labor costs, optimize cycle time and improve overall production line efficiency.
| Robot model | GP180 | GP12 |
| Degree of freedom | 6 | 6 |
| Horizontal extension | 2702mm | 1440mm |
| Transportable mass | 180kg | 12kg |
| Main body mass | 1020kg | 130kg |
| Repeat positioning accuracy | ±0.05mm | ±0.02mm |
| Controller | YRC1000 | YRC1000,YRC1000micro |
| Protection level | Main body: IP54, wrist axis: IP67 | Main body: IP54, wrist axis: IP67 |
| Installation method | Floor mounted | Floor-mounted, wall-mounted, inverted, tilted |
| Purpose | Transportation, picking/packaging, palletizing, assembly/disassembly | Transportation, picking/packaging, palletizing, assembly/disassembly |
Mold Temperature Controller
The mold temperature controller (MTC) is a crucial device in the polyurethane car seat foaming process, designed to maintain consistent mold temperatures throughout production. Stable mold temperature is essential for proper material flow, uniform foaming, and achieving high-quality seat components with minimal defects.
Utilizing precision heating and cooling systems—often with oil or water circulation—MTCs preheat the mold before material injection and stabilize the temperature during the foaming and curing phases. Advanced models come with PID control, real-time monitoring, and integration with the production line’s PLC system for fully automated temperature management.
By ensuring consistent thermal conditions, mold temperature controllers help reduce cycle time, improve surface finish, minimize shrinkage or voids, and ultimately enhance the repeatability and efficiency of the entire seat manufacturing process.
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Polyurethane Raw Materials
Pioneer polyurethane car seat raw materials are mainly composed of polyether polyols, polyisocyanates, catalysts, foaming agents and additives. The system has good fluidity and reaction controllability, can achieve rapid foaming and curing in a short time, and form a foam material with stable structure and excellent resilience. Its softness and support can be flexibly adjusted according to demand, taking into account both riding comfort and durability, and is the mainstream choice of current car seat foam. We can customize special formulas according to customers’ different requirements for hardness, density, rebound rate and other indicators to meet various application scenarios such as cars, commercial vehicles, and high-end seats.
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High Pressure PU Foam Machine
Our high-pressure foaming machine has high mixing accuracy and uniform foaming, ensuring that the seat foam has excellent elasticity, resilience and comfort. With a stable metering system, intelligent PLC control, and convenient operation interface, it is suitable for various types of automobile seat production lines such as ring line, disc line, banana line, etc., to meet different production and automation requirements.
It can be seamlessly connected to the robotic arm to achieve automatic pouring operation. By working in coordination with the robotic arm, it not only greatly improves production efficiency, but also effectively reduces manual errors, ensuring that each seat has consistent foaming accuracy and stable quality, which is particularly suitable for large-scale, highly automated automobile seat production lines.
Request a QuoteInstallation Instructions for Fully Automatic PU Car Seat Production Lines
▶ Watch on YouTubeCustomer Cases Of Carousel Car Seat Production Line
In order to expand the production capacity of car seat foam, an automobile parts manufacturer from the United States ordered a 10-meter diameter, 16-station rotary car seat production line from us. The customer has strict requirements on the automation level, beat control and mold adaptation of the equipment. We customized a complete solution for it according to its production capacity goals and process requirements, and equipped it with a high-pressure foaming machine and mold frame system to ensure accurate and stable foaming at each station.
After the equipment was delivered, the customer quickly completed the installation and commissioning. At present, it has achieved a stable output of more than 1,000 pieces of seat foam per day. It highly praised the efficiency and operating experience of the equipment, and continued to negotiate with us for cooperation on the second production line.
