ABB Automation Technologies AB

www.abb.com/automotive 1

Diesel Engine Assembly Line

Industry: • Automotive OEM

Product: • Diesel Engines

Installation Date: • December 2003

Description:

Diesel Engine assembly line is based on ABB standard modular concept. This line consists of four conveyor systems, one for short block assembly, one for piston sub assembly, one for cylinder head sub assembly and one for final assembly. The assembly lines are a mix between manual, semi automatic and automatic stations, between some of the assembly stations is a buffer station placed. Currently assembles 4-9 liters (4-6 cylinder) engines with weekly production reaching 1000 units with two shift operation

Equipment:

• 21 Automatic stations • 87 Manual stations • 16 Semi-auto stations • 6 robots • ABB turnover device • ABB nut runner stations • ABB leakage test station for cylinder head

Customer Benefits:

• High quality assembly processes to assure product quality and production • Automatic assembly of heavy parts with robot • Cost effective solution • High flexibility, currently assembles 4 types in the line 4-9 liters • Glueing application by robot • Easy and low cost startup of new variants

ABB Automation Technologies AB ABB Inc. ABB Automation GmbH ABB Engineering Ltd. Powertrain 1250 Brown Road Business Area Unit Robotics 31 Industrial Building Omformargatan 18 Auburn Hills, Michigan 48326 Grüner Weg 6 Fu Te Dong San Road SE-72137 Västerås T/ 248-393-4600 D-61169 Friedberg Waigaoqiao FTZ, Pudong Sweden F/ 248-393-4603 Germany Shanghai, P. R. China 200131 T/ +46-21-3600-400 T/ +49-6031-85-0 T/ +86-21-6105-6666 F/ +46-21-3600-450 F/ +49-6031-85-297 F/ +86-21-6105-6667

ABB Automation Technologies AB www.abb.com/automotive 2

Diesel Engine Assembly Line

Technical Data • Capacity: 50,000/year (2-shift production)

• Cycle time: 90 seconds

Unique Elements:

• Automatic assembly of cam shaft bearings • Automatic control of axial clearance and rotation torque • 3 automatic leakage test stations • Laser key up check

Customer Provided Equipment:

• None

Project/Steps to Implementation:

• Concept design • Concept approval • Engineering (Detail design) • Project management • Manufacturing • Installation • Training • Production support on site 6 month.

Project Responsibility: Video/Photos/Reference:

Powertrain Can be supplied by ABB.

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Cylinder head line

Short block line & Piston line

Final assembly

100 m