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Cylinder Head Installation and Automated Torquing

23:55
47:01
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BluePrint Engines Factory Full Tour & Behind The Scenes: How Does a Crate Engine Get Made?

What happens here

The final assembly of the engine is performed by skilled technicians. A key aspect is the precise torquing of cylinder head bolts. Instead of manual torque wrenches, specialized DC torque tools are used. These tools have pre-programmed settings and provide instant feedback, ensuring bolts are tightened to exact specifications and preventing issues like under- or over-torquing. This automated process, orchestrated by a robot arm, eliminates manual effort and ensures consistent quality. A green light signals a successful torque, while a red light indicates an out-of-spec condition, allowing immediate troubleshooting. This automation significantly reduces human error and supports a 'mistake-proofing' approach to manufacturing.

Goal: Install and precisely torque cylinder heads using automated tools.

Tools and materials

  • Cylinder Heads — Cylinder heads ready for installation onto the engine block
  • DC Torque Tool — Precisely tightening cylinder head bolts
  • Engine Blocks — Engine blocks with pistons and connecting rods installed
  • Pallet Conveyor System — Moving engines on pallets
  • Robot Arm Fanuc — Automating the torquing process
  • Safety Light Curtain — Ensuring operator safety during machine operation

What they say

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any leader that works on my team is trained to do that they carry a radio or they have a phone so if they see an issue they can call somebody right away and get them here and allow the operator to stay at their station and keep working this line has been in place for us for about six months but we're still trying to get everything in place to run it the way that we want to this is jeff jeff how many pistons do you think you've installed in your career about a million and a half about a million so he's put in about a million and a half pistons you think about a guy who's putting a million and a half pistons they've done it over and over they're very precise they do a great job he catches issues that you would be amazed that he has the ability to tell by how he installs them one of our challenges is if jeff ever wants to have a day off to put somebody there and have them go do as good as he does it's challenging without that much practice so we've got machines that are designed to remove the variation and make it easier for a newer person to be able to do what he's doing with as close to a level of quality you can have if you haven't installed a million and a half pistons so you'll see tools like this around the plant that help us increase our flexibility and reduce the complexity of what we're doing and that's really one of the themes i hope you pick up on around the plant less complicated more flexible which gives us the ability to control quality better and make it so that we have a very consistent product going out the door yeah i have noticed that you got little little tips and tricks everywhere there you go you know some of the things that we do you got an oil pump and a

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