The goal was challenging: to double the production of the new V6 engine blocks made in Ferrara by FCA Cento. Yet the Modena-based system integrator successfully achieved the objective by designing and installing a line that puts two twin cells together and integrates them with the help of Comau’s robots designed to assist in the production floor.
Since 1947, VM Motori has been known worldwide for the production of high-performance diesel engines destined to supply a wide variety of companies within the automotive, agricultural and naval sectors, as well as for power generation applications. The plant in Ferrara has a long-lasting partnership with the Modena-based system integrator SIR SpA, through which they develop and supply high-tech industrial automation solutions.
The integration with the FCA Group has allowed the company which is now known as FCA Cento, to further optimise its production. Following what is viewed as a sound manufacturing philosophy, the company is increasingly strengthening the strategic connection between the group’s design offices and working departments. Aligned with the perspective of a continuous implementation of its production capacity, and thanks to its long-time collaboration with SIR, the company installed a new automated line featuring the robots. The result is a significant increase in the production of crankcase panels for the new three litre V6 diesel engines.
Ramping Up The Automated Lines
The request made by FCA Cento to the system integrator was precise and clear – the creation of an automated plant that would be able to double the production rate of new cast iron engine blocks. An additional requirement was to utilise reliable machines, in terms of the mechanics and electronics, which would ensure good value for the money.
“The company had an old robot cell for loading and unloading that was equipped with a machine tool and a Smart H2 robot,” explains Davide Passoni, Head of R&D at SIR SpA. “To meet the company’s needs, we optimised the existing cell by replacing the mechanical system with a new, two-spindle machining center and keeping the same robot that had been used for years to produce the engine blocks. We also created a new twin cell that was connected to the first and designed for the same operations. This new cell was set up with a similar machining centre and connected to a new generation Smart NJ 110 robot. This intervention has allowed FCA Cento to double the production of engine blocks that used to be carried out with a single robot cell.”
The process involves a conveyor belt takes the unprocessed pieces to the two cells where they are recognised by a sensor and loaded inside the machining tool centres that then implement, in parallel, the mechanical operations necessary for the production of the engine blocks. At the end of the cycle, the robots pick up the pieces and place them on a rotating table for a dimensional control and, if the pieces meet the parameters and tolerances required, they are transferred to an industrial washing machine to complete the process.
Right Implementation, Greater Rewards
Thanks to the new systems, the company has been able to optimise their production, ensuring even higher production capacities, which today are around 60,000 engine blocks per year for a single line.
The operation implemented by SIR was developed in different stages, ending with the installation of the second robotic cell in January 2015. This automated system has presented several advantages over the last few months. By automating the loading and unloading of pieces with the robots, it was possible to convert the work of employees who were no longer needed for heavy and repetitive operations, and could be assigned to more specialised and less burdensome tasks, such as maintenance or general management of the line. Since the line is not expected to implement excessively strict cycle times – which last around 20 minutes per cell with the process divided in two phases at the end of which the piece is taken back – it was also possible to optimise the robots with particular attention to the care required for the handling of finished pieces such as the engine block.
Reliability The Key
For the automation of the second line installed was the Smart NJ110 model robot was used. With a payload of 110 kg, the robot can lift heavy engine blocks weighing about 21 kg each. Given that it also has a reach of about 3 metres, it can easily perform the machine tool tending operations as well as all the other handling operations required to carry out the production process as efficiently as possible. The system installed by SIR covers a significant part of FCA Cento’s production, which today serves clients such as Jeep, Chrysler, Lancia, LTI (London Taxis) and Maserati.
The line is dedicated to the production of engine blocks and crankcase panels for new 3000cc V6 diesel engines which are mounted on vehicles such as the Maserati Ghibli and the Jeep Grand Cherokee, to name a few. Thanks to the 60-degrees V6 architecture, this engine is particularly compact and versatile, and can be customised to meet the customer’s requirements for both transverse and longitudinal applications. The engine is therefore ideal for sedans, SUVs and high-end vehicles for markets with EU 5 and NAFTA emission regulations.
In addition to the new V6 diesel engine, FCA Cento is also developing new versions of V6 engines that can deliver even higher power and lower emissions. The 2015 production capacity of V6 engine blocks is 115,000 pieces per year, although the company is working to further improve their performance. This is accompanied by the production of the historical 4-cylinder engine, which is also intended for the automotive market, with 15,000 units per year and, last but not least, engines for naval and industrial applications, with the production of an additional 15,000 pieces per year.
