The Challenge
Automating High-Stakes Liner Installation into Multi-Ton Engine Blocks
Manual liner placement into massive engine blocks posed severe risk: a single misalignment could require scrapping an entire $100K part. The customer needed a robotic solution that could:
- Handle ultra-heavy engine blocks with positioning accuracy
- Insert large cylinder sleeves without risk of collision
- Adapt to variable block configurations with minimal programming
- Maintain high-production speed while protecting expensive parts
MWES was chosen for their ability to deliver high-precision automation in heavy-duty assembly.
The Solution
Track-Mounted Robotic Cell with Laser Calibration & Sequenced Tooling
MWES delivered a robust automated system featuring:
- Engine-block load station with MWES-engineered locator plates for precise part positioning
- Robot system with tool changers: one for probing block location via laser sensors, another for liner insertion, and a third for pressing
- Automated supply and lubrication of liners prior to insertion
- Cartridge press tool to seat liners with controlled insertion force
- Operator interface for selection of assembly recipes and part verification
This cell automates all major steps—from probing to lubrication, insertion, and pressing—within a guided framework that guards against damaging high-precision blocks.
The Results
Safe, Repeatable Liner Assembly with Zero Scrap Risk and Minimal Labor
MWES’s execution yielded clear benefits:
- Precision liner insertion with calibration ensures zero scrap due to misalignment
- Heavy engine blocks handled safely without manual intervention
- Reliable, repeatable assembly with minimal operator support
- Fast deployment of planet-scale engine assembly without delicate manual alignment
By automating critical alignment and insertion operations, MWES provided a production-ready solution that protected costly engine blocks, improved throughput, and eliminated high-risk manual handling.
