Here’s how International upgraded its plants to manufacture the advaced 6.4L turbodiesel.
Power, performance, reliability and durability are the characteristics that define the new 6.4-liter Power Stroke® Diesel engine. Manufacturing technology and process controls set the stage for a new standard in the manufacture of diesel engines at International Truck and Engine Corporation’s Indianapolis, Indiana, and Huntsville, Alabama, plant, which both produce the new V-8 turbodiesel engine.
International prepared for the 2007 launch of the 6.4-liter Power Stroke diesel with manufacturing and assembly processes that integrate quality assurance and testing procedures to create an even higher standard of excellence. These upgrades created a new benchmark for engine manufacturing while further streamlining the manufacturing process and controlling production costs.
“Since 2004, International has invested over $100 million in manufacturing process changes and improvements to create the new 6.4-liter diesel,” said Tom Horn, vice president, Manufacturing and Strategic Initiatives, Engine Group, International Truck and Engine. “A team of designers, engineers and manufacturing personnel poured over every design and manufacturing detail to ensure absolute reliability of the engine from start to finish.”
International modified its Indianapolis and Huntsville engine plants with updated crankshaft and assembly lines, including three new clean rooms at each plant for assembly of the engine’s advanced high-pressure common-rail fuel system. In addition, a number of advanced control measures were implemented across the entire manufacturing process in order to meet customer reliability and performance demands.
From its humble roots to today’s powerhouse status, we look at how the Power Stroke has never let us down.
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The updated crankshaft line features a streamlined process with added flexibility that produces a stronger and more durable part, capable of delivering what drivers want – more power and torque.Driving the advancements on the line are two advanced technology heat-treatment machines.
Featuring enhanced controls, the machines allow for greater command of the heating and quenching processes that provide component strength. Previously, the crankshafts were heated and then completely cooled before being drawn through a tempering oven to increase strength. Now, operators are able to control and monitor the amount of water-based quench being applied to specific parts of the crank as it is rotated, allowing heat to remain in the part.This remaining heat then auto-tempers the crankshaft, providing the added strength without the need of the costly and time-consuming tempering. This leaner manufacturing process not only produces a better part, it also provides a significant energy savings. In a high-volume production environment this lean process positions International to meet the increased demands for diesel.
International also implemented advanced computer systems and controllers to the rough machining of its crankshafts. The increased precision of the machine’s computers allow for the cutter and the crankshaft to turn simultaneously, producing a much better geometry in the undercut. This improved surface finish gives the crankshaft more strength and durability.
“International products are known for their durability,” Horn said, “We design our manufacturing processes to assure we exceed our customers’ expectations with the components we manufacture.”
International’s Indianapolis and Huntsville plants share the following capabilities:
International implemented a part traceability system for the crankshaft line to boost quality assurance. Each part is serialized, allowing it to be tracked through every operation on the line. Should manufactured parts not be up to International’s exacting standards, the plant can immediately quarantine a serial number range, effectively isolating potential problems and preventing those parts from being used in an engine. This protects customers who rely on these products for their business.
Computer-controlled Integrated Quality Assurance (IQA) stations apply a system of inspection during the assembly process, ensuring the engine meets the highest standards at each stage of inspection, rather than waiting until the engine is completely built. International was the first diesel engine manufacturer to incorporate a signature analysis, where the fingerprint of a perfect engine is compared to the product being tested.This analysis detects even the slightest variations in the engine early in the assembly process. The IQA stations keep engines with deviations from reaching the end of the line, identifying inconsistencies during the assembly process so they can be corrected.
Before reaching the end of the assembly line, each engine undergoes a quality verification process. The engine is first cold tested, which allows operators to check pressures, torque, operating sensors and mechanical attributes without running the engine. After cold test, each engine moves on to a hot-test station, where it is tested for idle stability and fuel system startup. The last stop is the audit test cell, where each engine is warmed up for three minutes and then undergoes three minutes of Dynamometer testing.
The accuracy of new machining equipment further enhances engine quality. The new equipment using state-of-the-art technology, improves manufacturing process capability thus, minimizing part to part variation and assuring that each engine that comes off the line will adhere to the defined engineering specifications and perform as designed.
“All of these quality control processes complement each other to verify that each engine meets our high standards when it comes off the line,” said Horn. “Our customers can rest assured they are getting the best products possible every time because they are continuously tested.”
The 6.4-liter Power Stroke Diesel was the first truck engine in North America to feature a high-pressure common rail fuel system with piezo injectors. This technology provides customers with a new level of quiet diesel operation while allowing International’s engineers to develop clean emissions strategies that contribute to society’s demand for clean air.This innovative-first drove International to rethink the way the fuel system was assembled and tested and to add three new clean rooms to its Indianapolis and Huntsville plants. Inside these clean rooms, fully automated processes using complex controls assemble the fuel system with exacting precision for unmatched quality and reliability. The advanced process also includes automated tightening of the fuel system’s connections, an industry first that further exemplifies International’s manufacturing excellence and leadership.
Once assembled, the fuel system is aggressively tested to ensure the integrity of the joints and that it will be leak-free for the life of the engine. Unlike traditional methods that utilize air to test for leaks, International uses a functional tester that pumps specially dyed fuel through the system at full fuel pressures.Using new automated camera systems and black lights, the fuel system is visually inspected thoroughly to ensure it is completely leak free and to guarantee its reliability and integrity.