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  • Have you ever wondered how a truck really works?

  • How it's built? How it's developed? Let us show you.

  • This is 'Truck's Anatomy'.

  • I'm feeling a bit nostalgic, sitting here making my own tin soldiers.

  • It's a fairly easy process,

  • where the secret to success lies in the preparation of the mould.

  • However, we are here to talk about bigger things.

  • The process of casting engine parts

  • here at the diesel engine manufacturing plant in Skövde, Sweden,

  • is based on the same principles. The Volvo Group Trucks Operations' site

  • for manufacturing heavy-duty diesel engines, covers 265,000 m².

  • In 2012, they produced approximately 72,000 engines.

  • The site houses two foundries: G1 and G2.

  • The G2 is a state-of-the-art facility where the casting process

  • has been refined and its environmental impact reduced.

  • Water is used to cool down the casting mould,

  • which speeds up the solidification process and makes the iron stronger.

  • The water is then recycled. About 50 % of the energy generated

  • from the casting process, is reused for heating.

  • 85 % of the sand from the mould is also recycled,

  • which means that the G2 foundry has a very high recovery rate

  • by international standards.

  • Before the casting process, the mould has to be assembled.

  • Here, the core package for the cylinder head is glued together by robots.

  • They perform the job with millimetre precision.

  • It is then coated with a refractory fluid called black wash,

  • making the surface flawless. The core package is then put together,

  • making the mould complete for the final step: the casting.

  • All the parts that leave the casting need to be machined.

  • The machining process is highly automated and consists of several steps.

  • And it's under constant monitoring by advanced measuring systems

  • that measure accuracies by a thousandth of a millimetre.

  • The plant in Skövde machines cylinder heads, engine blocks,

  • cranks and camshafts, flywheels and gears.

  • In the assembly plant, the engine is starting to come together.

  • Here, the camshaft is being assembled to the cylinder head.

  • This particular engine is a D13.

  • A 13-litre 6-cylinder 24-valve diesel engine.

  • This model represents the heart of more than a third of all the trucks

  • from Volvo Trucks.

  • All engines manufactured today meet strict environmental requirements.

  • The Euro 6 engine, with selective catalytic reduction, SCR,

  • exhaust gas recirculation, EGR, and a diesel particulate filter, DPF,

  • reduces nitrogen oxide emissions by 77 %

  • and particulate emissions by 50 %, compared with the Euro 5.

  • In there, behind the windows, the engine springs into life for its first time.

  • The test lasts about two minutes.

  • It's run without liquid in its cooling system.

  • During those two minutes, nine important parameters

  • are monitored, measured and saved.

  • For example, turbo pressure, sound and the rpm are monitored closely.

  • When the engine passes all nine parameters,

  • it's moved to the paint shopthe last step in the manufacturing process.

  • This freshly painted engine is now going to be shipped

  • to the Tuve assembly plant in Gothenburg, Sweden.

  • It will be installed into a brand new FH truck,

  • where it will stay for hundreds and thousands of kilometres.

  • Remember this? This is my creation of the day.

  • I'm going home to hone my skills in tin casting, because I know how by now.

  • See you in the next episode of 'Truck's Anatomy'.

Have you ever wondered how a truck really works?

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B1 US casting engine mould cylinder process diesel

Volvo Trucks - How 72,000 heavy-duty engines a year are manufactured - Trucks' Anatomy E02

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    joey joey posted on 2021/06/06
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