Durham-based Altec Engineering Ltd (www.alteceng.co.uk) has devised a semi-automated system for Nissan to fit a series of dowels and cam brackets to a cylinder head before the cam bolts are tightened.

The system comprises two operational stations, a roller transfer system, a Kuka robot and Bosch Rexroth nut drivers, all enclosed by perimeter safety guarding that has an operator access aperture protected by a light guard.

At the first station, the cylinder head is manually loaded onto a base plate and locked in position. A guide plate is placed on top, and six dowel pins are located and pressed home by a pneumatic hammer tool.

Sensors on the guide plate detect that the dowels are fully inserted before the cylinder head is released. At the second station, the cylinder head is located on a transfer table, and the operator positions a guide plate that ensures the correct placement of the cam bracket and bolts.

Sensors ensure that the correct bracket has been fitted, before the table presents the cylinder head to the Kuka KR16 robot, which has two torquing spindles mounted to the wrist.

The bolts are tightened in pairs in a pre-determined sequence — first to a mid-torque point to ensure seating and location, then to the final required torque figure. The cylinder head is then returned to the operator.