George Lendich wrote:

We were not allowed to take pictures of the automated parts of the

machining

lines. Each major casting of the engine such as rotor, rotor housing, end

housings

and front cover go down automated 300 foot long  machining lines designed

and built in

1969. One line for each unique casting. The spindle motors that machine

the parts

on these lines are typically about 18 inches in diameter and two feet

long.

My guess is they are about 25 HP each. Usually there are two motors per

stop.

Each stop does only one or two machining operations. Then the casting

automatically

moves to the next stop. A pallet of raw castings is positioned at the

start of the line.

The raw castings  are loaded into the lines by robots one by one.

We did not get a tour through the casting foundry.

There are very few workers on this part of the operation. My guess is only
two or three. Computers are not used to control these operations. Relays,
ladder logic and hydraulics are used. There is an exception and that is
a conventional NC mills are now used to port the side exhaust ports on the

RX8

engine at one or two stops. They are automatically loaded and and

unloaded.

That of course was made necessary by the change in porting from peripheral

to

side. Rotor slots are induction hardened as are end housing wear surfaces.
This is easily incorporated into automated machining lines. Several stops
on each line are used to measure the machined parts to ensure they
meet tolerances.

The factory manager said it would cost over one billion US dollars
to duplicate this part of the operation if it were built today. I have no

doubt

that that number is correct.

You can see parts of the green colored lines in the background in these

pictures.

More later on final assemble and testing.

Paul Lamar

Paul,
What process are you referring to by 'Induction Hardening'?
George (down under)

High power high current RF coils are used to heat the metal and harden it.
http://www.ameritherm.com/overview_hardening.html

Paul Lamar

 
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