The Problem: Retrofitting an Engine Assembly Line for a New Casting Design

A world-leading diesel engine manufacturer developed a new engine block casting for the latest generation of their engines. While the new design delivered performance improvements, it introduced a major manufacturing challenge: the existing robotic handling system could not accommodate the new block geometry.

One of the most critical operations in the engine assembly line required the 1,600 LB block to be:

1. Lifted from its shuttle pallet
2. Rotated upside down for crankshaft installation
3. Rotated back over and accurately returned to the pallet

This operation was previously performed using dual industrial robots with a shared end-of-arm tool (EOAT) that clamped onto the engine block during the flip.

With the new casting, that tooling approach was no longer viable.

The robot and controls integrator responsible for the line needed a solution that would work without risking downtime, safety, or long-term reliability.

They partnered with American Precision Engineering (APE) to evaluate whether the existing EOAT could be modified, or if a new design was required.

The Challenge: Complex Geometry and High-Risk Material Handling

After a detailed engineering evaluation, it became clear that the existing end-of-arm tooling design could not be adapted.

The new engine block introduced:

• Geometric constraints that interfered with clamping surfaces
• Features that created unstable load paths during rotation
• Increased risk during unexpected robot motion

Attempting to force the old concept onto the new block would have added unnecessary complexity and increased the likelihood of failure in a mission-critical operation.

For ahigh-throughput engine manufacturing line, that risk was unacceptable.

The Solution: A New End-of-Arm Tool Designed from First Principles

APE designed a completely new robotic end-of-arm tool based on a fundamentally different handling concept.

Rather than adapting legacy tooling, the new EOAT was engineered to:

• Reduce the number of moving components
• Improve mechanical simplicity and robustness
• Provide inherent safety constraints during robot motion
• Lower long-term maintenance requirements

By simplifying the mechanism and optimizing load paths, the new design improved both operational safety and system reliability, while maintaining precise control throughout the flip operation.

Validation and Testing: Engineering for Zero-Failure Operation

Because this tooling supported a critical engine assembly process, extensive validation was required before installation.

APE conducted comprehensive in-house testing, including:

• Full-cycle operational testing under normal production conditions
• Load testing at 150% of expected operating loads as a factor-of-safety verification
• Adverse condition testing well beyond what the tool would ever see in service

Throughout development and testing, APE worked closely with:

• The robotic systems integrator
• Plant engineers
• Maintenance and operations personnel

This collaboration ensured that real-world lessons from previous tooling issues were incorporated into the final design.

The Outcome: Reliable Robotic Handling for High-Volume Engine Manufacturing

By redesigning the robotic EOAT from the ground up, APE helped eliminate a major manufacturing bottleneck and enabled the successful launch of a next-generation engine platform.

Key results included:

• Safe and repeatable engine block handling
• Reduced mechanical complexity
• Lower maintenance burden
• Zero impact to production startup schedules

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Custom Robotic Tooling Built for High-Stakes Manufacturing

At American Precision Engineering, we design and build custom robotic tooling, fixtures, and mechanical systems for manufacturing environments where failure is not an option.

If your production line requires:

• Robotic end-of-arm tooling
• Custom material handling systems
• Custom industrial fixtures
• High-reliability mechanical     design and fabrication

We specialize in solving the hard problems, before they ever reach your factory floor.