Several flexible, multi-purpose HANSBERG core manufacturing facilities are in operation at TUPY’s Joinville and Maua foundries, producing all sorts of motor block core packages as well as cylinder head core assemblies at the nominal rate of 75 cycles/h.

Each facility is typically based on two H100 core machines facing an automatic core assembly/coating line. Sometimes, a facility may consist of three, or even four core machines. One of the facilities has three H150 core machines producing heavy duty motor block core packages weighing up to 650 kg.

On account of the better core box surface utilization and shorter process times offered by horizontal-split tooling, most of TUPY’s core manufacturing facilities feature horizontal core machines.

Each machine produces part of the core requirement for one complete package. For example, on a two-machine facility producing Siamese 4-cylinder motor block packages, each machine makes one FRONT END / REAR END core and two CRANKCASE/BARREL section cores. When producing V-block cores, one of the machines shoots the WATER JACKET and BASE cores, which are assembled and coated as a kit, and added to the main package after drying.

As in all HANSBERG machines integrated in automatic core handling cells, the cores are presented already de-finned on a de-finning/takeout template for pick-off either by operator or robot.

The cores are removed from the templates and placed in sequence on the core support fixtures of the core assembly line. These are designed to be used for different package typologies, including 4- and 6-motor block core packages, both single and Siamese, as well as V-block core packages. Different packages may require the fitting on the support fixtures of specific core location / adaptation pads.

Ancillary cores, such us WATER PUMP cores, are manually assembled off-line on the FRONT END / REAR END core before the latter is placed on the support fixture.

When the package is completed, tie-rods are manually introduced through the length of the package. Up to four tie-bars can be placed through a given package.

The locking nuts are automatically fed by a vibratory feeding unit and driven in place by automatic nut-driving units. Special nuts with integrated washer, or nuts with idle washer arrangement, are used for the automatic bolting of the core packages.

The assembled packages are then removed from the assembly line fixtures, always by robot or gantry manipulator, and dipped in the special, constant-level coating tank.

Finally, the coated core packages are deposited on universal pallets and proceed through a gas-heated tunnel drying oven. Coming out of the oven after about 30 min at a temperature of 120°C, the dried packages are ready for storage.