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How a Heavy Truck Manufacturer Streamlined Turbocharger Assembly with a Multi-Axis Press Solution
Solving Multi-Pin Press Challenges with Intelligent Automation
In the heavy truck industry, precision is non-negotiable, especially when assembling critical components like turbochargers. One manufacturer faced a particularly complex challenge: pressing multiple pins into a turbocharger at different heights and locations using just one actuator, all while ensuring accuracy, force control, and complete traceability.
Manually repositioning the part for each pin was slowing production, increasing risk of error, and making quality consistency harder to achieve. The customer needed a smarter way to perform multi-location pressing without handling the part multiple times.
The Challenge: Multi-Pin Pressing Without Manual Repositioning
The manufacturer required a system that could:
- Press multiple pins at different depths
- Navigate to multiple press locations without moving the turbocharger
- Deliver high-force capability for tough components
- Maintain precise X, Y, and Z control
- Capture force and position data for every pin
- Integrate seamlessly into existing processes without becoming a one-off “science project”
They needed accuracy, flexibility, and reliability, all within a simple, easy-to-support platform.
The Solution: Promess Gantry + 20kN EMAP + UltraPRO Controller
To meet these requirements without custom engineering, Promess delivered a standardized multi-axis solution built from proven components:
Gantry System for Full X/Y/Z Motion
The Promess Gantry provided high-precision movement across all axes, allowing the press head to reach each pin location without manually moving the turbocharger.
20kN Electro-Mechanical Assembly Press (EMAP)
The EMAP delivered up to 20kN of programmable force control, ensuring each pin was pressed to the exact depth and specification—fast, repeatable, and accurate.
UltraPRO Controller for Unified Control
Using one common controller and one common software interface simplified setup, programming, and long-term support. No custom controls. No proprietary complexity. Just a clean, straightforward solution.
Because the entire solution was built from standard Promess products, integration was quick and hassle-free.
The Result: Faster Production, Higher Accuracy, and Complete Traceability
With their new multi-axis automated press solution, the customer achieved significant performance and quality improvements:
✔ No More Manual Repositioning
All pins were pressed in one setup, eliminating handling time and reducing operator involvement.
✔ Pin-By-Pin Precision
Each pin reached its exact height with controlled force, improving product consistency and reducing scrap.
✔ Complete Force/Position Data for Every Pin
Real-time data ensured full traceability and reliable quality assurance.
✔ Faster Cycle Times
Automation streamlined the entire process, making production faster without sacrificing precision.
✔ Scalable, Maintainable, and Easy to Support
Because the system used standard Promess products and controls, the customer gained a long-term solution that’s simple to operate, upgrade, and maintain.
A Smarter Way to Assemble Turbochargers
This case highlights how the right combination of precision motion control, force feedback, and intelligent automation can transform a complex, multi-location assembly task into a fast, reliable, and repeatable process.
For manufacturers working with large, high-value components—and who need flexibility without complexity—Promess’ multi-axis solutions provide the performance, scalability, and data-driven validation needed in modern heavy-vehicle production.
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