Engine Manufacturing

The Engine's History

1876 four-cycle engine

The first successful four-stroke internal combustion engine was built in 1876 by Nicolaus Otto.  His invention, called the “Otto Cycle Engine”, offered the first practical substitute to steam engine as a power source.

Combustion is the chemical process of releasing energy from a fuel and air mixture.  The expanding combustion gases push the piston, which rotates the crankshaft.  Then, through a system of gears in the powertrain, motion drives a vehicle’s wheels.

Throughout the 20th century, the two most common internal combustion engines manufactured were the diesel and petrol engines.  Today, in the 21st century, electrical engines are starting to become mainstream with newer technology being introduced every day.  This is an important point to mention, as PPE needing worn by employees must change within different manufacturing plants.  Example being, workers that manufacturer electric engines are using thinner gauged metals and will need even higher levels of cut-resistant gloves.

Engine Products

Engines come in many different shapes and sizes, and are built for a multitude of different purposes.  Here is a quick rundown of the different types of engines.

Gasoline Engines

In this internal combustion engine, fuel is mixed with air and then inducted into the cylinder during intake.  With fuel-air inside the engine, a spark ignites, causing combustion.  Hot gases produced are used to drive the pistons.

This type of engine is the primary engine used in automobiles. Other applications for this engine include aircraft, motorcycles, motorboats, and small engines.

Diesel Engines

In this internal combustion engine, only air is inducted into the engine and then compressed.  The diesel engine then sprays fuel into the hot compressed air, causing it to ignite.

Heavy-duty diesel engines are primarily manufactured for freight trucks, however, they may also be found in light- and medium-duty trucks.  They are used for several purposes: heavy-duty transportation, medium-duty trucks, and for industrial machinery engines.

In 2017, there were roughly 900,000 diesel engines manufactured in the U.S.

Electric Engines

Electric engines are powered by an electric current that generates a magnetic charge and turns the driveshaft.  These engines utilize large lithium-ion batteries or batteries made with newer technologies.

An Electric Vehicle's Battery

There are two basic types of electric engine: all-electric vehicles (AEVs) and plug-in hybrid electric vehicles (PHEVs).

Economic Impact

Ultimately, the global automotive engine & parts manufacturing industry is linked to motor vehicle production, as engines are the essential component of the automobile.  The industry is forecasted to hit $299 billion in 2019.

Automotive engine & parts manufacturing involves making the following products: camshafts, crankshafts, engines, fuel injectors, pistons, valves, and pumps.  With regard to this industry resource page, we highlight the manufacturing of engines, not all the components that make up this industry.

The engine and turbine industry is linked to more industrial production and is projected to reach $55billion in 2019.

Companies

Honda is the world’s largest engine manufacturer, producing more than 23 million units annually.  Have you ever wondered who makes the best automotive engine?   Well, Ranker knows the answer to that question, as over 81,000 people have voted on the topic.  Honda is ranked the #1 engine by voters.

Many automotive companies manufacture engines in their own automotive plants.  However, some treat the engine as they do other parts and source from outside suppliers.  GM has sourced from others over the years, including Suzuki’s 3-cylinder portfolio, but have produced their engines more in-house in recent years.

Engine manufacturing goes beyond just the engines found in automotive vehicles.  The Truck and Engine Manufacturers Association represents manufacturers of internal combustion engines.  Their collection of members represents some of the largest industrial companies operating across the world.

Caterpillar, Cummins, and General Electric Company are three of the largest companies from this list.  Here are some of the many areas where you will find industrial engines used:

• Buses
• Electric generators
• Farm, construction, and industrial equipment
• Lawn and garden
• Locomotives
• Marine vessels
• Motorcycles
• Power transmission equipment
• Turbines Trucks

As we mentioned above, engines serve a wide range of purposes.

Die-Casting the Engine Block

The companies mentioned above manufacture a multitude of parts, with the engine block making up the core component.   It is the main structure housing hundreds of parts allowing the engine to function properly.

Engine Block

The manufacturing of the engine block is primarily accomplished by sand casting.  The reason for this is that the engine must be able to withstand the extreme pressure created when combustion occurs.  Green sand molding casting is the process most widely used.  This means it must withstand high temperatures and constant vibrations.

Stages in Manufacturing the Engine Block

The engine block, a one-piece component, is the single largest piece of metal in an automobile.  It is where combustion converts into mechanical energy.

Here are the steps for manufacturing it:

As you can imagine, working around heat and metal means MCR Safety gloves, made with DuPont Kevlar®, are an ideal choice for workers.  Be sure to check out MCR Safety’s industry page on foundries for further casting information.

Assembly and Testing

Once the engine block is manufactured, a working engine is only halfway complete.  An engine consists of an assortment of mechanical and electronic components, all of which must be assembled into a working whole.

A robot is at the heart of most of this process, completing tasks like installing the pistons into the cylinder bores and attaching pistons to the crankshaft.  However, the engine assembler still closes up the back of the engine block, tightens bolts, arranges wires, and moves the engine to the motor vehicle assembly line.

Engine Being Assembled

Employment

There are around 96,000 employees manufacturing industrial engines.  Whether it’s an automotive engine or an industrial diesel engine being manufactured, many workers find occupations that provide employment.   Here is a look at the occupations found in this industry.

Occupations

Manufacturing engines, like most other automotive industries, requires assemblers that fasten piping, install wiring, and cut out parts.  Many of the same occupations that make up the part manufacturing industry also work in this industry.  However, we’re going to highlight the engine assembler.

As you might already have guessed, where the automobiles are manufactured is where you will find most U.S. engines being manufactured.  Here are the states employing the most engine assemblers.

Automotive parts manufacturing is where you find most engine assemblers.

Work Activities Performed by Engine Assemblers

A.

• Apply lubricants and coolants
• Assemble electromechanical and hydraulic systems

C.

• Clean
• Cut industrial materials for fabrication and processing
• Conduct quality inspections

D.

• Drill holes in metal parts

H.

• Handle hot objects
• Head assembly

H.

• Operate grinding equipment
• Operate metal forming equipment
• Operate typical shop equipment such as hoists, jacks, hand tools, cleaning machines, wiring, etc.

P.

• Paint
• Place preassembled cylinder heads, aggregates, and belt drives

M.

• Mount cables, pistons, and bearings

S.

• Smooth out metal surfaces and edges

Safety

What do 91% of engine assemblers say their work requires every day?  If you guessed PPE, you would be correct.   Compared to other automotive industries, manufacturing engines isn’t as dangerous as something like metal stamping; however, it still has more injuries than the overall industry average.

Manufacturing engines is about 16% more dangerous on average.  It might be even higher if not for the fact that most of the engine manufacturing is an automated process.  With that said, employees still come into contact with heat, abrasive sand, oil, sharp metal, and numerous other hazards.

At MCR Safety, We Protect People with state-of-the-art PPE. Let us keep you safe when you are manufacturing engines!