Volvo Group North America: Crankshaft Grinders Upgrade

Background

In 2014, Volvo Group North America retrofitted its Hagerstown facility’s grinders with new state-of-the art Computer Numerically-Controlled (CNC) grinding machines. CNC grinding machines are used for machining or grinding the crankshafts along with the main and pin bearings. The facility replaced 13 existing grinding machines that had been in place since 1961 with 3 new machines. The new machines are not only more energy efficient, but can process more crankshafts per day than the original units. The new grinders provide a 56% reduction in electricity consumption, 35% increase in production rate, 53% reduction in water consumption and 60% reduction in coolant chemicals. The retrofitting began in 2014 and has been fully operational since completion in 2015.

Volvo Group’s 1.5 million-square-foot powertrain facility in Hagerstown, Maryland, employs 1,800 people who produce heavy-duty diesel engines, transmissions and axles for Mack Trucks, Volvo Trucks, Volvo Bus, and Prevost coaches.

Solutions

The retrofit required an input of approximately $8.5 million USD but offers significant pay back. The new grinders do not have any idle time and need only 15 minutes to warm up before operation. This helps saves energy when compared to the old grinders, which were kept at idle state consuming significant amounts of energy. Additionally, the new grinders are able to process multiple crankshafts with different width pins or mains without having to stop to make tooling changes. The new highly flexible machine can grind main journals, pins, thrust faces, post, flange and oil seal diameters-operations, which would previously require as many as four separate grinders. This project cut the facility grinders’ energy use by more than 50% while improving output, making it a key part of the company’s strategy to meet growing demand.

Other Benefits

The project was completed as part of ISO 50001 EnMS and SEP certification. The savings achieved from this project helped the facility achieve Platinum level SEP certification. In addition to energy savings, the project has yielded additional savings and productivity gains. The new grinder machines generate much less waste. This has enabled the facility to divert 68 tons of grinding sludge from landfills which equates to $8,500 in landfill disposal costs. In addition, the new machines require 53% less water and 60% less volume of coolant chemicals. Due to the increased productivity of the new grinder machines the Hagerstown facility was able to keep up with the fast-growing demand for trucks that Volvo Group has experienced in recent years.

ANNUAL ENERGY USE

ANNUAL ENERGY COST

ANNUAL WATER USE

ANNUAL WATER COST

ANNUAL PLANT ELECTRICITY USE

ANNUAL PLANT ELECTRICITY COST

IN BUILDING ENERGY USE

IN BUILDING ENERGY COST

ACROSS NETWORK USE

ACROSS NETWORK COST

ANNUAL EMISSIONS

USE

COST

Volvo Group North America: Crankshaft Grinders Upgrade

ANNUAL ENERGY USE

ANNUAL ENERGY COST

ANNUAL WATER USE

ANNUAL WATER COST

ANNUAL PLANT ELECTRICITY USE

ANNUAL PLANT ELECTRICITY COST

IN BUILDING ENERGY USE

IN BUILDING ENERGY COST

ACROSS NETWORK USE

ACROSS NETWORK COST

ANNUAL EMISSIONS

USE

COST

New grinder machines

Volvo Hagerstown facility

Volvo Group North America: Crankshaft Grinders Upgrade

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New grinder machines

Volvo Hagerstown facility