Cummins Crankcase Ventilation Valve

High-Precision Automated Assembly & End-of-Line Testing Cell

The Project

Cummins, a global leader in diesel engine manufacturing, required a dedicated automated cell to assemble and validate Crankcase Ventilation (CCV) valves. These critical components regulate oil and diesel fumes within the engine, mitigating the risk of "diesel runaway"—a catastrophic condition where an engine accelerates uncontrollably by consuming its own oil as fuel.

Technical Contributions

  • Mechanical Design: Engineered precision part nests and part presenters for high-speed automated handling.
  • Validation Systems: Designed the final mass flow and valve flow test stations to ensure 100% component compliance.
  • Troubleshooting: Led the optimization and technical troubleshooting of the pre-assembly operator stations to increase cell throughput.

Visual Documentation

CAD Design
Initial CAD: SolidWorks modeling of the assembly nests and tooling geometry.
Test Procedure
Validation: Analysis of customer-specified pressure and flow test procedures.
Flow Tester
Station Detail: Operation of the pre-assembly valve flow tester station.
Final Machine
Deployment: Completed assembly machine with integrated mass flow sensor.