Automated Production Cell Complete Machining of V8 And V12 Diesel Engines

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Tatra Trucks is bringing its engine production up to the latest standards. A production cell with three Heckert HEC 800 machining centers, automated by a pallet system, increases efficiency.

Tatra, a car manufacturer from Kopřivnice, Czech Republic, started producing carriages back in 1850 and has been manufacturing automobiles since the end of the 19th century. Today, it is above all the heavy Tatra trucks that impress with their off-road capability, high reliability and outstanding utility properties—even in extreme weather conditions such as frost and desert temperatures.

One of the special features of the vehicles is the Tatra concept: a chassis with a central support tube and individually suspended semi-axles, which makes it possible to mount any number of axles, from 4x4 to 12x12 and more. The direct air-cooled V8 and V12 diesel engines of the Tatra T3 series with supercharging and intake air cooler are also among the USPs.

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Production takes place at the headquarters in Kopřivnice in the Czech Republic. The complete chassis for the T158 Phoenix vehicles, which are available with various superstructures such as containers, concrete mixers, tanks and special superstructures, are produced there. Vehicles from the T815-7 Force series are also produced, which are available in both civilian versions (e.g. as fire engines etc.) and military versions. Technology and Process Manager Martin Kappler explains:

We manufacture almost all components for our Force series vehicles ourselves: the complete chassis, cab, engine and transmission.

Martin Kappler, Technology and Process Manager, Tatra

Tatra's production portfolio also includes the Tactic series of medium-sized vehicles, which are designed exclusively for military purposes.

Automated Production Cell Replaces Transfer Line

As far as engine equipment is concerned, Tatra Trucks lets its customers choose from several options. Liquid-cooled engines from proven manufacturers and Tatra's own V8 and V12 engines in various power variants are available. The latter have been manufactured on a transfer line in Kopřivnice since 1980.

Despite its age, the technical condition of this system is still good, but the energy costs are extremely high, as is the consumption of cooling lubricants. We therefore decided to switch engine housing production to a cell with automated machining centers.

Martin Kappler, Technology and Process Manager, Tatra

He also argues that the changeover from V8 to V12 on the transfer line takes a long time, usually several production shifts: "In view of the flexibility required today, the new production cell also scores points in this respect. With our universal device, we are quick to change over and can manufacture each engine housing individually. This makes us much more efficient with the machining centers, even if the pure machining time of a motor housing on the transfer line is shorter."

As a result, the production managers at Tatra Trucks decided in 2024 to order a Heckert HEC 800 from Starrag as the basis for the planned production cell—supplemented by an automation solution in the form of a Fastems FPC3000 system.

A Decision With A History

Tatra replaced an ageing machining center back in 2017. Its original tasks were the milling of base surfaces and the machining of index holes, which are required for clamping and positioning the cast parts in the transfer line. Purchaser Libor Kalíšek recalls: "After comparing several suppliers at the time, we opted for a Heckert HEC 800 as it seemed the most suitable and offered an extended machining spectrum."

Since then, Tatra has been using the Heckert HEC 800 to pre-machine 8 and 12-cylinder engine housings. The lower part of the housing is completely machined in a single operation, including the index holes and all holes for attaching the oil pan.

We also rough the motor housing surfaces on the Heckert HEC 800 and drill holes that cannot be machined on the line. Before we send the pre-machined housing to the transfer line, the motor housing is completely reworked, including the various covers, the pump seat, etc.

Dušan Kelnar, Technologist, Tratra

Dušan Kelnar points out that he and his colleagues have been familiar with the machine manufacturer Starrag and the Heckert centers for a long time: "We bought the first Heckert CWK 630 machine for machining gearbox housings 25 years ago." In the years that followed, Tatra regularly invested in further Heckert machines: two CWK 630s for machining axle housings, three CWK 500s for swing arms and wheel reduction housings and two CWK 500s for components from the Tatra Tactic series. By 2017, three HEC 630 and two HEC 500 machining centers had also replaced other old machines. "We therefore have extensive experience with Heckert machines," emphasizes Kelnar. "These machines have proven themselves thanks to their design, reliability and long-term accuracy."

Production Cell is Expanded Step By Step

The new Heckert HEC 800, which was delivered at the beginning of 2025, is the basis of the production cell that has since been put into operation. The machine has special equipment, including, for example, a travel path extended to 81 inches in the Z axis, an NC axis in the spindle for controlling special tools and a magazine for long tools up to 49 inches.

The cell takes over the complete machining of our 8 and 12-cylinder engine housings and is increasingly replacing the transfer line.

Martin Kappler, Technology and Process Manager, Tatra

The blanks are cast parts made of Cu-alloyed GG20 cast iron with dimensions of around 47 × 24 × 28 inches and a weight of around 882 pounds. Complete machining is carried out in four clamping operations using special hydraulic clamping devices developed and manufactured by Starrag.

In a second step, the production cell will soon be expanded to include an identical Heckert HEC 800 machine. And in a third expansion stage, Starrag will integrate the Heckert HEC 800 already installed, which is currently still responsible for the external pre-machining of the cast blanks.

A flexible pallet storage system, consisting of a rack with twelve pallet spaces and a linear conveyor, automates the production cell. The latter transports the pallets between the machines or the machine set-up stations. The pallet storage system will also be expanded as the number of machines grows.

Enormous Increase in Productivity Per Unit Area

Martin Kappler compares the two production systems: "Our transfer line recently had a capacity of around 1,600 units per year, which we are currently only using to half capacity. Our production cell will also reach this number of units in the final expansion stage in two-shift operation, which is important for us. Because we expect demand to grow strongly. If necessary, we can cover a further increase in demand with a third shift."

His enthusiasm for the new production solution is primarily due to its high efficiency. There are several reasons for this, as Kappler emphasizes:

Thanks to automation, our new production cell can be operated by a single employee. Compared to the previous transfer line, the operating costs are many times lower and the production cell takes up just over a quarter of the space at 6,130 square feet.

Martin Kappler, Technology and Process Manager, Tatra

Purchaser Libor Kalíšek, who initiated the purchase of the Heckert HEC 800, has since retired. His successor Tomáš Holčák also praises the cooperation with Starrag: "All offers and negotiations were at a high technical and commercial level. We greatly appreciate the fact that Starrag supplies us with turnkey machines as a fully functional unit comprising machine, tools, fixtures, technologies, testing and handover. The technical support, service and maintenance are also excellent." Based on the positive experience, further projects to modernize and rationalize production are already being planned.

Wolfgang Klingauf is a freelance author

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