Robot Welded Engine Stillages for BMW’s Hams Hall Plant
BMW’s Hams Hall plant in Birmingham expanded its storage facility to house over 6,700 combustion engines, moved by an automated conveyor system. Universal Fabrications was contracted to manufacture and install the engine stillages (platens) that carry each engine through the system. With over 45 years’ experience manufacturing complex metal fabrications for the automotive, specialist vehicle and defence sectors, we combined robotic welding and precision machining to deliver at production scale.
The Challenge
Each stillage had to hold three engine types, including V8 and V12 units whilst keeping the load balanced as it moved. It also had to withstand the weight of the engine, minimise frictional forces, and travel safely and securely throughout an automated storage system where any inconsistency could stop the line. All of this had to be proven before full production, and then delivered within an 8-month production window.
Universal Fabrications’ Role
We prototyped and tested the stillage design to confirm it met BMW’s load, friction and movement requirements before committing to production. This included load testing and tensile strength tests through Lucideon’s UKAS-accredited testing facilities, giving BMW independent verification of the stillages’ load capacity and weld strength. The production units were built as robot welded mild steel box frames, each with a machined central spigot, using our robotic welding cells and in-house precision machining. Every stillage was finished in a scratch-resistant powder coat to stand up to daily handling, with welding carried out by accredited welders qualified to BS EN ISO 9606-1 for mild steel, under our ISO 9001 quality system, before installation on site.
Why It Mattered
Proving the design through prototyping meant BMW could commit to full production with confidence, and robotic welding delivered the consistency an automated system depends on – every stillage behaving the same way on the conveyor. Delivering within the 8-month window supported the expansion of engine storage at one of BMW’s key UK sites. It’s the same approach we bring to all our production work: prove it early, then build it right every time.
Have a robot welding or production fabrication project? Call 02476 370272 or email email@universalfabrications.com.
Speak to a Manufacturing Specialist today. Call 02476 370 272 or send us an email.
