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Audi builds 5-millionth vehicle with Quattro

Quattro, the trademark name Audi has put on its all-wheel-drive system engineered for passenger vehicles, recently celebrated its five-millionth installation. The driveline has been offered in more than 140 different vehicles since its introduction more than three decades ago.
The all-wheel-drive technology made its world debut at the 1980 International Geneva Motor Show, beneath the floorpan of the Quattro Coupé, a low-volume two-door. It didn't take consumers long to embrace Audi's innovative approach. While most four-wheel-drive systems at that time utilized heavy transfer cases or second cardan shafts, Quattro was virtually tension-free, light, compact and efficient. Most importantly, enthusiasts found it was especially suitable for sports cars.
Today, the automaker offers Quattro on its full line of passenger vehicles and it is unquestionably successful (the technology enjoyed a 43 percent take rate in 2012). On models with transverse-mounted engines (A3 and TT), Audi uses an electronically controlled multi-plate clutch with hydraulic actuator. Under normal conditions, the clutch sends power almost exclusively to the front wheels (if wheel slippage occurs, up to 100 percent of the torque may be sent to the rear). Vehicles with transverse-mounted engines (A4, A5, Q5, etc...) use a self-locking center differential sending 40 percent of the engine torque to the front axle and 60 percent to the rear under normal conditions (it is able to send the majority of the power to the axle with better traction when needed). The highest-performing Quattro systems use torque vectoring to further improve cornering grip and speeds.

Production 4.0: Audi plans for the smart factory

Automotive production is becoming more integrated and at the same time has to be more intelligent and more efficient. Flexible production of customized vehicles is one of the big challenges for the future, especially for a premium carmaker like Audi. How will the "Vorsprung durch Technik" brand meet its aim of offering premium quality with added custom flexibility? The company sees the "smart factory" as the key. Whether it's body-color moldings or light-alloy wheels in a special size, almost every car is ordered with some kind of customization, and the demands are increasing. This requires of course already a lot of flexibility. While the variety of models and quality demands are increasing, automotive manufacturers such as Audi are eager to make production sustainable. In an Audi interview, innovation management members Alois Brandt and Henning Loser talk about "production 4.0" and the upcoming "smart factory." How will Audi manage the production site with its very high standards of quality, efficiency, and environmental acceptability? Will the so-called "smart factory," which should be the intelligent factory of the future, only employ robots? Alois Brandt: "With a deep look into the production, I am convinced that our employees and not machines are the relevant working forces behind the Audi brand. Machines can be bought anywhere." Increasing digitalization is paving the way for the smart factory – the intelligent, digitally connected production facility. New high-tech solutions in manufacturing should further increase the high level of quality, while at the same time the assembly work should be easier and result in better ergonomics. Can you give us a clearer imagination of the "smart factory"? Alois Brandt: "There are a lot of ideas. But the big question at the moment is: Which one is really needed and leads into the right direction?" Can you tell us a little bit more about "production 4.0"? Alois Brandt: "The assembly line as we know it in the present will no longer play the same role. If it makes sense, it will be terminated and replaced by – let's call it – a virtual assembly line. The production will be more modular than before and the car will be directed to a production point – a so-called 'island of competence' – where it is needed." Henning Loser: "If the vehicle is to be assembled to the customer's wishes, it is obvious that efficient programming of robots and coordinating with the human workers is needed.

VW recalling 2.64M vehicles worldwide over engine, light issues

Volkswagen is staging a massive, worldwide recall that's already grown from 1.68 million to 2.64 million vehicles and covers three different issues across a number of vehicles. We already reported on 61,000 Tiguans getting recalled over lighting issues - that was just in the US. Globally, however, VW will be recalling 800,000 Tiguans, according to Automotive News, with the focus on CUVs built between 2008 and 2011. The issue with the Tiguan relates to a simple fuse swap, so this is rather unremarkable, aside from the sheer number of vehicles being fixed. The real, troubling issues relate to gearboxes and pickups.
239,000 Amarok pickups (pictured right) are being recalled over fuel leaks, while 1.6 million vehicles are being recalled to swap the synthetic oil in dual-clutch transmissions with mineral oil. Now, the transmission issue is one for the global Volkswagen Group to address, not just the VW brand - vehicles from Audi, Škoda and Seat use the same seven-speed DSG and are covered under the recall, as well.
Why the switch from synthetic to mineral oil? Apparently, using the synthetic oil in a DSG and then subjecting it to stop-and-go conditions or heavy loads in a hot and humid climate can lead to electronic malfunctions, according to a Volkswagen press release. The switch, from the sounds of it, is largely a preventative measure.