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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.

Everybody's doing flying cars, so why aren't we soaring over traffic already?

"Where's my flying car?" has been the meme for impending technology that never materializes since before there were memes. And the trough of disillusionment for vehicles that can take to sky continues to nosedive, despite a nonstop fascination with flying cars and a recent rash of announcements about the technology, particularly from traditional automakers. Earlier this month, Toyota applied for an eye-popping patent for a flying car that has wheels with spring-loaded pop-out helicopter rotors. The patent filing says the wheels/rotors would be electrically powered, while in on-land mode the vehicle would have differential steering like tracked vehicles such as tanks and bulldozers. At an airshow in July, Aston Martin unveiled its Volante Vision Concept, an autonomous hybrid-electric vertical takeoff and landing (VTOL) vehicle it developed with Rolls-Royce. Aston says the Volante can fly at top speeds of around 200 mph and bills it as a luxury car for the skies. Audi used the Geneva Motor Show in March to unveil a flying car concept called the Pop.Up Next it developed with Airbus and Italdesign. If the Pop.Up Next, an electric and autonomous quadcopter/city car combo, gets stuck in traffic, an app can be used to summon an Airbus-developed drone to pick up the passenger compartment pod, leaving the chassis behind. Audi said that the Pop.Up Next is a "flexible on-demand concept that could open up mobility in the third dimension to people in cities." But Audi also acknowledged that at this point it has no plans to develop it. The cash-stoked, skies-the-limit Silicon Valley tech crowd is also bullish on flying cars. The startup Kitty Hawk that's backed by Google co-founder Larry Page announced in June that it's taking pre-orders for its single-seat electric Flyer that's powered by 10 propellers and is capable of vertical takeoffs and landings. The current version can only fly up to 20 mph and 10 feet in the air and has a flight time of just 12 to 20 minutes on a full charge. The Flyer is considered a recreational vehicle, so doesn't require a pilot's license. Uber says it plans to launch its more ambitious Elevate program and UberAIR service in 2023. "Uber customers will be able to push a button and get a flight on-demand with uberAIR in Dallas, Los Angeles and a third international market," Uber Elevate promises on its website.

Audi 4.2-liter V8 to live again in next-gen R8

Fellow auto enthusiasts, it looks like the car gods have smiled upon us. Word is that Audi's stupendous 4.2-liter V8 will once again be available in the next-generation R8. Rumors pegged the trusty 4.2 as a dead engine revving, thanks to Audi's newer 4.0-liter twin-turbocharged V8 found in models like the S6 and S7.
We expected the 4.0-liter to be the go-to engine in the next R8, but according to Car and Driver, there have been some issues cooling the force-induced mill in the mid-engine R8. The issues are so severe, in fact, that the 4.2 is going to be retained in the car's second generation.
It's more than just practical matters like cooling that are keeping the R8 from going turbocharged. C/D reports that even with the current state of forced induction, a turbocharged R8's throttle response and its resultant exhaust note would suffer too much to be feasible.