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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.

Audi says new 48 volt micro-hybrid system improves fuel economy, paves way for electrification

Most cars use a 12-volt system to power their electrical components. But, with more and more electric bits and bobs being added to new vehicles, a dozen volts is looking a bit weak these days. In fact, Audi says that standard 12-volt systems are being stretched "to their very limits." Enter 48 volts. If used in a car that gets 40 mpg, that would translate to around 43.5 mpg. Audi is testing a supplemental 48-volt electric system in two prototype vehicles – modified mild-hybrid versions of the A6 TDI and the RS 5 TDI – in order to add in more electric technology (an electric compressor, for example, to improve acceleration) and "convenience systems for dynamic chassis control." Audi says it has more applications in the pipeline, but the overall gist is that the German automaker sees 48 volts as an "important building block in electrification strategy." As you can see in the picture above (click to enlarge), the RS 5 TDI concept uses a li-ion battery installed in the back of the car and an alternator to provide 48 volts when the engine is off. Audi says that the 48-volt system can save up to 0.4 liters of fuel per 100 kilometers. To put that into US numbers, if used in a car that gets 40 miles per gallon today, that would translate into a bump up to around 43.5 mpg. The Advanced Lead Acid Battery Consortium (ALABC) is also working on a 48-volt system to improve fuel economy and we've got a deep dive of Audi's electric turbocharger here. Even more powerful and efficient – the new 48-volt technology from Audi Important building block in electrification strategy More voltage and more power for new technologies Scalable platform concept suitable for wide-ranging uses Ingolstadt, August 25, 2014 – Audi is to upgrade part of its vehicle electrical system from twelve to 48 volts. The move represents another technical building block for facilitating the integration of new automotive technologies while increasing the power and efficiency of its cars. "We are using the full bandwidth of electrification in our drive principles strategy. Running part of the vehicle electrical system at 48 volts plays a central role in this," commented Prof. Dr. Ulrich Hackenberg, Member of the Board of Management for Technical Development at Audi. "It enables us to make more energy available.

Audi Quattro concept production hopes still alive, could be more radical

Remember the gestation period of the Lexus LFA, the one that, in automotive time, took so long that its origins could have been carbon dated? We feel like it's deja vu all over again, as Yogi Berra would have said, this time featuring the Audi Quattro and Audi Sport Quattro. It was 2010 when our cameras first glimpsed the Audi Quattro Concept (pictured right) at the Paris Motor Show, and we tasted its turbocharged 2.5-liter, five-cylinder powerplant not long after. Last year we met the hybrid, 700-horsepower Audi Sport Quattro concept at the Frankfurt Motor Show, but we got no closer to finding out if there'd ever be a version we could buy. A report in Autocar keeps the flame of hope burning, quoting Audi design chief Marc Lichte at the LA Auto Show saying, "We are working on Quattro, it is still alive." Lichte went on to say, however, that the next imagining is "more extreme" than those we've seen, and, "There will be surprises." Those words alone are a surprise. The last we heard about the Quattro revival was Audi boss Ulrich Hackenberg saying he wanted a more accessible homage to the original, and we don't know how "more extreme" jives with that. Seeing that Audi is serious about the idea, at least, we shouldn't have to wait long to find out. Just don't get your hopes up about its affordability yet.