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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 bringing TT Clubsport Turbo concept to Worthersee

Is the world ready for an Audi TT with 600 horsepower? Well it had better be, because that's exactly what Ingolstadt has in store for this year's GTI-Treffen at Worthersee, Austria. Billed as a "technology concept," this TT show car packs a 2.5-liter inline-five with two electric turbochargers. Audi is developing electric turbos for its diesel engines, but has found a performance application here in a gasoline engine. The result is a whopping 600 horsepower and 479 pound-feet of torque, driving all four wheels through a six-speed manual transmission. Weighing in at 3,078 pounds and with those electric turbos spooling up quick, it's said to reach 62 in 3.6 seconds en route to a top speed of over 192 miles per hour. In a TT. The turbos are powered by a 48-volt electrical system, juiced by a compact lithium-ion battery in the trunk that can store regenerated power. It's also got a coilover suspension and electric jack to get over obstacles like curbs and speed bumps. The whole thing rides on 20-inch alloys with a two-tone finish, with carbon-ceramic discs to keep it all in check, and as you can see, a rather aggressive-looking widebody aero kit. All of which makes for a rather stunning concept, even if its encroachment on the R8 means it will likely never see production. Related Video: Ingolstadt/Reifnitz, 2015-05-08 Tremendous thrust right from the start: the Audi TT clubsport turbo technology concept car - Premiere at Worthersee: show car has 2.5 TFSI and electric biturbo - 441 kW (600 hp) and 650 Nm (479.4 lb-ft), 0 to 100 km/h (62.1 mph) in 3.6 seconds - Development chief Prof. Dr. Hackenberg: "Technology close to production readiness" Wide add-on parts, a powerful rear wing and a power output of 441 kW (600 hp) – the Audi TT clubsport turbo impresses with its power and design. From May 13 to 16, Audi will be showing its technology concept car on the Worthersee Tour in the Austrian town of Reifnitz. The inspiration for the show car came from the successful Audi 90 IMSA GTO of the late 1980s. A new technology is making its debut under the hood. The car's electric biturbo adds even more dynamism to the driving experience with its spontaneous response. "The electric biturbo signifies a new dimension in driving enjoyment; it boosts sprinting ability and torque and enables high peak power," explains Prof. Dr. Ulrich Hackenberg, Audi Board Member for Technical Development. "In our TDI engines, we are close to production readiness with this technology.

2014 Audi Q5 TDI

I've struggled with diesel technology. It's not that I have a problem with it or dislike it, but rather that I don't particularly understand what stops its wider-spread adoption. Sure, memories of rust-prone, smoky, sluggish and uneconomical Oldsmobile diesels aren't exactly easy to erase from the collective memory of the North American motoring public, but I'd think that a few years into the latest crop of clean diesels, there'd be wider adoption - or at least consumer consideration - by now.
Part of the issue is the still limited number of segments that diesels are available in. The Volkswagen Golf/Jetta TDI is finally getting a challenger in the form of the Chevrolet Cruze Diesel, and the BMW 328d is bringing something new to the entry-level sports sedan, but there are still a huge group of segments where diesel-power has no representation.
The small, luxury crossover realm is not one of those. It has the Mercedes-Benz GLK250 Bluetec, a stylish crossover with a silky-smooth 2.1-liter, turbodiesel four-cylinder that can return the kind of fuel economy that makes people take notice. And while the GLK250 is quite good, economy will only spread the diesel's appeal so far. People need to experience the seat-flattening torque that these mills can produce, and for that, we most humbly recommend the new 2014 Audi Q5 TDI.