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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.

2016 Audi TTS

We recently drove the Audi TT, and although we wish it were radically entertaining instead of merely very fun, it's nevertheless a sharp coupe that vaults ahead of its predecessor with an inspired interior and eager handling. That car will be precursor to this TTS when it gets here a year from now, with the TTS adding adjectives like "more" and "better" to just about everything found on the base coupe. With the standard car having already put on such a fine edge, we wheeled the TTS on Spanish roads and at the Ascari race track to find out how much better and higher-performing the S will be.
Driving Notes
As of this writing, today's TTS commands an $8,350 premium over the TT. Assuming a commensurate gap is carried over into this next generation model, that supplemental dosh will get you 310 horsepower and 280 pound-feet of torque instead of 230 hp and 273 lb-ft in the standard TT. That would mean more for your money, too, since the gap between the current TT and TTS is 54 hp and zero lb-ft of torque. To achieve the new numbers, the 2.0 TSFI engine from the TTS benefits from upgrades like sturdier valves, revised aluminum pistons and stronger connecting rods with new bearings, a reinforced crankshaft and a high-performance intercooler. The amplified brawn rips 0.7 seconds off the 0-60 mile-per-hour time, getting you there in 4.6 seconds.

Audi creates new diesel fuel from carbon dioxide and water

What if you could power cars of the future with pollution created by the cars of the past? That's what German automaker Audi is hoping to achieve by creating a new synthetic fuel using renewable energy to turn water and carbon dioxide gas into a new kind of fuel they call "e-diesel." The new diesel is being produced at Audi's pilot plant Sunfire in Dresden, Germany. Only a few gallons were created, which the German Federal Minister of Education and Research Johanna Wanka put into her Audi A8 to prove the fuel's bonafides. The base fuel is known as "blue crude" and begins from a green source. Audi uses electricity from wind, water or solar power sources to separate hydrogen from oxygen in water. The hydrogen is then mixed with carbon dioxide which has been converted in carbon oxide. The blue crude is then further refined to create the e-diesel. The carbon dioxide is currently supplied by a biogas facilities, but some of that CO2 was captured from the air. "The engine runs quieter and fewer pollutants are being created," says Sunfire CTO Christian von Olshausen. The fuel can be combined with conventional diesel fuel, as biodiesel fuels already and would be competitively priced against regular diesel, according to Gizmag. Sunfire can produce about 42 gallons of e-diesel a day. That seems like barely a drop in the bucket in terms of Europe's energy use, but Audi is ready to commercialize the technology with plans to expand production with a bigger facility in the future.