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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.

Delphi thrilled with results from autonomous car's cross-country trip

In the first trip across the United States ever made by an autonomous car, engineers from Delphi Automotive were surprised to learn that, in some cases, their vehicle behaved a lot like a human driver. "The car was scared of tractor trailers," said Jeff Owens, the company's chief technology officer. "The car edged to the left just a little bit when it would pass trucks, and that was an interesting observation." Engineers made hundreds of notes throughout the drive, as the autonomous car covered 3,400 miles through 15 states en route to a showcase near the New York Auto Show. Overall, company officials said the car performed better than anticipated in a variety of road and weather conditions. In the course of the cross-country drive, drivers actually controlled the car only for about 50 miles, and those cases were limited to on-and-off ramps and the occasional construction zone where lanes were not marked or only sporadically marked. The purpose of the trip was to glean information on how the autonomous car worked in a real-world environment. Google and others have tested autonomous cars and autonomous features in select real-world environments before, but Delphi's adventure was the first to trek into a test with such varied challenges over a nine-day trip that began near the Golden Gate Bridge on March 22. There are some things the engineers have already learned, like the fact the camera systems had the occasional blip when the sun-angle was low. And there are some things to still be learned, as they pour over three terrabytes worth of data from cameras, radar and lidar sensors in the weeks ahead. "It's going to take us a couple weeks to digest all this," Owens said. "But we had all the data from tests. It was time to put this on the road." Built into an Audi SQ5, the vehicle was striking, if only for the fact it looked like a normal car. Many other autonomous vehicles have quirky sensors atop the roof or other features that make them stand out as experiments. Delphi arranged this one to look as much like a normal car as possible, right down to stowing an army of computers under cargo mats, so the rear contained as much trunk space as the production model. If a fellow motorist didn't know where to look -- or take the time to notice the person in the driver's seat didn't have their hands on the wheel -- there was no reason to suspect this was anything other than a regular car.

VW announces reworked 6.0 W12 TSI engine

Nobody makes more engines with a dozen cylinders than the Volkswagen Group. They're W12s, of course, owing to the novel shape of their cylinder banks. Now the German industrial giant has announced a comprehensively reworked version of that engine at the same Vienna Motor Symposium where it presented its new 2.0-liter turbo four. The new W12 retains the same arrangement and the same 6.0-liter displacement, but updates it all with the latest powertrain tech. In place of Audi's FSI direct injection and Bentley's TMPI multi-point injection, the engine has adopted a new TSI system. It's also got a pair of new twin-scroll turbochargers, APS-coated cylinders, a new cooling system, active engine mounts, cylinder deactivation, and a stop/start system. And – crucially for application in the upcoming Bentayga – it has an oil circuit designed for off-road use. The revised package now produces 600 horsepower and 664 pound-feet of torque. Considerably more than the 567 hp and 516 lb-ft offered in the Bentley Continental GT W12, but less than the GT Speed, which we suspect will get an even more powerful version of this new engine. It's also more powerful than even the top version of Audi and Bentley's 4.0-liter twin-turbo V8, to make the W12 a more compelling option. Of course that's just as far as the Continental GT is concerned. The W12 has also found use in the Continental GTC and Flying Spur, as well as the Volkswagen Phaeton and Audi A8, and could find further applications under the Flying B emblem and elsewhere in the future. VW says that in the right application (say, in the production version of the Bentley EXP 10 Speed 6 concept, for example), the new twelve-pot could deliver 0-62 times of under four seconds and a top speed in excess of 186 miles per hour. Volkswagen at the 36th International Vienna Motor Symposium Dr. Heinz-Jakob Neusser: "The car of the future will continue to fascinate people" - CO2 reduction, electromobility and digitalisation are the greatest challenges facing the automotive industry - The future of the internal combustion engine will be characterised by high rpm diesel and high-performance three-cylinder TSI engines - Laser roughening – innovative coating process in large-scale production - New 6.0 W12 TSI with 447 kW (608 PS) – performance and refinement - New generation of EU6 TDI engines for light-duty vehicles Dr.