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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 is working on a suspension that gets power from bumpy roads

Regenerative brakes aren't new. They're on virtually every hybrid and EV, and they're even starting to pop up on traditional gas-powered cars, like with the i-ELOOP-equipped Mazda6. But even with these systems, cars can get more efficient, and Audi thinks it found yet another source of wasted energy. The source? The suspension. The idea is to turn the kinetic energy that goes into the dampers into usable energy instead of as waste heat. Audi isn't the first auto company to come up with regenerative suspension – nearly three years ago, ZF introduced its GenShock technology, which used a valve attached to traditional, oil-filled hydraulic shocks to recapture kinetic energy from movement caused by bumps in the road. Audi's prototype technology, which it calls eROT, replaces traditional dampers with horizontally oriented electromechanical rotary dampers. eROT is apparently short for electromechanical rotary damper. Neat. In testing, eROT recovered an average of 100 to 150 watts on a typical German road, three watts from a fresh piece of pavement, and 613 watts on a rough stretch of tarmac (wattage is calculated as power over time, so this is actually the rate at which the system harvests energy). The dampers channel that energy to a tiny, 0.5-kWh, 48-volt battery. The prototype is claimed to cut CO2 emissions by three grams per kilometer (4.8 grams per mile), while the company believes a future production version could save up to 0.7 liters of fuel per 100 kilometers of driving. Converting the savings to American miles per gallon isn't easy, so we'll use a practical example. In the US, the Q7's supercharged 3.0-liter V6 returns a combined rating of 21 miles per gallon, which works out to 11.2 liters per 100 kilometers. Apply eROT's 0.7L/100km savings, and the Q7's economy would improve to 10.5L/100km, or 22.4 mpg, a 1.4-mpg improvement. That's not huge, but because math, 0.7L/100km is more dramatic on a more fuel efficient vehicle – taking an A3's 27-mpg combined rating and adding eROT would drive efficiency up 2.4 mpg, for example. There are a few other big benefits beyond fuel and emissions savings – Audi claims eROT provides a more comfortable ride than traditional active suspensions, because engineers can tune the compression and rebound strokes independently of each other. Beyond that, the horizontally oriented rear suspension geometry means more cargo space, since the dampers don't poke up into the cabin like they normally do.

Audi diverting a third of R&D budget to electrification

Companies make promises all the time. We'll do X by Y. The new A will be our biggest seller in B. You know the drill. But it's when an automaker puts its money where its mouth is that we really stand up and take notice. That's precisely what Audi is doing as it attempts to convert 25 percent of its sales to electrified vehicles by 2025. Citing two sources with knowledge of Audi's plans, Reuters reports that around a third of the company's research-and-development budget will go to " electric cars, digital services, and autonomous driving." Of course, shifting that much money over to newer technologies means sacrifices elsewhere – Reuters' sources claim Audi will move money away from combustion engines and reduce country-specific powertrain variants, but the sources wouldn't get more specific. According to Reuters, Audi is 22nd in total sales of hybrids and EVs. That's eight spots behind Mercedes and ten spots behind BMW (not to mention hybrid-happy Lexus). Audi's only electric representatives in the US market are the A3 e-Tron and Q5 Hybrid and things aren't much better in Europe – the company needs to dump buckets of money into expanding its meager lineup to bring up the percentage of EVs it sells. Expect greater detail on Audi's electrification plans very soon – CEO Rupert Stadler will discuss the company's path forward on Wednesday at a closed-door meeting in Munich with over 2,000 managers. It's unlikely all those managers will be able to keep quiet. We'll be listening. Related Video: Featured Gallery Audi E-Tron Quattro Concept View 36 Photos News Source: ReutersImage Credit: Audi Green Audi Volkswagen Green Driving Electric Hybrid PHEV e-tron audi e-tron electrification