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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 pins hopes on 2016 R18 Le Mans prototype

Down but not out, Audi is carrying forward its endurance racing program with the new R18 you see here. Unveiled on Saturday at the Audi Sport Finale end-of-season event in Munich, the new LMP1 is billed as the company's its most powerful and efficient race car yet. And it has been thoroughly redesigned to bring the Four Ring brand back to the winner's circle. Though technical details remain a closely guarded secret, Audi says that the latest evolution of the R18 (now apparently labeled sans the E-Tron Quattro) benefits from revised aero, lightweight construction, and "a modified hybrid system with lithium-ion batteries for energy storage, plus an efficiency-optimized TDI engine." That spells the end of the mechanical fly-wheel setup of the previous version, but sticks to the diesel fuel that Audi has championed instead of the gasoline favored by rivals Porsche and Toyota. With all its revisions, Ingolstadt undoubtedly hopes this latest version will perform better than the last. This past season was the worst Audi has endured since 2009. Its sister company Porsche beat it to both the drivers' and manufacturers' titles in the FIA World Endurance Championship and to the winner's circle at the 24 Hours of Le Mans. That marked the second straight year of defeat in the championship, following Toyota's domination last season, and marked only the third time Audi was defeated at Le Mans since 2000, following Bentley's win in '03 and Peugeot's in '09. In order to avoid costly inter-agency arms race, Audi and Porsche have agreed to each field two entries instead of three in both the championship and the headline race in Western France. Audi has yet to confirm its driver lineup, but Porsche has revealed its lineup consisting of defending champions Timo Bernhard, Brendon Hartley, and Mark Webber in one car, and Romain Dumas, Neel Jani, and Marc Lieb in the other. That leaves out the Le Mans-winning trio of Nico Hulkenberg, Nick Tandy, and Earl Bamber, with the former already counted out due to an F1 conflict. More powerful and efficient than ever before: Audi R18 celebrates world premiere in Munich - New hybrid race car for the 2016 Le Mans 24 Hours - Unchanged driver line-up in the DTM - High demand for new Audi R8 LMS GT3 sports car The brand with the four rings will be entering the 2016 motorsport season with the most powerful and efficient race car Audi has ever built.

Audi buys Ballard fuel cell patents for $80 million

While some auto companies (e.g., Toyota and Hyundai) are giving away some hydrogen fuel cell patents, others are paying a pretty penny to gain access to the H2 tech. Audi announced today that it has purchased a suite of fuel-cell patent from Ballard Power Systems. The deal between Volkswagen Group and the Canadian fuel cell pioneer is worth over $80 million US. Unsurprisingly, the value of Ballard's stock shot up about a dollar (to $2.61 as of this writing) on the announcement. VW and Ballard will also extend their development agreement, originally scheduled to end in 2017, to March 2019, and possibly another two years after that. Thus far, the deal – which revolves around the "design and manufacture of next-generation fuel cell stacks" for VW's H2 demonstration program – and Ballard says it is a leader in "critical areas of fuel cell product design – including the membrane electrode assembly (MEA), plate and stack components – along with certain testing and integration work." At the LA Auto Show last fall, VW showed off a Golf SportWagen and a Passat with a hydrogen hybrid HyMotion powertrain as well as a Audi A7 Sportback H-Tron Quattro. Audi buys fuel-cell patents from Ballard Power Systems Development agreement with Ballard extended until 2019 Audi's Head of Development Prof. Hackenberg: "The entire VW Group will use these patents." Ingolstadt/Burnaby, February 11, 2015 – AUDI AG has acquired a package of patents relating to fuel-cell technology from Ballard Power Systems Inc. In addition, the Volkswagen Group has extended its cooperation with the Canadian clean energy company until 2019. The purchase of these patents will provide new impetus for the development of fuel-cell drive systems at Audi, VW and the Volkswagen Group. As explained by Prof. Dr. Ulrich Hackenberg, Member of the Board of Management for Technical Development at AUDI AG and responsible for the steering of the development departments of all brands in the VW Group: "Audi is acquiring these strategically important patents for the entire group and will make them available to all the brands. In this way, we are securing crucial expertise that will provide new impetus for the further development of this technology." Ballard Power Systems Inc. is based in Burnaby, Canada, and is one of the world's leading companies in the technology of proton exchange membrane fuel cells.