2017_ECB_AUDI A8

Plant Neckarsulm
Production facility space: 50.000 m² Number of robots: 500 Joining technology:
› 90 tongs for resistance spot welding › 270 tongs for semi-hollow self-piercing riveting › 60 Flow-Drill screwing systems › 90 bonding systems
Paint shop
Press shop Assembly
New body shop
The new Audi A8 EuroCarBody 2017
Joining sequence
Substructure 1
Build-up 1
Substructure 2
Build-up 2+3
Mounting
The new Audi A8 EuroCarBody 2017
The new Audi A8 EuroCarBody 2017
Rear crash concept
Minimal distortion Size and complexity
Virtual engineering Package conform CAD model
Bionic principles Optimization of topology
The new Audi A8 EuroCarBody 2017
Torsion torus – Front structure
The new Audi A8 EuroCarBody 2017
Torsion torus – Front structure
The new Audi A8 EuroCarBody 2017
Finish Hang on parts Upper car Side Platform Provision in standby
Thank you
The new Audi A8 EuroCarBody 2017
MMI Touch Response
The new Audi A8 EuroCarBody 2017
Luxury of Space
The new Audi A8 EuroCarBody 2017
AGENDA
Product Highlights ASF® Evolution Material Toolbox Joining Innovation Production Concept
EuroCarBody 2017
The new Audi A8
Tim Hämmerle Dr. Dominik Hußmann
The new Audi A8 EuroCarBody 2017
AGENDA
Product Highlights ASF® Evolution Material Toolbox Joining Innovation Production Concept
The new Audi A8 EuroCarBody 2017
Comfort requirements Rigid construction
Improved comfort, acoustics and stiffness Additional reinforcement Panoramic sunroof version Force distribution points Local dynamical stiffness
2.0 mm
Ultra-highstrength range
The new Audi A8 EuroCarBody 2017
1.7 mm 1.5 mm
Transfer range
Ductile deformation area
Aluminum alloy cast parts – new strength class
Front car
Build up 1.2 Outer side panel
Build up 1.1
Mounting / Finish UB1
Submission to paint shop
Rear car
Building C11
Building C13 Level 02
The new Audi A8 EuroCarBody 2017
Production flow in body shop
Building C09 Level 01
Building C13 Level 01
Rear doors Front doors
Front lid Rear lid
Build up 3 Inner side Build up 2.1 Build up 2.2
Joining techniques
Semi-hollow self-piercing riveting
Clinching
Friction-element welding
Flow-drill screw driving
Resistance spot welding steel
Resistance spot welding aluminum
Simulation of welding distortion of zero-gap roof joint
Drape simulation of CFRP rear wall
AGENDA
Product Highlights ASF® Evolution Material Toolbox Joining Innovation Production Concept
The new Audi A8 EuroCarBody 2017
ห้องสมุดไป่ตู้
Cross member forefront
t=1.3 mm
t=1.3 mm
t=1.8 mm
The new Audi A8 EuroCarBody 2017
-20%
Weight
B-pillar - Partial tempering and tailor rolled blank 1.7 mm
Multimaterial Audi Space Frame
Aluminum sheet Aluminum extrusion Aluminum casting Steel conventional Steel hot formed
Magnesium casting Carbon fiber
58% Aluminum
Magnesium
Steel
8 Sheet materials
Carbon
3 Extrusion materials
11 Sheet materials
2 Forged materials
1 Cast material
1 Carbon material
3 Cast materials
29 different materials in total
The new Audi A8 EuroCarBody 2017
Current A8
Next A8
Safety standards
The new Audi A8 EuroCarBody 2017
Front crash concept Distribution of crash energy Three load levels
100% Hybrid
The new Audi A8 EuroCarBody 2017
100% Hybrid – 48V Technology
48 Volt mainsystem
48 Volt Belt starter
generator
The new Audi A8 EuroCarBody 2017
DC/DC generator
12 Volt battery
48 Volt Lithium ion battery
100% Hybrid – Plug-in Hybrid
3.0 TFSI engine
8 speed Automatic transmission
Charging point
Fuel tank
Laser beam remote welding
The new Audi A8 EuroCarBody 2017
Door sill flange dimensions
Grip self-piercing riveting
Roller hemming
Piece-locking
The new Audi A8 EuroCarBody 2017
Structure front end Extrusion profiles construction
The new Audi A8 EuroCarBody 2017
Front crash concept
The new Audi A8 EuroCarBody 2017
Side crash concept
Shape – Shift – Sense - Space
The new Audi A8 EuroCarBody 2017
Exterior Styling
The new Audi A8 EuroCarBody 2017
Interior Styling
The new Audi A8 EuroCarBody 2017
Torsion torus – Rear structure
The new Audi A8 EuroCarBody 2017
Stiffness achievements
Torsional stiffness
+ 24 %
Lightweight index
+12 %
Current A8
Next A8
Weight
Carbon Rear Wall
The new Audi A8 EuroCarBody 2017
AGENDA
Product Highlights ASF® Evolution Material Toolbox Joining Innovation Production Concept
Virtual production feasibility
Thermal load and distribution of joining technologies
Development and joining process simulation
The new Audi A8 EuroCarBody 2017
The new Audi A8 EuroCarBody 2017
AGENDA
Product Highlights ASF® Evolution Material Toolbox Joining Innovation Production Concept
Material modules
Aluminum
+50%
-15%
-19%
Strength
Wall thickness
Weight
The new Audi A8 EuroCarBody 2017
Side panel - manufacturability Current A8
Next A8
The new Audi A8 EuroCarBody 2017
High-voltage-battery
Electric motor
Power electronics
The new Audi A8 EuroCarBody 2017
Audi AI
› Audi AI Remote Parkpilots › Audi AI Piloted Driving
AI
The new Audi A8 EuroCarBody 2017
Magnesium strut brace
-33% -28%
The new Audi A8 EuroCarBody 2017
Density
Weight
Carbon Rear Wall Structure
-45%
-50%
The new Audi A8 EuroCarBody 2017
Density
Roller hemming
Grip self-piercing riveting
Laser beam welding Zero-gap roof joint
MAG welding steel
Laser beam welding steel
MIG welding Alu/ Mod. Alu-CMT
Bonding