The Audi e-tron GT is the first four rings model for which production was planned entirely without physical prototypes. Multiple technical innovations made this possible, including three-dimensional building scans, machine learning processes and the use of virtual reality. All assembly processes, such as procedures and employee actions were tested and optimized in virtual spaces that model their real-world counterparts down to the finest detail. Virtual planning is now used across site boundaries, enabling digital, connected working without business trips or foreign assignments – and not just during the coronavirus pandemic. 3D scans and the planning in virtual spaces make processes more efficient and sustainable.

Where is virtual planning used and why are 3D scans so important for this?

A variety of prototypes are used in the conventional planning process for the production of a new Audi model. The vehicle prototypes are fabricated during the early planning phase as one-off models with hand-built parts. This is time consuming and cost intensive. Assembly Planning uses these prototypes to define and optimize the later production processes. What are the employee’s tasks? Where does a part have to be located for the employee to have optimal access to it? Can the employee hold and install the part by him- or herself? How does she have to move to do it? Are other parts in the way? What tools does he need? During production planning for the Audi e-tron GT, these questions were derived and answered entirely in the virtual world. Every step and every action was tested in the digital space using virtual reality. The goal of virtual planning is to ensure that during the later production of the vehicle, all processes are perfectly meshed and the cycles along the line are seamlessly coordinated. This requires that every detail of the production hall be modeled precisely and to scale. This is where 3D scans come into play. Using special hardware and software, they create a virtual reproduction of the physical production facility, including all equipment, tools and shelves. 

How do 3D scans work and what role does artificial intelligence play?

A scanner – the hardware – is essential for generating the corresponding data. It is roughly two meters (6.6 ft) tall and is mounted on four wheels so that an employee can move it around the spaces. At the top is a LiDAR (Light Detection and Ranging) unit and three additional laser scanners as well as a camera. Two processes are conducted simultaneously while scanning a space: The wide-angle camera takes a picture of the space while the lasers precisely measure it and generate a three-dimensional point cloud of the surroundings. 250,000 square meters (2,690,977.6 sq ft) of production hall space at the Neckarsulm site alone has already been scanned using this technology. But it is the interaction between the hardware and software that takes the points, images and data sets generated and turns them into a usable overall image that can be used with the existing planning systems. The software used here is an in-house Audi development based on artificial intelligence and machine learning. The point cloud and the photographs are combined to produce a three-dimensional, photo-realistic space similar to what is seen in Google Street View. Proportions and sizes are true to scale and correspond to reality. The software also automatically recognizes all objects, such as machines, shelves and systems in the space.

It also learns automatically with each scan to recognize, distinguish and classify objects even more precisely. For example, the system distinguishes between a shelf and a steel beam. The position of the shelf can be changed in the program later and relocated in the virtual space. That of the steel beam cannot. These data enable a virtual walk-through of the scanned production facility from any starting point and can be used directly in planning processes.

Where is virtual planning with virtual reality already being used and what advantages does it offer?
 

The Audi e-tron GT is the brand’s first vehicle for which the assembly procedures and associated logistics processes were tested exclusively virtually and without any physical prototypes.

To do this, a holistic, virtual model of the planned assembly with vehicle data, material handling, equipment, tools and the planned processes is prepared as a so-called digital model. The 3D scans are one element of this. The digital model is the basis for further innovations, as Andrés Kohler, responsible for virtual assembly planning at Audi, explains. “Thanks to a VR solution developed here at Audi and the digital model, colleagues from all over the world can now meet in virtual spaces and find themselves in the middle of the production facility of tomorrow. They can look over the shoulders of digital workers as they perform the planned procedures. They can also experience and optimize the planned processes for any part variants in our application.” The results can then be used to train employees, also on the basis of the VR application. These new possibilities are now being used in an increasing number of additional projects and at multiple sites. A 3P workshop (3P = Production Preparation Process), for example, was held at the Audi site in San José Chiapa, Mexico, and project team members from Ingolstadt also took part. As digital avatars and thus completely virtually, the experts discussed and planned the production of the Audi Q5 face lift and the new Q5 Sportback in VR. 

All assembly procedures are jointly defined and tested in real time, as are ergonomic aspects or the exact arrangement of machines, shelves and parts along the assembly line. Audi is the Group lead for the development of the comprehensive VR solution including the digital model. The project is being continued across brand lines under the leadership of the four rings as a Group project and rolled out to more and more sites. 

More than buildings and processes: How does virtual container planning work?

Virtual planning is not restricted to just processes and work procedures. Objects such as containers for the transport and storage of sensitive parts, called special load containers, can also be planned using this technology. These containers for individual, particularly sensitive parts of the Audi e-tron GT, such as electric modules or interior parts – were planned using Audi’s cross-site and cross-division virtually reality application rather than using multiple physical prototypes of iron and steel. Virtual container planning works like this: Since there are data sets for all parts, these can be loaded directly and to-scale in the VR application. As in the 3P workshops, multiple employees from different sites meet in a virtual space, where they use the part to check the perfect and tailored load carrier. Employees from Logistics, Assembly Planning, Occupational Safety, Quality Assurance, Material Flow Planning and also suppliers are involved in this process. They use digital pens to mark their changes on the virtual containers. The containers are loaded and unloaded, moved and measured during this process. 

Optimal safety of the part during transport is one objective of this planning. But employees or a robot must also be able to easily grab the part and remove it from the load carrier. Once the virtual design is complete, the data are simply exported and the special load carrier manufactured. 

What makes virtual planning so sustainable and ecological?

Sometimes less is more. There are thus three points that make virtual planning so sustainable: 

 
  • Fewer resources: The virtual planning of the Audi e-tron GT without physical prototypes saved not just time, but also materials and thus resources. It’s the same thing with the special load carriers and virtual container planning: Making prototypes of iron and steel requires resources and energy. Virtual planning makes this step superfluous in many cases.
  • Less waste: Rather than in special load carriers, sensitive parts were often transported in universal load carriers with a custom protective lining. This protective lining is always purely disposable, however, and the use of custom containers makes it superfluous. Virtual planning thus directly reduces waste.
  • Fewer business trips: Sustainability and environmental protection are the primary goal. But in times of the coronavirus pandemic, there are also health reasons for reducing the number of business trips as much as possible. Virtual planning is a major contributor here. Processes that once required a physical meeting are now possible in a virtual space.

What future perspectives does virtual planning open up?

The digital model is the basis for further possibilities in the virtual space. If you combine the possibilities of virtual planning including the digital model, 3D scans and the virtual reality application with those of 3D printing, 3P workshops could also be conducted in mixed reality in the future. Individual parts would then be produced immediately via a 3D printer and only slight amounts of resources. This enables the physical testing of individual elements in the virtual space, such as assessing the haptics and weight of the parts. A key step combining the advantages of both worlds. Virtual meetings and collaboration via avatars in the virtual world could increasingly replace foreign assignments and longer business trips. It is already possible today to use the spaces created by the 3D scanner for digital indoor navigation. And the positioning of machines and equipment in the space can be planned down to the centimeter using augmented reality.

Article source: www.audi-mediacenter.com

 
 

Audi is advancing into new dimensions in automotive lighting technology. Originally, vehicle lighting mainly served the purpose of ensuring traffic safety for all road users. Previously unknown prospects are now opening up in the wake of digitizing headlights and rear lights: light becomes a medium of external communication and interaction, personalizes design, and provides customers with new styling and customization options.

 

Lighting has made a veritable technology leap: The evolution from halogen light to xenon headlights to LED technology in automobiles took less than two decades. These milestones of new technologies provided customers with noticeably added value. As well as continually enhancing visibility, Audi lighting has been defining the face of the brand’s models in every era while extending everyday usability by an equally communicative and aesthetic dimension.

In the wake of the transformation of lamps, both illumination and energy efficiency improved. Now, digitization provides another innovation boost with all-new design potential: Light is becoming smart. By means of light signals, the car interacts with its surroundings. As far back as in 2003, the then A8 offered adaptive light with automatic-dynamic headlight range control before a camera on the windshield began detecting other road users in 2010. Two years later, the brand underpinned its innovative prowess and pioneering role in the R8: The introduction of the dynamic turn signal that allows indicated directional changes to be perceived out of the corner of one’s eye marked a significant gain in safety – and still does. In 2017, following their debut in the R8 LMX, Audi presented LED headlights featuring HD Matrix technology with the laser as an additional high-beam light in the A8 luxury sedan – a world innovation in large-scale production. Now, the premium manufacturer is digitizing the Matrix LED headlight while adding even greater variety. The digital OLED rear lamps in the new Q5 have been opening the door to car-to-x communication since this year and, for the first time, make choices of new taillight designs possible at the time of configuring the vehicle.

As well as intelligently illuminating the road, Audi provides its models with an unmistakable personality using distinctive signatures and dynamic lighting scenarios. Even at this juncture, customers are offered various model-dependent lighting signature options, to be followed by further differentiations. The dynamic turn signal or the impressive scenarios of the leaving and coming home functions cause the light to strike an emotional chord. Going forward, lighting technologies will make driving even safer, the individuality of each model even more visible, and external communication even more effective.

Article source: www.audi-mediacenter.com

Victories in five categories: Audi achieved a major success in the Auto Trophy 2020 voting by readers of the specialist magazine Auto Zeitung. The A1 Sportback, A3 Sportback, Q2, Q8, and e-tron Sportback models each won in their categories. For the A3, it was already the third important award within the space of a few weeks. It previously claimed victory in its category in the “autonis” design competition by auto, motor und sport and the “Golden Steering Wheel” from Auto Bild.

“The success with the Auto Trophy confirms that we are on the right track with our model policy,” said Oliver Hoffmann, Chief Operating Officer (COO) of Technical Development. “I am particularly happy that our successful A3 Sportback keeps on winning in comparative tests and competitions. It presents our technological expertise in the compact segment – from digital daytime running lights and the modern operating concept to all-round connectivity. It is a perfect all-around vehicle, sporty and balanced, and a real eye-catcher.”

The Auto Trophy took place for the 33rd time this year. 18,811 readers of Auto Zeitung voted on the best brands and models from a total of 442 cars in 21 categories. The participants each had two votes: one for the overall winner of the category and one for the best imported model. The A3 Sportback won its category with 15.0 percent of the vote.

The A1 Sportback won in the “City Cars” category with 21.7 percent of the votes cast. The most compact Audi model is an ideal companion not only in urban environments but also on longer journeys. Its infotainment and driver assist systems are on par with the full-size class. 

The Q2, which emerged victorious among the SUVs under EUR 25,000 with 17.4 percent of the votes, is a versatile compact SUV with good all-around qualities. The Q8, which dominated in the “Luxury SUV” category with 13.9 percent of the votes, combines great practical talent with the elegance of a four-door luxury coupé and confident driving characteristics. The same can be said of the fully electric Audi e-tron Sportback (winner of the “Electric SUV” category with 19.0 percent): The dynamic SUV coupé combines elegance with powerful performance and high-tech features with great everyday usability.

 
Article source: www.audi-mediacenter.com

Audi is facing one of the greatest challenges in motorsport: The brand with the four rings will be competing in the famous Dakar Rally for the first time in 2022 with an innovative prototype. The alternative drive concept combines an electric drivetrain with a high-voltage battery and a highly efficient energy converter for the first time. Cross-country rallying will be the spearhead of the factory motorsport commitment in the future.

 

“A multifaceted commitment to motorsport is and will remain an integral part of Audi’s strategy,” says Markus Duesmann, Chairman of the Board of Management and Board of Management Member for Technical Development and Product Lines at AUDI AG. “We want to continue demonstrating the brand’s slogan ‘Vorsprung durch Technik’ in international top-level motorsport in the future and develop innovative technologies for our road cars. The toughest rally in the world is the perfect stage for this.”

After many international successes in a wide range of categories, Audi is thus returning to rallying, which marked the beginning of the brand’s successful history in motorsport. From 1981, the Audi quattro revolutionized rallying. Today, permanent four-wheel drive is a standard, not only for rally cars. It also guarantees maximum safety in the sportiest Audi production models, and now also electrically in the e-tron models.

With the use of an alternative drive concept in the Dakar Rally, Audi is now facing up to the most extreme conditions. The vehicle will be driven by a powerful electric drivetrain. The energy required for this comes from a high-voltage battery, which can be charged as required while driving via an energy converter in the form of a highly efficient TFSI engine. The aim is to permanently improve the performance of the electric drivetrain and the battery in the years to come. The experience gained in this process should then be incorporated into the further development of future electrified production models. 

Audi is the first car manufacturer that has committed to develop a viable alternative drive concept for the Dakar Rally, making it a pioneer in motorsport once again. In 2012, Audi achieved the first victory of a hybrid racing car in the Le Mans 24 Hours. The Audi R18 e-tron quattro remained unbeaten in the world’s most important endurance race three times in a row.

Since 2014, Audi has also been successful in fully-electric racing with Formula E. First in a supporting role for the team of its longstanding partner ABT Sportsline, and from 2017 with full factory involvement. After six years, the Audi Sport ABT Schaeffler team is the most successful entry in the history of Formula E with a total of 43 podium finishes, including twelve victories. Special highlights include winning the drivers’ title in 2017 and the teams’ title in the first season on a factory level in 2018.

“Formula E has accompanied the transformation phase at Audi,” says Markus Duesmann. “Today, electromobility at the four rings is no longer a dream of the future, but the present.” The Audi e-tron is a bestseller in many markets. With the RS e-tron GT, Audi will soon bring its sporty spearhead onto the road. And as early as 2025, around 40 percent of sales are expected to be achieved with purely-electric vehicles and plug-in hybrids. “This is why we are taking the next step in electrified motorsport by facing the most extreme conditions. The many technical freedoms offered by the Dakar Rally provide a perfect test laboratory for us in this respect.”

The Dakar Rally will replace Audi’s factory involvement in Formula E, which will no longer be continued in the form of an Audi factory team after the 2021 season. The use of the newly developed Audi powertrain by customer teams will remain possible beyond next year. 

 

Customer racing remains the second major pillar in AUDI AG’s future motorsport program. Audi Sport customer racing will continue to offer its customers a comprehensive model portfolio, as well as intensive service for worldwide racing. In addition, the program includes competing with the Audi R8 LMS in major endurance races like the Nürburgring 24 Hours and in international racing series such as the Intercontinental GT Challenge.

“In addition, we are evaluating other possible fields of activity for us in international motorsport,” says Julius Seebach, Managing Director of Audi Sport GmbH. “In doing so, we have our customers’ wishes in mind as much as the company’s future strategy, which is clearly focused on electrification and carbon-neutral mobility. This is why we are intensively preparing to enter the new sports prototype category LMDh with its highlight races, the Daytona 24 Hours and Le Mans 24 Hours. The most important message for our fans is that motorsport will continue to play an important role at Audi.”

From December 1, 2020, Julius Seebach will assume responsibility for the company’s international motorsport activities in addition to his function as Managing Director of Audi Sport GmbH. Dieter Gass, who has held management positions at Audi Sport for almost ten years and was jointly responsible for the sporting success as Head of Audi Motorsport from 2017 to 2020, will devote himself to new tasks in the future, following the successful conclusion of the factory involvement in the DTM.

Article source: www.audi-mediacenter.com

The sporty SUV in the compact segment now has an even fresher look: Audi has revised the SQ2. Thanks in part to the new headlights and bumpers, its appearance is even sportier and more striking, and new Audi connect services and assist systems make driving the car even more effortless. It also offers a strong performance: The 2.0 TFSI with 221 kW (300 PS) accelerates the SQ2 from 0 to 100 km/h (62.1 mph) in 4.9 seconds. Thanks to quattro all-wheel drive and the S sport suspension, the power is applied smoothly to the road.

 

Since its debut two years ago, the SQ2 has made a name for itself as a car full of character. It is a dynamic compact SUV for individualists who value standalone design, a high utility value, and dynamic handling. The key figures speak for themselves: 0 to 100 km/h (62.1 mph) in 4.9 seconds, top speed of 250 km/h (155.3 mph), and an average fuel consumption of just 7.7 liters per 100 km (30.5 US mpg). 

Sporty all-around engine in peak form: the 2.0 TFSI

The 2.0 TFSI draws its power from 1,984 cm3 of displacement and is a sporty all-around engine. It is installed in many Audi models – in the SQ2, it delivers 221 kW (300 PS) and a constant 400 Nm (295.0 lb-ft) of torque across a broad range of between 2,000 and 5,200 rpm. The turbocharged four-cylinder has an excellent throttle response, and its sound becomes fuller as the speed increases. This is due in part to the flaps in the exhaust system.

The 2.0 TFSI has some progressive technologies for power and efficiency on board. The Audi valvelift system (AVS) switches the stroke of the outlet valves between two levels as needed, thereby optimizing the charge cycle in the lower engine speed range in particular: The improved flow of exhaust gas to the turbocharger results in an agile response and powerful torque build-up. Sophisticated thermal management controls the coolant flow, and the exhaust manifold integrated in the cylinder head helps the engine to warm up quickly, which allows exhaust gas aftertreatment to be activated early on. Needless to say, the Audi SQ2 complies with the limits of the new Euro 6 AP emission standard.

Driving pleasure and driving safety: the seven-speed S tronic and quattro drive

The seven-speed S tronic is standard in the Q2 top model. Its lower gears feature short, sporty ratios while the seventh gear is long to reduce fuel consumption. Drivers can operate the lightning-fast dual-clutch transmission in modes D or S, or shift themselves. If the Audi drive select system is in “efficiency” mode, the clutch disengages when coasting, allowing the compact sport SUV to freewheel.

The quattro all-wheel drive provides the updated Audi SQ2 with the crucial amount of additional dynamism and stability. Its electro-hydraulic multi-plate clutch distributes the torque smoothly between the axles. Should the front wheels lose traction, the clutch redirects it completely to the rear within a few milliseconds. The SQ2 is fitted with the latest generation of the multi-place clutch, which features many improvements, for example to the bearings and oil supply, that increase its efficiency. The pump is powered by a low-wear, brushless electric motor. The entire clutch is just under one kilogram (2.2 lb) lighter than the part in the predecessor model. This is due in part to the fact that the control unit is integrated in the clutch housing. 

The driving pleasure provided by the electronically controlled quattro drive has remained at the same high level. During sporty driving, the clutch can direct some of the torque to the rear axle and thereby increase dynamism as soon as the driver turns the wheel. The quattro management system enables precise turn-in during load reversal, and provides maximum control and reliability when drifting on a low-friction surface. The wheel-selective torque control rounds off the handling with minor brake interventions at the relieved wheels on the inside of the curve.

Dynamic character: suspension and steering in the Audi Q2

The S sport suspension of the Audi SQ2 lowers the body by 20 millimeters (0.8 in). The standard progressive steering is geared in such a way that its steering ratio becomes more direct as the angle increases. This makes the SQ2** even more agile – when maneuvering, in urban traffic, and in tight curves.

The standard equipment of the sporty compact SUV also includes the Audi drive select dynamic handling system that offers the profiles “auto,” comfort,” “dynamic,” “efficiency,” and “individual.” It changes the character of the steering, the seven-speed S tronic, the engine, and other systems. The driver can press a button to set the Electronic Stabilization Control (ESC) to off-road mode. 

The Audi SQ2 rolls off the line with 18-inch alloy wheels and size 235/45 tires at the main Audi plant in Ingolstadt. The range offered by Audi and Audi Sport GmbH also includes 19-inch wheels with size 235/40 tires (standard with the SQ2 exterior package). The large brakes have a diameter of 340 millimeters (13.4 in) at the front axle and 310 millimeters (12.2 in) at the rear axle. Their brake calipers feature S badges and are painted red as an option.

Strong character with angles and edges: the exterior design

With its angles and edges, the Audi SQ2, which measures 4.21 meters (13.8 ft) in length, is a car full of character. Its design has become even more expressive with the update. The octagonal Singleframe is now slightly lower, and the slats in its insert also interpret the polygon motif that characterizes the entire car. There are narrow slits between the grille and the hood. Wide frames painted in selenite silver surround the large implied air inlets.

LED headlights are standard, and Audi installs the new Matrix LED headlights as an alternative. One shared module houses seven individual LEDs. The intelligently controlled high beam light always illuminates the road as brightly as possible without blinding other road users. Ten further light-emitting diodes installed behind rhomboid optical components generate the daytime running light. Seven LEDs generate the dynamic turn signals independently. LED lights are installed at the rear as standard. When installed with the Matrix LED headlights, they also feature dynamic turn signals. In this case, the headlights and rear lights present dynamic light sequencing when the car is locked and unlocked.

In the side view of the revised Audi SQ2, the aluminum-look mirror housings, the strips along the sills, the roof edge spoiler, and the silver blades on the C-pillar add accents. The rear bumper with its pentagonal polygons varies the design motif of the front apron and two exhaust tailpipes are each framed by the diffuser insert. The luggage compartment is located behind the tailgate and has a volume of 355 to 1,000 liters (12.5 to 35.3 cu ft) depending on the position of the rear backrests. 

The color palette of the Q2 top model includes ten colors and the attachments are painted in contrasting Manhattan gray as an option. The blades on the C-pillars are available in selenite silver (standard), vehicle color, Manhattan gray, platinum gray, and brilliant black. With the black styling package, the Singleframe, the air inlet grilles, and the diffuser are finished in gloss black, and the bumpers feature a contrasting paint finish. The SQ2 exterior package also applies black styling to the mirror housings, the blade on the C-pillar, and the tailpipe trims. The roof edge spoiler features a special contour here, and quattro logos on film adorn the doors.

Dark tones, specific and upscale materials: the interior

As is the case with all Audi S models, the interior of the SQ2 is dominated by dark tones and particularly high-quality surfaces. The headlining is designed in black and the door panels feature a new material that is pleasant to touch. The pedal caps and the footrest are made of stainless steel and the illuminated door sill trims sport S logos. The display shows S-specific start screens when the ignition is switched on.

All equipment in the sportiest Q2 model is bundled in packages; there are four packages for the upholstery and colors. Customers can choose from a combination of fabric and leather (standard), pure fine Nappa leather – with a rhombus pattern as an option – and a mixture of leather and the microfiber material Dinamica, which is replacing Alcantara. It looks and feels like suede but consists mainly of recycled polyester, which is sourced from textiles and PET bottles, for example. Accent stripes and contrasting stitching adorn the seats. They are available in rock gray, black, and magma red. The optional backlit trim strip constitutes a major exception in the segment.

New structure: operation and display, packages and equipment

The Audi SQ2 comes as standard with automatic air conditioning, a sport multifunction steering wheel, and the sport seats. The optional convenience features are bundled in the climate control, comfort, function, interior, infotainment, dynamism, and assist systems packages. In terms of operation and infotainment, the range extends to the Audi virtual cockpit, which can be switched over to a sports view, and the MMI navigation plus (available with the navigation package). It is operated via a rotary pushbutton on the center console.

The top-of-the-line infotainment system brings the Audi connect services with LTE plus speed on board, and a Wi-Fi hotspot integrates the passengers’ mobile devices. The services of Audi connect emergency call & service and Audi connect remote & control are new additions and are both part of the standard equipment. They allow the owner to lock the vehicle remotely or check the fuel level, for example. To do this, owners can use the myAudi app on their smartphones, which is also free. The Audi smartphone interface, the Audi phone box, and the Bang & Olufsen Premium Sound System complete the infotainment program. 

Even greater confidence on the road: the driver assist systems

The compact Audi SQ2 is also at the cutting edge in its segment in terms of driver assist systems. It comes with the Audi pre sense front safety system as standard. This system can contribute to preventing potential accidents involving pedestrians, cyclists, or other vehicles in front of the car or reducing their severity.

The adaptive cruise assist, which can help the driver in many situations with accelerating, decelerating, and steering within the lane, is a new addition to the optional systems. In order to maintain lateral guidance, the driver only needs to touch the capacitive steering wheel gently, which is part of the system, to prove that they are paying attention. In combination with the camera-based traffic sign recognition, the adaptive cruise assist ensures that the car decelerates in certain situations, for example when approaching speed limits and town signs. As soon as the restricted area ends, it accelerates the SQ2 again. The park assist is another optional system. It steers the sports SUV into and out of parking spaces automatically.

Article source: www.audi-mediacenter.com

More Articles...

  1. Sporty, powerful, and efficient: Audi presents the new generation of the SQ5 TDI
  2. Intelligent assistant for electric driving: the Audi e-tron route planner
  3. Limited-edition special model marks anniversary: the new Audi TT RS 40 years of quattro
  4. Small Q, big coup: The Audi Q2 in new top form

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