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Posted on 08. Jul, 2015 by in Audi Canada

Bodyshell prolongation for a new Audi R8 is a really special low-volume prolongation operation. The trickery during Audi Böllinger Höfe tighten to Neckarsulm, non-stop in tumble 2014, is set adult for tiny prolongation runs and extended farrago – and for high-end imagination in lightweight engineering. The high-performance sports car’s multi-material Audi Space Frame (ASF) weighs only 200 kilograms, nonetheless is intensely unbending and impact safe. It is done 70 percent from aluminum and 13 percent from carbon-fiber reinforced cosmetic (CFRP) – in suitability with a Audi sign “The right element in a right amounts in a right place.”

“At full capacity, we will furnish 40 bodyshells per day in two-shift operation,” explains Jochen Wagner, Head of Production Quattro GmbH. “We have divided bodyshell prolongation into dual categorical areas – Bodyshell Production 1 is for a aluminum elements, and Bodyshell Production 2 is for adding a CFRP parts. In Bodyshell Production 1, we also compute between a section for welding work and a area for bolt-on tools and finish. The coherence we benefit by this helps us when it comes to building derivatives such as a R8 LMS GT3 competition car.

The bodyshell of a new Audi R8 is combined in a prolongation stroke of about 30 minutes, with people and robots swapping tasks. In a initial step, specialists coupling together a front finish of a car, a executive building and a behind finish from aluminum castings and extruded profile. They afterwards bond a 3 modules to emanate a substructure. Robots hoop a cold jointing processes – a finish ASF consists of 270 semi-hollow punch rivets, 270 blind rivets, 241 metric and 270 self-tapping screws; a welded seams are a good 89 meters long.

The bodyshell grows serve with a hothouse and a roof. In a cell, a five-axis appurtenance pointing cuts a joining points for a CFRP components, a cessation and a steering to within hundredths of a millimeter. Inline laser measuring apparatus checks a dimensional correctness of a ASF. At a geometry station, technicians insert doors, lids, fenders and side tools – done from aluminum – with a assist of precision-guided fixtures.

Once a bodyshell has been by a Finish area – a final hire in Bodyshell Production 1 – it is driven on a lorry to a Paint Shop during a Neckarsulm plant. After cathodic drop coating, it cures in an oven during 200 degrees Celsius, where a aluminum alloys strech their final strength. “The CFRP tools are still blank during this point, because, distinct aluminum, they wouldn’t expand,” explains Jochen Wagner. “We don’t arrange them until a bodyshell is behind here in a workshop. We do that in Bodyshell Production 2.”

The CFRP components form a high-strength spine of a bodyshell. Their structure varies almost depending on where they are used. For a behind bulkhead’s cross beams, for instance, where a primary duty is limit lateral strength, a layers of webbing are laid mostly unidirectionally. Up to 14 of them are organised one on tip of a other in a covering 5 millimeters thick.

People and machines work closely together when it comes to wise a CFRP parts. Robots request finely totalled quantities of constructional glue and lift out accurate jointing procedures. One of them inserts a behind bulkhead into a ASF, for that it is incited around a longitudinal axis; another positions a core hovel on a carrier, onto that a bodyshell is afterwards lowered. The employees of quattro GmbH implement what is famous as a constituent B-pillar and a outdoor shell, afterwards lift out a fixture and riveting processes

At a sealant station, robots request sealing devalue to all those areas where CFRP and aluminum tools accommodate in sequence to forestall hit corrosion. Finally, a bodyshell is put by another oven, this time during 80 degrees Celsius, where a glue and sealant cure. The new R8’s ASF is now finished – 200 kilograms of strong hi-tech. Audi lightweight pattern to a new turn of perfection.

Fuel expenditure of a models named above:

Audi R8 Coupé V10 and 5.2 TFSI quattro (449 kW):
Combined fuel consuption in l/100 km: 12,3** (19.1 US mpg);
Combined CO2-emissions in q/km: 287** (461.9 g/mi)

Audi R8 Coupé V10 5.2 TFSI quattro (397 kW):
Combined fuel consuption in l/100 km: 11,4** (20.6 US mpg);
Combined CO2-emissions in q/km: 272** (437.7 g/mi)

** Fuel expenditure and CO2 emissions information as good as a potency classes are contingent on a choice of wheels and tyres.

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