Porsche is posterior dual categorical goals with a 2025 strategy, with a initial relating to a obliged use of resources, while a second is to invariably enhance imagination in a margin of lightweight construction. Even if this idea were not in focus, shortening weight to a smallest has to be a tip priority in stylish, high-tech sports cars such as a new Porsche 911 Carrera, that is because a physique and framework have been designed wholly regulating innovative aluminium combination panels.
The suit of aluminium amalgamate components used in a 992 bodyshell has been dramatically increasing in comparison to a prototype model, with extruded aluminium profiles used for elements including a front and back categorical framework members, interior and extraneous doorway sills, and building bracing. Cast aluminium tools are used on a front startle mount, a back hovel dungeon and a impact absorber mounts. The outdoor bombard of a new 911 is fabricated totally from aluminium, with a difference of a front and back apron. Only a tools that approximate a newcomer dungeon are done from hot-formed steel, in sequence to yield a limit probable insurance for occupants.
Intelligent component mix
This intelligent component brew means that a bodyshell of a eighth-generation 911 is no heavier than a predecessor, notwithstanding somewhat incomparable measure and aloft reserve requirements. “Depending on a version, we are looking during usually 240 to 280 kg,” explains Steffen Soyez, conduct of a bodywork plant.
Reducing weight to a smallest has to be a tip priority in high-tech sports cars
Though Porsche is of march no foreigner to combination construction, carrying started work on this basement 15 years ago, a combination construction used in a new 911 requires wholly new prolongation technologies. With this in mind, and following conference with internal residents, Porsche stretched a existent bodywork plant during a Zuffenhausen site to embody an additional trickery in May 2015. “Because there is singular earthy space in a city for expansion, we had to build upwards,” explains Steffen Soyez. “Production now runs on 3 floors, that is a genuine plea – generally when it comes to circuit equipment.” The initial 992 bodies were constructed in a 69,000 m² building from Sep 2018.
High turn of automation
The “best-fit” public resolution – involving automated, sensor-based and precisely tranquil public of physique tools – that had already proven a value in prolongation of a prior model, was stretched and optimised for a new 911. “The turn of automation we use has increasing greatly,” Soyez explains, “and a already irregularly used human-robot collaborations (HRC) have been designed with totally new reserve features. The robots’ sensors are automatic so that they stop relocating a second a chairman gets too tighten to a reserve cell.”
The automatic public of physique tools was stretched and optimised
Not usually are a bodywork plant employees lerned on how to hoop a new collaborative robots, though they also have a plain education in innovative combination construction. “We offer modernized courses for specialists who wish to concentration on a specific work area,” says Soyez. Assembly of bonnets and finishing work are areas that need rarely learned and specialised craftsmanship: “Surface finishing is truly an art.”
Step by step
It requires usually 9 public stairs to erect a 911 bodyshell in a new plant. Anyone who fabricated a indication automobile in their childhood understands a simple idea: one finish territory is fabricated from many particular components. In a box of a 911 body, a front end, back finish and centre of a building vessel are initial assimilated to a chassis; to this, robots supplement a front circle arches together with a startle mounts and categorical framework member. Aluminium and steel panels from that a physique is fabricated are delivered by a applicable suppliers on a just-in-time basement to a categorical Zuffenhausen plant, from where a tugger sight complement conveys them to lines in a bodywork plant, as specified by a public cycle.
It requires usually 9 public stairs to erect a 911 bodyshell
Robots lift a framework of a new Porsche 911 onto a skids regulating doing grippers, and these skids lift a prepared framework to a bodywork stations in stages. A probably finish 911 gradually emerges: a modular roof, doors, fenders, foot and carp take their positions behind a side panels. Other new techniques now in use embody attrition component welding, full self-piercing riveting, and drum hemming (for fasten aluminium tools to steel components). Incidentally, a eighth-generation 911 can exaggerate a new record in terms of connected connections, with a sum of 180 metres of connected join used in a final vehicle.
Baptised with a birth certificate
When a bodyshell – now recognizable as a new Porsche 911 – finally creates it to a final station, a car is “baptised” with a arising of a birth certificate. The central duplicate is propitious with a transponder that contains an marker formula specific to a vehicle. Finally, gifted finishers check a aspect finish and all tools for correctness of fit: “The car geometry has to be accurately right to safeguard that all runs ideally in final assembly,” says Soyez, explaining a procedure. The bodyshell afterwards heads to a paint shop.
Author: Egbert Schwartz
Text creatively seemed in “Automobil Produktion” – special 2018 emanate “The new Porsche 911”
Model Range 911 (Typ 992): Fuel expenditure total 9.1 – 8.9 l/100 km; CO2 emissions 208 – 205 g/km