Five sites on two continentscontinents
Neckarsulm plant –
Neckarsulm plant –
Assembly of a fixture for
Assembly of a fixture for
bodyshell production.
bodyshell production.
Audi Toolmaking is networked in many directions within
Audi Toolmaking is networked in many directions within the Volks-the Volks-
wagen Group. It is represented at five plants on two continents
wagen Group. It is represented at five plants on two continents
– in Ingolstadt, Neckarsulm, Barcelona, Győr and Beijing. With
– in Ingolstadt, Neckarsulm, Barcelona, Győr and Beijing. With
the ex
the exception of Beijing, each location produces its own tools,ception of Beijing, each location produces its own tools,
body
bodyshell production plant and fixtures.shell production plant and fixtures.
Audi’s press tools are used by almost all of the
Audi’s press tools are used by almost all of the
Group’s brands. Besides Audi itself, this currently extends to the
Group’s brands. Besides Audi itself, this currently extends to the
Bentley, Lamborghini, Seat, Škoda, Porsche, Volkswagen and Volks-
Bentley, Lamborghini, Seat, Škoda, Porsche, Volkswagen and Volks-
wagen Nutzfahrzeuge brands, as well as joint-venture company
wagen Nutzfahrzeuge brands, as well as joint-venture company
3
3
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Intelligent Tools
Intelligent Tools
The intelligent tools from Audi Toolmaking are able to distribute the high
The intelligent tools from Audi Toolmaking are able to distribute the high
press forces extremely precisely, thus ensuring the finish of the sheet-metal part –
press forces extremely precisely, thus ensuring the finish of the sheet-metal part –
to within hundredths of a
to within hundredths of a millimeter.millimeter.
TOOL
TOOLIINNGG
U
UPP
11 2 2 3 3 4 4 5 5 6 6 7 7 Laser sensor Laser sensorActive drawing aid
Active drawing aid
Stamp
Stamp
Bottom part of the tool
Bottom part of the tool
Blank holder
Blank holder
Die
Die
Top part of the tool
Top part of the tool
1 1 2 2 1 1 2 2 1 1 2 2 1 1 4 4 2 2 1 1 2 2 1 1 5 5 3 3 6 6 7 7 9
922 EEnnccoouunntteerr Smart Factory Smart Factory 9393 EncounterEncounter Smart Factory Smart Factory
Audi means precision – above Audi means precision – above all, it is on the exterior skin of all, it is on the exterior skin of the cars with the four rings
the cars with the four rings where the enormous pas-where the enormous pas- sion for the tiniest details is most
sion for the tiniest details is most evident. The obser-evident. The obser- ver can see and feel this in
ver can see and feel this in the sharpness of the tornadothe sharpness of the tornado line, with its evenly
line, with its evenly tight radius, and in the consistent-tight radius, and in the consistent- ly taut surfaces. On the Audi A3 and TT models, the ly taut surfaces. On the Audi A3 and TT models, the outer shell of the aluminum hood has two sharp con- outer shell of the aluminum hood has two sharp con- tours. The so-called “Zischers” (sizzlers), as they are tours. The so-called “Zischers” (sizzlers), as they are known internally, are created using new, intelligent known internally, are created using new, intelligent tools (IWZ).
tools (IWZ).
Like every mechanical process, the forming Like every mechanical process, the forming of the sheet steel
of the sheet steel and aluminum panels in the pressesand aluminum panels in the presses is subject to certain parameters. In some cases, the is subject to certain parameters. In some cases, the material composition of the blanks or their lubrication material composition of the blanks or their lubrication is not completely homogeneous. This influences the is not completely homogeneous. This influences the feed of the blank – the so-called flange feed – as it is feed of the blank – the so-called flange feed – as it is pulled over the shaping tool. If the flange pulled over the shaping tool. If the flange feed is toofeed is too low relative to the specification, the tension is low relative to the specification, the tension is tootoo high, which could lead to tea
high, which could lead to tea rs in the component. If,rs in the component. If, on the other hand, too much
on the other hand, too much material follows through,material follows through, i.e. the flange feed is too
i.e. the flange feed is too high, the component stabil-high, the component stabil- ity could suffer.
ity could suffer.
New intelligent tools solve this problem – New intelligent tools solve this problem – they enable stable processes in consistent first-class they enable stable processes in consistent first-class quality. Project Leader Hannes Mautz explains the prin- quality. Project Leader Hannes Mautz explains the prin- ciple that Audi has developed
ciple that Audi has developed to production maturity.to production maturity. “We use sensors that make the process inside the tool “We use sensors that make the process inside the tool visible – to identify how the material is flowing and visible – to identify how the material is flowing and what forces are being exerted on the blank. This data what forces are being exerted on the blank. This data shows us whether the processes are
shows us whether the processes are remaining withinremaining within the narrow window we have defined for them. If not, an the narrow window we have defined for them. If not, an actuator in the tool autonomously adjusts the distribu- actuator in the tool autonomously adjusts the distribu- tion of forces within the tool. This enables us to tion of forces within the tool. This enables us to ensureensure precision to within hundredths of
precision to within hundredths of a millimeter.”a millimeter.”
The fascination of the new technology lies The fascination of the new technology lies in the interaction between brute force and high-reso- in the interaction between brute force and high-reso- lution electronics. A computer manages the work done lution electronics. A computer manages the work done by the intelligent tool, receiving its information from by the intelligent tool, receiving its information from up to 24 sensors, such as laser sensors that measure up to 24 sensors, such as laser sensors that measure flange feed extremely
flange feed extremely precisely using triangulation.precisely using triangulation. The steel forming tools weigh up to 40 met- The steel forming tools weigh up to 40 met- ric tons and the presses shape the components by ap- ric tons and the presses shape the components by ap- plying up to 2,000 metric tons. During the drawing plying up to 2,000 metric tons. During the drawing process, the blank’s flanges are clamped in place by process, the blank’s flanges are clamped in place by eight cylinders applying forces of 20 to 60 metric tons eight cylinders applying forces of 20 to 60 metric tons each. Pressure distribution is finely metered through each. Pressure distribution is finely metered through each of the active
each of the active drawing aids, which contribute up todrawing aids, which contribute up to 50 metric tons. They use wedge drives with electric 50 metric tons. They use wedge drives with electric stepper motors that permit very
stepper motors that permit very high-precision adjust-high-precision adjust- ment. Should the clamping force in their area get too ment. Should the clamping force in their area get too high, the drawing aids can push the
high, the drawing aids can push the stamping die – thestamping die – the top half of the tool –
top half of the tool – upward by a few hundredths of aupward by a few hundredths of a millimeter to allow the blank to flow a little more freely. millimeter to allow the blank to flow a little more freely. Photos Photos Manfred Jarisch Manfred Jarisch Matt Stark Matt Stark Text Text Johannes Köbler Johannes Köbler 1 1 2 2 3 3 Preparation –
Preparation –geometric calibrationgeometric calibration of a laser sensor for
of a laser sensor for exact orientationexact orientation of the beam.
of the beam.
Technology model – Technology model –the screenthe screen shows an image of the technology shows an image of the technology components in the intelligent tool. components in the intelligent tool.
Fine adjustment – Fine adjustment –Project LeaderProject Leader Hannes Mautz with the intelligent Hannes Mautz with the intelligent tool for the TT hood. tool for the TT hood.
Internationalization:
Internationalization:
Five sites on two
Five sites on two continentscontinents
Neckarsulm plant –
Neckarsulm plant –
Assembly of a fixture for
Assembly of a fixture for
bodyshell production.
bodyshell production.
Audi Toolmaking is networked in many directions within
Audi Toolmaking is networked in many directions within the Volks-the Volks-
wagen Group. It is represented at five plants on two continents
wagen Group. It is represented at five plants on two continents
– in Ingolstadt, Neckarsulm, Barcelona, Győr and Beijing. With
– in Ingolstadt, Neckarsulm, Barcelona, Győr and Beijing. With
the ex
the exception of Beijing, each location produces its own tools,ception of Beijing, each location produces its own tools,
body
bodyshell production plant and fixtures.shell production plant and fixtures.
Audi’s press tools are used by almost all of the
Audi’s press tools are used by almost all of the
Group’s brands. Besides Audi itself, this currently extends to the
Group’s brands. Besides Audi itself, this currently extends to the
Bentley, Lamborghini, Seat, Škoda, Porsche, Volkswagen and Volks-
Bentley, Lamborghini, Seat, Škoda, Porsche, Volkswagen and Volks-
wagen Nutzfahrzeuge brands, as well as joint-venture company
wagen Nutzfahrzeuge brands, as well as joint-venture company
FAW-V
FAW-Volkswagen. Toolmaking in Győr fulfills olkswagen. Toolmaking in Győr fulfills another special taskanother special task
above and beyond this – it supplies Audi and Lamborghini with
above and beyond this – it supplies Audi and Lamborghini with
finished bodyshell components for their high-performance sports
finished bodyshell components for their high-performance sports
cars and RS models.
cars and RS models.
Audi Toolmaking also incorporates plant and fixture
Audi Toolmaking also incorporates plant and fixture
manufacturing. Among the products made, it is the framers
manufacturing. Among the products made, it is the framers thatthat
stand out in particular. The so-called group framer is
stand out in particular. The so-called group framer is a core func-a core func-
tion in bodyshell manufacturing – positioning the side walls on the
tion in bodyshell manufacturing – positioning the side walls on the
substructure. As it currently stands, the installation is set
substructure. As it currently stands, the installation is set up forup for
up to four different vehicle types; the next expansion stage will
up to four different vehicle types; the next expansion stage will
bring that to six models, with shorter cycle times
bring that to six models, with shorter cycle times and lower costs.and lower costs.
The roof framers are large, bridge-shaped clamping
The roof framers are large, bridge-shaped clamping
and positioning stations. The so-called bell, which carries the ve-
and positioning stations. The so-called bell, which carries the ve-
hicle’s roof, is made from carbon-fiber reinforced plastic (CFRP),
hicle’s roof, is made from carbon-fiber reinforced plastic (CFRP),
so that it can be
so that it can be moved by two robots. This solution, which comesmoved by two robots. This solution, which comes
from Audi’s extensive expertise in
from Audi’s extensive expertise in lightweight design, saves enor-lightweight design, saves enor-
mous amounts of energy compared with the heavy technology
mous amounts of energy compared with the heavy technology
used previously. Audi Toolmaking’s latest framer is at the Brati-
used previously. Audi Toolmaking’s latest framer is at the Brati-
s
slava plant, where it positions the new Q7’s outer lava plant, where it positions the new Q7’s outer side walls withside walls with
a whole new level of
a whole new level of precision. The ongoing progrprecision. The ongoing progress being madeess being made
in framer technology is just one example of the exceptional, in-
in framer technology is just one example of the exceptional, in-
novative power of
novative power of Audi Toolmaking.Audi Toolmaking.
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3
Scan the QR code to see the video on Scan the QR code to see the video on intelligenttooling. intelligenttooling. 1 1 2 2 94
Audi means precision – above Audi means precision – above all, it is on the exterior skin of all, it is on the exterior skin of the cars with the four rings
the cars with the four rings where the enormous pas-where the enormous pas- sion for the tiniest details is most
sion for the tiniest details is most evident. The obser-evident. The obser- ver can see and feel this in
ver can see and feel this in the sharpness of the tornadothe sharpness of the tornado line, with its evenly
line, with its evenly tight radius, and in the consistent-tight radius, and in the consistent- ly taut surfaces. On the Audi A3 and TT models, the ly taut surfaces. On the Audi A3 and TT models, the outer shell of the aluminum hood has two sharp con- outer shell of the aluminum hood has two sharp con- tours. The so-called “Zischers” (sizzlers), as they are tours. The so-called “Zischers” (sizzlers), as they are known internally, are created using new, intelligent known internally, are created using new, intelligent tools (IWZ).
tools (IWZ).
Like every mechanical process, the forming Like every mechanical process, the forming of the sheet steel
of the sheet steel and aluminum panels in the pressesand aluminum panels in the presses is subject to certain parameters. In some cases, the is subject to certain parameters. In some cases, the material composition of the blanks or their lubrication material composition of the blanks or their lubrication is not completely homogeneous. This influences the is not completely homogeneous. This influences the feed of the blank – the so-called flange feed – as it is feed of the blank – the so-called flange feed – as it is pulled over the shaping tool. If the flange pulled over the shaping tool. If the flange feed is toofeed is too low relative to the specification, the tension is low relative to the specification, the tension is tootoo high, which could lead to tea
high, which could lead to tea rs in the component. If,rs in the component. If, on the other hand, too much
on the other hand, too much material follows through,material follows through, i.e. the flange feed is too
i.e. the flange feed is too high, the component stabil-high, the component stabil- ity could suffer.
ity could suffer.
New intelligent tools solve this problem – New intelligent tools solve this problem – they enable stable processes in consistent first-class they enable stable processes in consistent first-class quality. Project Leader Hannes Mautz explains the prin- quality. Project Leader Hannes Mautz explains the prin- ciple that Audi has developed
ciple that Audi has developed to production maturity.to production maturity. “We use sensors that make the process inside the tool “We use sensors that make the process inside the tool visible – to identify how the material is flowing and visible – to identify how the material is flowing and what forces are being exerted on the blank. This data what forces are being exerted on the blank. This data shows us whether the processes are
shows us whether the processes are remaining withinremaining within the narrow window we have defined for them. If not, an the narrow window we have defined for them. If not, an actuator in the tool autonomously adjusts the distribu- actuator in the tool autonomously adjusts the distribu- tion of forces within the tool. This enables us to tion of forces within the tool. This enables us to ensureensure precision to within hundredths of
precision to within hundredths of a millimeter.”a millimeter.”
The fascination of the new technology lies The fascination of the new technology lies in the interaction between brute force and high-reso- in the interaction between brute force and high-reso- lution electronics. A computer manages the work done lution electronics. A computer manages the work done by the intelligent tool, receiving its information from by the intelligent tool, receiving its information from up to 24 sensors, such as laser sensors that measure up to 24 sensors, such as laser sensors that measure flange feed extremely
flange feed extremely precisely using triangulation.precisely using triangulation. The steel forming tools weigh up to 40 met- The steel forming tools weigh up to 40 met- ric tons and the presses shape the components by ap- ric tons and the presses shape the components by ap- plying up to 2,000 metric tons. During the drawing plying up to 2,000 metric tons. During the drawing process, the blank’s flanges are clamped in place by process, the blank’s flanges are clamped in place by eight cylinders applying forces of 20 to 60 metric tons eight cylinders applying forces of 20 to 60 metric tons each. Pressure distribution is finely metered through each. Pressure distribution is finely metered through each of the active
each of the active drawing aids, which contribute up todrawing aids, which contribute up to 50 metric tons. They use wedge drives with electric 50 metric tons. They use wedge drives with electric stepper motors that permit very
stepper motors that permit very high-precision adjust-high-precision adjust- ment. Should the clamping force in their area get too ment. Should the clamping force in their area get too high, the drawing aids can push the
high, the drawing aids can push the stamping die – thestamping die – the top half of the tool –
top half of the tool – upward by a few hundredths of aupward by a few hundredths of a millimeter to allow the blank to flow a little more freely. millimeter to allow the blank to flow a little more freely. Photos Photos Manfred Jarisch Manfred Jarisch Matt Stark Matt Stark Text Text Johannes Köbler Johannes Köbler 1 1 2 2 3 3 Preparation –
Preparation –geometric calibrationgeometric calibration of a laser sensor for
of a laser sensor for exact orientationexact orientation of the beam.
of the beam.
Technology model – Technology model –the screenthe screen shows an image of the technology shows an image of the technology components in the intelligent tool. components in the intelligent tool.
Fine adjustment – Fine adjustment –Project LeaderProject Leader Hannes Mautz with the intelligent Hannes Mautz with the intelligent tool for the TT hood. tool for the TT hood.
Internationalization:
Internationalization:
Five sites on two
Five sites on two continentscontinents
Neckarsulm plant –
Neckarsulm plant –
Assembly of a fixture for