Using artificial intelligence, Audi analyzes around 1.5 million spot welds on 300 vehicles each shift at its Neckarsulm site. By comparison, until recently, production staff used ultrasound to manually monitor the quality of resistance spot welding (abbreviated WPS in German) processes based on random analyses. With the ultrasound method, they checked around 5,000 spot welds per vehicle. By applying AI, employees can now focus on possible anomalies. This new approach will enable them to control quality more efficiently and in a more targeted way.

Preparations for using the technology at other plants in the Volkswagen Group have already begun. For example, the technical infrastructure for AI use is currently being installed at Audi Brussels. The Volkswagen plant in Emden is scheduled to install the necessary infrastructure this year, as will Audi’s headquarters in Ingolstadt. To install the technical infrastructure at these locations, the team of experts is currently identifying differences in weld settings in order to retrain the AI model accordingly.

“The rapid expansion of the charging infrastructure in Europe and worldwide is crucial for the success of e-mobility. We see this as a joint task for politics and industry. The Audi charging hubs are our way of supplementing the public charging infrastructure,” says Audi CEO Markus Duesmann.

High charging output without any drop in performance through “Vorsprung durch Technik”

The Audi charging hub differs from many other quick-charging stations in that it does not require a medium-voltage connection. This sets it apart from many other quick-charging stations, which often necessitate additional infrastructure. The concept is based on “charging cubes” – modular containers that contain refurbished lithium-ion batteries (second-life batteries) made from disassembled Audi development vehicles. The design reduces the strain on local grid capacity and means the charging hub requires no elaborate, expensive infrastructure.

The Audi charging hub in Salzburg has four charging points with a buffer storage unit that enables constant charging with up to 320 kW of output at each of them, even if they are all in use at the same time. At full capacity, that is, when all four charging points are used simultaneously, each charging point can always supply 320 kW.

Accessibility

In designing the charging hub, barrier-free accessibility was of the utmost importance. Wheelchair users in particular will find sufficient space to open the doors and move around the vehicle thanks to the spacious dimensions. The payment terminals can be moved to a wheelchair-friendly height at the push of a button. Charging becomes even easier if the vehicle uses Plug & Charge. This feature enables the vehicle to exchange payment information directly with the charging point – eliminating the need for physical payment or verification. Additionally, the charging cables are mounted on an innovative swivel arm so that the charging plug can be effortlessly moved to any position on the vehicle, allowing the user to conveniently reach the charging port no matter where it is, regardless of the vehicle model.

All payment cards accepted

The new charging concept for electric cars will not only be available to Audi drivers. Any electric car equipped with a CCS charging port can be charged, no matter the make. Audi customers are able to reserve a slot in advance. They can use the myAudi app to make an appointment for a no-wait charging slot. A bar ensures the booked charging point stays free for up to 15 minutes after the scheduled start time.

Figures from Nuremberg and Zurich underscore how drivers of electric cars from Audi or other brands are embracing the urban quick-charging concept of the brand with the four rings. In Nuremberg, where Audi has been operating the large Audi charging hub with six charging points and a 200-square-meter (2,150-sq-ft) lounge above it since December of 2021, the customer return rate is 70 percent. “Customers there have now integrated charging at the charging hub into their daily routine,” says Ralph Hollmig, Audi charging hub project manager. Audi has counted up to 62 charges per day in Nuremberg; on average, the first Audi charging hub registers 36 charges daily. Around half of users roll up to the hub in an electric Audi model. “When we launched the Audi charging hub in December of 2021, hardly anyone had predicted this level of success. By early 2023, we already had our 10,000th hub visitor,” Hollmig reports. “In Zurich, too, we are seeing similarly high demand. These figures completely validate our concept of urban charging in lieu of charging at home. This gives us confidence that an attractive location like here in Salzburg will continue the success story.”

The smart, dynamic load control Audi developed internally ensures efficient use of the existing power infrastructure. In selecting the location, Audi relied on an in-house data analysis to check on-site demand in advance.

Audi’s partner in operating the Audi charging hub MOON POWER handles the entire technical project management side. As charge point operator (CPO), MOON POWER purchases the electricity and runs the billing system. The location directly next to MOONCITY Salzburg with its preexisting, perfect infrastructure (including local amenities and restaurants adjacent to the site) is ideal for such a project.

“We are excited to open the Audi charging hub in Salzburg as our fourth location worldwide,” says Thomas Beran, Brand Director Audi Austria. “Flexible, premium quick-charging infrastructure in urban areas is becoming increasingly important due to the rising number of electric vehicles on our streets. The high desirability of our Audi e-tron models is doing its part to increase charging needs in cities like Salzburg, creating demand for premium charging stations in addition to the conventional charging stations we’re all familiar with.”

“Just like in production development, simulation plays a major role in our Formula 1 project. Our simulator is an important tool for the power unit development. It requires a development driver who in addition to a grasp of technology brings versatile experience to the project, especially in terms of energy management in racing conditions,” says Oliver Hoffmann, Member of the Board of Management for Technical Development of AUDI AG.

As a former test and reserve driver at Red Bull Racing, Jani spent many hours in a Formula 1 simulator. As a race driver in endurance racing, he gathered valuable experience in a hybrid race car. As a member of the Porsche factory team, he won the FIA World Endurance Championship (WEC) in 2016 as well as the famous 24-hour race at Le Mans. “I am delighted to accompany Audi on their way into Formula 1. It is both an honor and a great responsibility to be involved in a project of this magnitude at an early stage. I am sure that with my experience from Formula 1 and LMP projects I can forge good links between theory and practice,” says the Swiss.

Since the end of 2022 testing of a one-cylinder engine has been delivering valuable results for the development of the power unit. The continuing concept phase is laying the performance-related groundwork of the power unit for 2026 when the new regulations provide for increasing electrification. The electric motor (MGU-K) will then deliver nearly the same output as the internal combustion engine. The highly efficient 1.6-liter turbo engines are powered by sustainable synthetic fuel. 

“At the moment, we are mainly focused on fundamental concept questions with high relevance to performance. However, in evaluating various technical solutions we rely not only on digital methods. Know-how, experience and practically relevant development are indispensable elements of drawing the right conclusions from the simulation. With that combination, we can assess various operating strategies at an early stage and pave the way for efficient energy management of the power unit,” says Adam Baker, CEO of Audi Formula Racing GmbH. 

The first hybrid power unit consisting of the internal combustion engine, electric motor, battery and control electronics is planned to be run on the dyno before the year is out and provide the basis for the future vehicle concept. Thanks to open competition, Formula 1 serves as a technology driver for both electromobility and sustainable e-fuels. 

Article source: www.audi-mediacenter.com

Audi Brussels has produced the Audi Q8 e-tron and Audi Q8 Sportback e-tron - the brand with the four rings top electric SUV model - since December 2022. Audi's first fully electric model, the Audi e-tron, previously rolled off its production line. The Brussels plant is the world's first CO₂-neutral1 large-scale production facility in the premium segment to be certified by independent experts.

With the largest photovoltaic site in the Brussels region, covering 107,000 square meters, the Audi plant saves around 1,881 tons of CO₂. It produces around 9,000 megawatt hours of electricity from renewable energies annually – enough to charge 90,000 Audi Q8 e-trons.

In the second half of 2023, Audi Brussels will assemble the Audi Q4 e-tron in addition to production in Zwickau, Germany.

Audi wants to achieve carbon neutrality on the environmental balance sheet, which means a condition in which, after exhausting other possible reduction measures in relation to CO₂ emissions caused by Audi products or activities, existing and/or currently unavoidable CO₂ emissions as part of the supply chain, manufacturing or recycling of Audi vehicles are at least offset in quantity by voluntary and worldwide offsetting projects. During the usage phase of a vehicle, which means from the moment a vehicle is handed over to customers, CO₂ emissions are not taken into account.

Article source: www.audi-mediacenter.com