Audi 2014 Annual Report Download - page 35

During a tour of Audi Production, Waltl
wants to show where future technolo-
gies developed by his team are already
being put to use. A look behind the
scenes. A look at that bit of the future
that is already present-day reality.
The starting point for the production
experts’ excursion is Katharina Kunz’s
workplace, the D lab. Waltl chose
this fi rst stop for a reason. Production
begins here in the virtual reality of the lab.
It is pitch black. The only light is that
shining from four projectors onto screens
on the wall and fl oor. With the help of
D glasses and gesture control, Katharina
Kunz is testing the steps for the as-
sembly of new models on these surfaces
prior to the start of production. “The
physical and virtual worlds merge here,”
says Waltl. “Many science fi ction fan-
tasies pale in comparison with this.”
Intrigued, Neugebauer adds: “Potential
applications for this type of augmented
reality range from research to design,
but it could also fi nd use in sales, main-
tenance and even employee training.”
In the future, the entire production
process at Audi will be simulated virtually.
Tools, plants and operating materials –
all send data to the cloud in real time.
Each physical element is thus modeled in
the virtual world. This also enables
objects to communicate amongst them-
selves and with people. “Networking –
that is the core idea behind Industry .,”
adds Fraunhofer President Neugebauer.
After mechanical production, assembly
line production and digital automation,
data is the foundation for the fourth
industrial revolution. Data is becoming
the oil of the future. Machines already
produce myriad data today, usually in the
digital jargon of a computer language.
Soon still more machines and even ma-
terials will supply data. People will no
longer have to search through tables in
the event of an error. In the future, in-
telligent algorithms will be able to read
the data, identify previously unknown
errors and reveal undiscovered potential
for optimization.
Perfection in toolmaking :
A tool equipped with sensors is
used to ensure optimal forming
and e cient use of material.
Precise edges, accurate gaps. The dis-
tinctive design of an Audi demands quite
a bit from both materials and tools.
Tools that think for themselves have been
making the production process easier
at Audi since . Take the pressing of
body parts, for example. Sensors in the
tool measure the position of the sheet
and the forces acting upon it. Mecha-
tronic actuators make any necessary cor-
rections. A demanding material such as
aluminum can thus be precisely formed.
The reject rate is also reduced – in the
case of the trunk lid for the Audi A by
as much as  percent compared with
its predecessor. This saves material and
supports sustainable production. “That
is the ultra principle in production,” says
Waltl. “After all, e ciency and sustain-
ability apply to more than just our cars.”
Audi ultra is a philosophy that drives
Audi. The ultra philosophy is also lived in
production – via innovative technologies
such as the intelligent tool.
PHOTOS : AUDI AG