Considering the fact that manufacturing started out in late 2023, the Audi Q6 e-tron series has been the to start with superior-volume completely electric model series that Audi has generated at its headquarters in Ingolstadt. In trying to keep with the brand names 360factory creation method, Audi has integrated specific creation methods into present system store and assembly constructions and processes. Since January 1, 2024, Ingolstadt is the 3rd Audi place to manufacture with net zero emissions1, pursuing Brussels (2018) and Gyr (2020). In addition, the brand with the four rings headquarters is also the first Audi location in Germany to have its own battery assembly facility.

Audi CEO Gernot Dllner emphasizes the significance of the first design centered on the Premium System Electric powered (PPE): The PPE, and with it the Q6 e-tron collection, variety the basis for subsequent electrical Audi products. In this way, we are taking a decisive step towards featuring an electric powered model in all main segments by 2027. Audi Board Member for Generation and Logistics Gerd Walker sees the start off of manufacturing as an essential milestone for the 360manufacturing unit production tactic: By the end of the decade, we will have successively geared up all Audi destinations for the creation of electric types. We are harnessing electrification to comprehensively transform our existing vegetation. With the generation of the Q6 e-tron sequence, the Ingolstadt plant is having the upcoming step toward getting a 360factory. Audi has a very clear vision for the manufacturing of the upcoming.As portion of this holistic, sustainable strategy, the company is modernizing, digitalizing, and reworking its current crops. The Audi Q6 e-tron sequence, as properly as all other autos constructed at the website, have been manufactured with web zero emissions1given that 2024.

Condition-of-the-art output know-how in the new battery assembly facility

A single illustration of how Audi is modernizing and increasing its current units is the new battery assembly facility for PPE products. On an location of around 30,000 sq. meters (323,000 sq ft), 300 workers do the job in three shifts with an automation charge of nearly 90 percent to assemble up to 1,000 large-voltage batteries for each day to begin with for the Q6 e-tron series. At the same time, the model with the four rings is getting significant experience that it will afterwards use to also produce battery modules alone. The personnel are by now benefiting from the encounter their Brussels colleagues gathered during generation of the Q8 e-tron1 and the expertise of the battery screening center in Gaimersheim. In this way, we are rising our vertical vary of manufacture whilst also bringing extra expertise and systems to the area, explains Board Member for Creation and Logistics Walker.

The new facility, which is found in a devoted battery assembly corridor at the Logistics and Goods Transportation Centre (GVZ) in Ingolstadt, is run exclusively by eco-friendly electrical power. This also will allow Audi to realize even bigger flexibility and effectiveness in creation devoid of sealing additional areas for new buildings.

Electrical motors for PPE from the worlds most significant powertrain plant in Gyr

Ingolstadt is sourcing the electric powered motors for the new Top quality System Electric powered (PPE) technologies system from the worlds biggest powertrain plant in Gyr, Hungary. Audi Hungaria manufactures electric motors for the PPE on a few recently installed production lines. The motors are then transported to Ingolstadt by the transportation and logistics corporation DB Cargo with zero emissions. Audi has been generating at the Gyr web page with web zero emissions1 considering that 2020. Sustainable creation in current vegetation is the main of our 360factory producing system and an integral step on our path to making a foreseeable future-proof output community, says Walker.

Retooling and a versatile gear idea in the system store

In order to make creation of the Q6 e-tron collection sustainable and productive at the identical time, Audi has integrated production domains these as the system shop for the PPE into present constructions. The bodies for the PPE versions are assembled at the Ingolstadt plant on an space of all-around 148,000 sq. meters (1.6 million sq ft). There, 328 employees for every shift and 1,150 robots establish the physique parts for the Q6 e-tron series with an automation rate of 87 percent.

The extremely adaptable products will also enable the virtually seamless launch of long run models. In buy to make sustainable and synergistic use of sources, Audi is reusing 680 robots that had been presently made use of to produce other Audi models in the body store for the generation of PPE bodies. Audi is also placing a new fleet of extra than 40 automatic guided cars (AGVs) into procedure for the Q6 e-tron series. The AGVs source products in the hall and also provide the overall body shop with the necessary components in automatic procedure.

Assembly of PPE products with existing gear

Audi persistently relies on current units and devices for assembly. The Audi Q6 e-tron series has been seamlessly built-in into the recognized assembly line for the Audi A4 and A5 types. In this way, combustion and electrical cars from distinctive product collection are assembled on a shared line. It took Audi eight stages of modification to integrate the PPE designs into its assembly operations.

Greater automation in the paint shop

Manufacturing has also extended the paint store for the new thoroughly electric collection. Amid other adjustments, the dryer after the cathodic dip coating (CDC) course of action stage was extended and a new integrated method for instantly sealing holes was launched. Just after CDC, robots use adhesive pads to seal about 70 holes in the bodies, every of which is measured independently for this move. Formerly, workers had to manually execute this section of the method. Audi upgraded the dryer to satisfy the higher strength requirements for curing the bodies immediately after CDC. This modification makes sure all parts of the physique access the target temperature of 160 C (320 F) demanded for curing the CDC. The Ingolstadt paint shop also works by using automated creation engineering that allows detect, appraise, and process surface area irregularities. This tends to make it probable to objectively examine completed surfaces, expanding method reliability and building high quality checking more transparent. In the to start with step, robots scan the vehicle surfaces working with an automated measuring system. This procedure is the foundation for finishing, which is also an automated course of action. Just about every finishing robot is geared up with a grinding and polishing instrument. In the subsequent move, staff members examine the processed places on significant screens.

Flexible devices thought for scorching forming

At the press store in Mnchsmnster, a group of professionals has been functioning hard to improve the very hot-forming procedure for the PPE. Very hot forming is principally utilised to develop security-linked factors: This process presents more steadiness and crash basic safety to sheet steel components for the overall body construction of autos on the PPE, such as A- and B-pillars, as very well as pieces of the longitudinal members. Just after remaining heated to all over 950 C (1,742 F) in a particular furnace, sheets of metal are formed into the wanted ingredient in a forming push employing the suitable template. By regionally cooling the heated steel making use of air vents, Audi can affect the toughness of the parts as essential to further improve crash overall performance while minimizing the body weight of the system.Owing to the significant hardness of the content, it is then necessary to use unique lasers to slash the sought after contours into the parts.

In addition to factors for models dependent on the PPE, the output tools will also be employed to make factors for combustion-motor versions based on the PPC (High quality Platform Combustion) in the long term. This new level of versatility suggests the devices can be utilised to manufacture a overall of 44 elements in Mnchsmnster. Modifying the setup of the laser cells and forming presses is fully automated and time-optimized, resulting in a plant output of all over 20,000 person pieces for every doing work day.

1Audi understands web-zero CO2emissions to indicate a condition in which, after other probable reductionmeasures have been fatigued, the business offsets the carbon emitted by Audis products and solutions or activitiesand/or the carbon emissions that now are not able to be prevented in the source chain, production, andrecycling of Audi vehicles through voluntary offsetting tasks carried out around the world. In this context,carbon emissions produced for the duration of a autos utilization phase, i.e. from the moment it is shipped to thecustomer, are not taken into account.

1. Audi Q6 e-tron quattro: Put together energy consumption in kWh/100 km: 19.4 -17. (WLTP) CO2 emissions merged in g/km: CO2-class A