The new Audi R8 framework is only 200 kg car can be so thin?

The new Audi R8 framework is only 200 kg car can be so thin?

The lightweight design of new Audi R8 roadster to further consolidate the leading position in this field. The car body frame for the application of composite materials manufacturing, it is next to the located within the Neckarsulm (Neckarsulm) Bolling Gerhof (b o llinger h o FE) factory production.

The factory production began in the fall of 2014 the new R8 vehicle frame. Here the main production of various high-end and have small volume lightweight design production models. New R8 this high performance sports car ASF composite body frame weighed 200 kg, but it is very strong collision resistance. It consists of 70% of the aluminium material and 13% of the carbon fiber composite to build into the full interpretation of the Audi cars in the motto "the right materials according to appropriate proportion used in place."

"Under full load on two shifts every day we can 40 body frame production," said Quatro GmbH President Johan Wagner. "We put the whole production process of the vehicle body frame divided into two regions: region 1 to complete the production process for aluminum material part of the region 2 is responsible for adding carbon fiber composite materials in aluminum parts." We will also be further subdivided into 1 regional welding work area and work area and screw assembly work area. So, we in the production of R8 LMS like GT3 racing like derivatives will be more convenient and flexible.

In the professional technicians and robot interaction work, each producing a framework of the new Audi R8 car took about 30 minutes. The first step is the production of welding technician will cast aluminum body frame before, during and after the three part of the welding framework based on the composition of the whole body. Each frame welding length can reach 89 meters of the whole. The second step is to cold welding, done by robots, ASF Audi stereo vehicle frame needs 270 hollowing semi punching and riveting, 270 blind rivet, 241 metric screw and 270 tapping screws for fixing.

Then the vehicle body frame and cabin top processing. In the unit operation, the five axis robot will in the framework accurately cut point riveting, after installed carbon fiber composite parts, suspension and steering system to prepare. The riveting point error of only a few percent mm. The riveting point after finishing cutting, three-dimensional precision measuring instrument can detect ASF inline Aurora body frame. In the fixture assembly unit, the technician will use precision fixture will aluminum door, hood, fenders and auxiliary parts installation to the frame.

Once the body frame through the completion of area region 1 of the last station -- will be trucks transported in Kasur mu (Neckarsulm) in the factory paint shop, where, the frame of the vehicle will by cathodic immersion painting and oven 200 degrees Celsius degree heat treatment to achieve the ultimate strength. "Carbon fiber composite in complete this step before processing also cannot be installed on the vehicle body frame, because they do not change with temperature and expansion," Jochen - Wagner explained. "We will be shipped back in the frame and adding carbonaceous components. The work will be completed in the area of 2."

When the frame of the vehicle was returned to Bolingho Faye (b o llinger h o FE) factory, assembly composite carbon fiber parts in region 2 subsequently. High strength beam body frame is composed of carbon fiber composite. Carbon fiber composite material according to different map, the structure also has the distinction of the essence. For example, R8 diaphragm beam, the main purpose is to strengthen the root of the beam transverse strength of the body, so most of its fabric material layer is a one-way permutation. A total of 14 layers of fabric material layer superposed successively formed carbon fiber composite layer thickness is 5 mm.

Install carbon fiber parts need to work closely with technicians and robot in automobile frame. Responsible for the accurate structural bonding robot and welding work. They have passed through the longitudinal axis of the mechanical arm rotation of the carbon fiber rear baffle plate into the ASF body frame; other robots will car central channel is placed on the corresponding position of the pallet. Then, body frame have been placed in same pallet and with the central channel with. Quattro GmbH is responsible for technician parts of the B column and B column surface installation and assembly screws and rivets.

After the frame of the vehicle will be transported to the sealing station. Here the robot will to aluminum and carbon fiber composite gap add sealant to prevent crevice corrosion. Finally, the frame of the vehicle will was again put into the oven at 80 degrees Celsius heat treatment, to achieve the ultimate strength structural adhesives and sealants. So far, the new R8 ASF body frame production accomplished -- the 200 kg weight of the vehicle body frame embodies a concentrated reflection of the Audi in material application and processing and manufacturing of advanced technology. It is precisely because of these techniques, Audi can make the light body design towards a more perfect level.