The new Audi e-tron GT as an electric Gran Turismo!

Attention to detail, maximum precision and the highest quality: the new Audi e-tron GT reflects all the passion with which Audi develops and builds cars. In the production of the electrically powered Gran Turismo in the Audi Böllinger Höfe at the Neckarsulm site, the company uses tailor-made new technologies - but the finishing touches are done by hand, which is based on great skill. And because the dynamic synthesis of the arts should also sound good, Audi has composed its own sound for the e-tron GT, with musical flair and technical competence. It sounds powerful and progressive - just real Audi.

The production of the Audi e-tron GT

The Audi e-tron GT is the brand's first all-electric car to be built in Germany. The Gran Turismo will roll off the assembly line in the Audi Böllinger Höfe at the Neckarsulm site from the end of 2020. The small series production has been expanded, upgraded and retrofitted for its new task. The craftsmanship from the previous manufacture was retained, supplemented by digital processes and intelligent technologies. During the expansion, the production planners used new virtual methods. The testing of the work processes in assembly and the logistics processes was carried out virtually for the first time, the container planning was also supported by VR. The production of the e-tron GT was designed without physical prototypes - a novelty at Audi.

purely electrically powered Gran Turismo

The body of the purely electrically powered Gran Turismo consists largely of ultra-high-strength steel and aluminum. In order to produce this material mix in the planned quantities, a body shop was created that combines the manual skills of the employees with the full potential of automated production technology. It consists of an innovative body line through which each body runs twice. At its heart is the so-called double framer, in which ten robots attach the inner and outer side panels. It combines all of the production steps involved in joining the sides in a single system - thus making the production of the Audi e-tron GT possible on the existing space. The inline measurement process for the bodies is also new. It further increases the accuracy and allows to react very quickly to the smallest deviations. At the end of the assembly line, there is precise manual work: Experienced workers assemble the add-on parts and check the finish of the finished body. The expressive design of the Audi e-tron GT places unusually high demands on manufacturing quality - the side wall frame, for example, has an unusually large draw depth of 35 centimeters between the highest and lowest point.

36 instead of 16 working cycles

The expanded assembly line comprises 36 instead of the previous 16 work cycles. The e-tron GT shares it with the R8 - this integration of two technically completely different cars is unique in the Volkswagen Group. Both models are moved on the same automated guided vehicle (AGV) and on an electrically powered overhead conveyor. Humans and robots work directly together at one station on the line. If desired, a 3D printer can produce tailor-made assembly aids at the suggestion of the employees. After its completion, each car completes a 40-kilometer lap on public roads, which also includes passages on the motorway and in city traffic. "With the integration of the Audi R8 and Audi e-tron GT, a unique interplay of craftsmanship and smart factory is created in the Böllinger Höfe“, Summarizes production manager Wolfgang Schanz. "What makes me particularly proud is the passion and spirit of our team. "

The e-sound of the Audi e-tron GT

Whether quality, design or technical properties - the Audi e-tron GT is a car that has all of Audi's passion. This also applies to the sound of the electrically powered Gran Turismo. The engineers Rudolf Halbmeir and Stephan Gsell conceived and designed the progressive electronic sound - on the computer, in the sound laboratory, in the moving car and in customer studies. Like every electric car, the e-tron GT has the statutory acoustic vehicle warning system (AVAS), but it is embedded in a broader acoustic spectrum. A loudspeaker in the front of the vehicle emits the AVAS sound. If the customer orders the optional sound package, a second, large loudspeaker is added in the rear. At the same time, two loudspeakers in the interior ensure an emotional sound experience. The e-tron GT sound is permanently remixed by two control units, depending on parameters such as speed or accelerator pedal position. Using the Audi drive select system, the driver can set whether and how intensively he wants to hear him. If we get more information, there will of course be an update for this report. You will be informed of this if you simply do ours Feed subscribe to. Have fun watching the pictures and stay true to us!

Photos: Audi

The facts about the Audi e-tron GT:

Production

• Production of the Audi e-tron GT in the Audi Böllinger Höfe opened in 2014 at the Neckarsulm site; Expansion and renovation 2019; Planning with new virtual methods
• Production manager Wolfgang Schanz: "We are realizing a unique interplay of craftsmanship and smart factory"
• Body shop at e-tron GT about 85 percent automated; ten stations with a total of 34 robots
• Optimal space management thanks to the body line that each body travels through twice; Double framer combines several production steps in a limited space
• Correlation-free inline measurement as a new technology with the highest precision, possible deviation only a maximum of +/- 0,20 millimeters
• Joint assembly line from Audi e-tron GT and Audi R8, despite the different technology concepts, unique in the Volkswagen Group
• Different conveyor technologies in the assembly: 20 driverless transport vehicles, new electrically driven overhead conveyor, autonomous transfer station
• Human-robot cooperation when gluing front and rear windows
• Individual assembly aids from the 3D printer, based on ideas from employees

e-sound

• Development of the e-sound for the Audi e-tron GT with musical creativity and technical competence; creative work on the computer, in the sound laboratory and in the car
• 32 individual sound components; Weighting and modulation based on the drive management data
• Optional sound package: two control units in the luggage compartment, two exterior speakers on the car and two interior speakers in the rear doors
• Sound characteristics can be set in several stages via Audi drive select

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The new Audi e-tron GT as an electric Gran Turismo!

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