With an exceptionally low Cd value of 0.21, the Audi A6 Sportback e-tron1 is the most aerodynamic Audi of all time and leads the entire VW Group in its segment in terms of aerodynamics. The A6 Avant e-tron2 also achieves an excellent Cd value of 0.24, placing it at the top of its body segment. Aerodynamics developers Andreas Lauterbach and Matteo Ghelfi and wheel designer Andreas Valencia Pollex explain how they achieved the record value with meticulous attention to detail.

Aerodynamics has always played a key role in Audi’s long history of success. As far back as 1967, the NSU Ro 80 had an aerodynamic, wedge-shaped body with a Cd value of 0.35 that changed automotive design forever. The third-generation Audi 100 (C3), introduced in the summer of 1983, boasted a Cd value of 0.30, which was exceptional for its time. Right on its heels, the third-generation Audi 80 (B3) continued this success story with a drag value of 0.29. Now, the Audi A6 e-tron12 is writing a new chapter, proving once again that Audi always combines form and function in a perfect symbiosis.

“Over 1,300 simulations and countless hours in the wind tunnel.”

“From the very start of the project, we placed a high value on efficiency and range and pursued very ambitious goals, regarding the A6 e-tron12. To be honest, in the beginning, we weren’t sure if we would be able to achieve the values we were aiming for. Getting to that last thousandth of a Cd value is the hardest part, but in the end, we exceeded our goals,” Lauterbach recalls.

The outstanding result was achieved primarily through “excellent teamwork between us (Aerodynamics experts) and our colleagues in Design. We all pulled together. From the beginning of the project, the Designers shared their drafts with us so that we could provide initial aerodynamic evaluations. In an iterative process – firstly using virtual simulations and later the physical model in the wind tunnel – we went on to optimize the basic vehicle body.

In particular, the basic proportions with the slim greenhouse and the sloping roofline contribute to good aerodynamics.”

Lauterbach and Ghelfi devoted considerable time to working on the details with their colleagues in the Design team. Ghelfi: “In all, we ran over 1,300 simulations on the car and spent countless hours in the wind tunnel and in meetings collaborating with surface experts and designers. For example, air curtains are used to improve the airflow around the front of the car. The outside edge of the air curtain intake protruded somewhat, which impeded the airflow. Millimeter by millimeter, we reached a compromise that ultimately worked out for both sides.” Lauterbach adds: “Another example is the rear track width. Our team would have liked it to be narrower. Together, we found a solution that brought out the best in terms of design, dimensions, and aerodynamics.” Ghelfi: “Regarding aerodynamics, the aero bezels were particularly important. The lateral breakaway edges on the rear of the A6 Avant e-tron2 made it possible to achieve a clearly defined flow stall. They are significantly larger than in other Audi cars. Working in the wind tunnel with our Design colleagues, we carefully pored over each side's respective arguments and strived to find the best solution. The result is that the aero bezels alone improve the range by 0.008, equivalent to eight kilometers. That’s a significant advantage to come from a single design detail.”

“Looking at the car overall, neither side had to make any major compromises. When all was said and done, and I called my colleague in Design to tell him that together we had achieved the Cd value of 0.21 for the A6 Sportback e-tron1, he could hardly believe it,” recounts Lauterbach proudly.

“Every detail fine-tuned to the last millimeter.”

Achieving these top Cd values for the A6 Sportback e-tron1 and Avant e-tron* demanded considerable attention to detail. The switchblade cool-air intake under the Singleframe alone, which helps the air to flow around this area with few losses, realized a Cd advantage of 0.012, equivalent to about 12 kilometers.Lauterbach: “The underfloor also plays a significant role in a car’s aerodynamic performance. On the A6 Sportback e-tron1, we added radii, optimized stiffening ribs, and breakaway edges at critical points. The rear diffuser is another element crucial to aerodynamics: Due to the smooth underfloor, this part is exposed to direct airflow, and pressure recovery has a positive effect on the Cd value.”

Ghelfi adds: “The underfloor is largely finished, and we’ve fine-tuned many of its parts, including specially adapted wheel spoilers and 3D bumpers on the front wheels, each of which has been individually optimized for the Sportback and Avant models using CFD analysis, which improves the Cd by 0.002 and 0.009 according to wind tunnel measurements. The large underfloor cover (the engine undershield) in the front of the car was optimized by adding a large radius on the air outlet; the rocker panel and the rear axle have been largely covered. These are just a few examples. We looked at practically each individual radius. We were able to achieve all these optimizations thanks to excellent teamwork with the project leaders, system team leaders, component managers, and designers.”

Lauterbach explains the overall concept this way: “The balance between the basic shape, rear height, rear contours, and underfloor design impact not only the car’s Cd value but also its lift. We achieved an ideal balance between lift and Cd by fine-tuning the underfloor as described.” Ghelfi adds: “The Avant has an additional diffuser spoiler that compensates for the fundamental difference in aerodynamics between the Sportback and Avant silhouettes, which means that the underfloor airflow differs for the two A6 e-tron derivatives12. This is another reason the Avant uses wider 3D bumpers to improve airflow around the front wheels.”

“Practically all of the wheels for the A6 e-tron12 are designed for aerodynamics”

The aero optimizations that some of the different-sized wheels feature round off the aerodynamics concept of the Audi A6 e-tron12. Rim designer Andreas Valencia Pollex: “Formerly, wheels basically only had to meet stability requirements. Today, we develop and design intelligent aero wheels that are as efficient as possible because the wheels, and even the tires, have a major impact on the range of an electric car.” The A6 e-tron* has special 19” aero wheels and two special 20” aero wheels.

Valencia Pollex continues: “To achieve perfect aerodynamics, the rims had to be somewhat flat so that the air that hits the front of the car is directed sideways around the body without much turbulence. We want the wind to flow along a wall rather than a collection of geometric shapes. So, we also developed a 21” wheel with aero blades made from special plastic for the A6 e-tron12.”

Lauterbach adds: “If you look at the whole range of wheels, the best and the worst wheels in terms of aerodynamics are only 0.015 Cd apart. That means that practically every wheel is designed for maximum aerodynamics.”

Article source: www.audi-mediacenter.com

1. Audi A6 Sportback e-tron performance: Combined electric power consumption in kWh/100 km (62.1 mi): 15.9-14.0; combined CO2 emissions in g/km (g/mi): 0 (0) CO2-class: A

2. Audi A6 Avant e-tron performance: Combined electric power consumption in kWh/100 km (62.1 mi): 17.0-14.8; combined CO2 emissions in g/km (g/mi): 0 (0) CO2-class: A

Audi is adding an interesting entry-level variant to the Q4 e-tron series: the multifaceted Audi Q4 35 e-tron1 costs 45,600 euros, and the Sportback2 with an elegant rear is 47,600 euros. The all-electric premium model includes comprehensive equipment as standard, offers a range of up to 355 kilometers (Sportback: 365 kilometers), and a DC charging capacity of 145 kW. New in the Q4 e-tron: an integrated app store enables direct access to popular third-party apps such as Spotify or Audible without using a smartphone. The Q4 35 e-tron12 will be available to order from July this year.

The best-selling electric car of the Four Rings is becoming more attractive - thanks to an even broader model range. With the Q4 35 e-tron1, Audi is making it easier to enter the all-electric premium compact segment. It will be available from July and is equipped with a 55 kWh (52 kWh net) battery, which enables a range of up to 355 kilometers for the compact SUV and 365 kilometers for the Sportback. Under optimum conditions and thanks to improved cell chemistry, the battery's charge level increases from 10 to 80 percent in just 25 minutes when charged at a fast-charging station. Up to 125 kilometers (Sportback: 130 kilometers) can be recharged in just ten minutes. The maximum DC charging power is 145 kW. The Q4 35 e-tron (combined power consumption in kWh/100 km: 19.2-17.0 (WLTP); combined CO2 emissions in g/km: 0; CO2 class: A) sprints from 0 to 100 km/h in 9.0 seconds, with a top speed of 160 km/h. A permanently excited synchronous machine (PSM) with 125 kW (170 hp) (combined power consumption in kWh/100 km: 19.2-16.4 (WLTP); combined CO2 emissions in g/km: 0; CO2 class: A) and high efficiency as well as superior power delivery provide the propulsion at the rear axle. The electric motor with sophisticated thermal management features energy-saving cooling: the geometry and arrangement of the gearwheels in the gearbox and specially shaped components for forwarding and distributing the oil keep the temperatures in the drivetrain low. The cooling circuit ensures that the oil is kept at the right temperature. A water-cooling jacket on the outside of the stator supports the cooling.

Optimally networked in an urban environment

For the Q4 35 e-tron1 and the other variants in the Q4 e-tron model series, the Audi Application Store will be available in the vehicles’ Multi-Media Interface (MMI) for the first time from July this year. It offers access to a large and growing selection of popular apps, from news and podcasts, sports and games, to video and entertainment, without using a smartphone. A data package of 25 GB for one year is included*, which customers can activate free of charge via Cubic Telecom. The data connection is made via the vehicle's external aerial, improving reception quality and saving the smartphone's battery.

With a comprehensive navigation update, customers can plan charging more precisely. The desired battery charge level for the destination can be defined as a separate destination, or charging stations from specific providers, such as IONITY, can be selected. The smartphone interface connects the smartphone to the vehicle and seamlessly brings its content directly to the MMI touch display. Content, such as navigation, telephony, music, or selected third-party apps, can be transferred wirelessly or via a USB-C cable.

In addition, ChatGPT will be integrated into the online voice input of all Q4 e-tron models. ChatGPT offers a wide range of options that go beyond the previous voice control. With the extended voice control, customers can control the infotainment, navigation, and air conditioning and ask everyday questions. The ability to request information in natural language makes driving safer, as drivers can continuously monitor the traffic. ChatGPT is provided via Microsoft’s Azure OpenAI Service. The basis for this new function for Audi customers is the Chat Pro solution from Cerence Inc. with automotive-grade ChatGPT integration.

Extensive equipment as standard from 45,600 euros

Entry into electric mobility in the premium segment starts at 45,600 euros for the Q4 35 e-tron1. The Q4 Sportback 35 e-tron2 starts at 47,600 euros. The extensive equipment includes among other things Audi MMI navigation plus, Audi Connect navigation and infotainment, and the fully digital 10.25-inch Audi virtual cockpit instrument cluster. The boot lid is electrically operated and reacts to foot gestures in conjunction with the optional convenience key. The heated front seats are also part of the standard equipment. The model is available to order immediately in both body variants.

* A separate registration and authentication on the Cubic Telecom website (https://audi.cubictelecom.com) are required for the booking. A separate contract is concluded between Cubic and the customer for this purpose. The data package is limited to one year of use. For country-specific availability, please contact your Audi partner or visit https://audi.cubictelecom.com.

Article source: www.audi-mediacenter.com

1. 

Audi Q4 35 e-tron: Combined electric power consumption in kWh/100 km (62.1 mi): 19.2-17.0 (WLTP); combined CO2 emissions in g/km (g/mi): 0 (0); CO2 class: A

2. 

Audi Q4 Sportback 35 e-tron: Combined electric power consumption in kWh/100 km (62.1 mi): 18.7-16.4 (WLTP); combined CO2 emissions in g/km (g/mi): 0 (0); CO2 class: A

Two Audi customer teams ended July with important successes. In South Africa, privateer driver Arnold Neveling continued his winning streak from previous races in the Extreme Supercars driven by Dunlop. Saintéloc Racing achieved an important strategic interim success in the GT World Challenge Europe Endurance Cup. The French Audi privateer outfit celebrated its second class victory of the year at the third event. This gave Sébastien Chetail’s team an advantage in the title fight for the Gold Cup standings with two races to go. At Volkswagen’s big GTI fan festival, the many visitors were also able to admire the original winning car of the 2024 Nürburgring 24 Hours, the Audi R8 LMS from SCHERER SPORT PHX.

Audi R8 LMS GT3

Fourth win of the season in South Africa: The Audi customer team Stradale Motorsport was also first class on the sixth race weekend in the Extreme Supercars driven by Dunlop racing series. Having already won the previous three races, the team traveled to the East London Grand Prix Circuit with the Audi R8 LMS under the sponsorship of Goscor Lift Trucks full of expectation. Arnold Neveling finished the first race on the tradition-steeped circuit in the Audi in second place behind the Lamborghini of Stuart White. In the second race, the Audi driver was again behind his opponent and put him under pressure in the early stages. When a puncture forced the Lamborghini driver into the pits, the way was clear for Neveling. The 34-year-old Audi privateer driver from Johannesburg secured his fourth victory of the year with a 16.6-second lead. Neveling pointed to the good balance of his car, which gave him a lot of confidence on the fast circuit within sight of the Indian Ocean, as the reason for his winning margin. Saintéloc Racing celebrated its second win of the season in the Gold Cup class of the Fanatec GT World Challenge powered by AWS Endurance Cup. The two Frenchmen Jim Pla and Paul Evrard shared the team’s Audi R8 LMS with Belgian Gilles Magnus. At the start of the three-hour race at the Nürburgring, the white Audi was in second place in its class, in third position at the middle of the race, before Gilles Magnus pulled out a lead of 5.3 seconds at the end. After first place at the season opener in Le Castellet and second place at the Spa 24 Hours, the driver trio now celebrated its second class victory. This increased their lead in the Gold standings to nine points with two races still to go. Saintéloc Racing also leads the corresponding team standings.

Article source: www.audi-mediacenter.com

With the new Audi A5 family, the first models based on the Premium Platform Combustion (PPC) with partially electrified drive systems and new electronic architecture are rolling off the production line in Neckarsulm. The brand with the four rings is consistently gearing vehicle production towards sustainability. The goal: In line with the "360factory" production strategy, all models manufactured at the Neckarsulm site from 2025 will be net carbon-neutral. To achieve this, Audi is relying on more efficient production lines, a higher degree of automation, and innovative technologies. From 2025, the renovated paint shop will be one of the most modern in the automotive industry.

As production of the new Audi A5 in Neckarsulm commences, the largest start-up phase in the plant's history has begun. "Thanks to many years of experience in the production of vehicles with combustion engines and expertise in complex ramp-ups, the Neckarsulm team has the ideal prerequisites," says Board Member for Production Gerd Walker. Fred Schulze, Plant Manager of Audi Neckarsulm, adds: "For the new Audi A5 family, the Neckarsulm workforce has acquired further qualifications for new systems and automotive production technologies. At the same time, we have created a future-proof production plant infrastructure." Rainer Schirmer, Chairman of the Works Council at Audi Neckarsulm, is also confident: "Neckarsulm employees can handle complexity and are flexible. With these skills, we will contribute to the success of the Audi A5 for our site and Audi."

The Four Rings' vision for the production of the future is thus continuing to take shape: The company is modernizing, digitalizing, and transforming its plants to manufacture sustainably. By 2025, Neckarsulm, like all Audi sites worldwide, is set to achieve CO2-neutral production1. 

Significantly lower energy consumption in renovated paint shop

When it is completed in 2025, the renovated paint shop at the Neckarsulm site will be among the most modern in the automotive industry. Numerous processes have already been optimized, and environmentally friendly procedures have been introduced for the launch of the Audi A5. While sustainable water-based paints have long been standard at Audi, the latest models also undergo a new painting process. The filler is replaced by a pre-zone paint that can be applied wet-on-wet. The previous separate drying of the filler is no longer necessary, allowing the four rings to reduce energy consumption significantly: Up to 140 kWh can be saved per vehicle.

In Neckarsulm, Audi relies on modern and effective methods to prevent corrosion. Cathodic dip painting, for example, includes dipping and rotating the body upside down in the tank using a rotation process. This is more space-saving and thorough, as it avoids minimal air bubble formation and dirt deposits. A new, more energy-efficient process is also used for drying the cathodic dip coating. Instead of the previous external drying process, a so-called transverse drying process is now used. Air is blown into the interior, and the body is heated from the inside. In addition to being more energy efficient, the transverse dryer is better suited to future electric and hybrid vehicles and their strengthened floor assemblies.

Audi achieves a further energy saving of around 50 kWh per vehicle thanks to a new paint separation process. Previously, the paint mist was collected in water with 100 percent fresh air and disposed of. In the new dry separation process, it is captured by state-of-the-art filters instead. This process allows more than 90 percent of the filtered air to be reused, largely eliminating the need for energy-intensive fresh air conditioning. At the same time, in contrast to conventional wet separation, the use of fresh water and chemicals is eliminated.

Sustainable water use in production

Audi is committed to using valuable water resources responsibly across all its sites: The company aims to halve its ecologically weighted water consumption in production by 2035. To this end, the Four Rings in Neckarsulm relies on a closed water cycle using the Unteres Sulmtal Wastewater Association’s wastewater treatment plant adjacent to the site. New pipes and plant technology ensure that no more process water will be taken from the nearby Neckar canal. This will save up to 70 percent of fresh water from 2025. Audi will further treat the water purified by the wastewater treatment plant with the help of filter systems and membranes. The process water then flows back into the treatment plant. Last year, Audi joined the Alliance for Water Stewardship (AWS), once again underlining its commitment to the economical and efficient use of water.

A high degree of automation for premium quality

Neckarsulm is the first site in the Group to install all add-on parts in the body shop fully automatically. In this way, Audi improves the fitting accuracy of the add-on parts and minimizes external influences. Seven robots are used simultaneously for the highly complex fender attachment alone.

As part of Audi’s "360factory" production strategy, its supply chain relies on the smart, automated provision of materials. Automation roadmaps have been created for each location and are gradually becoming a reality. Neckarsulm was the first Audi site worldwide to put the freely navigating, driverless transport systems (DTS) into operation back in 2014. With the start of production of the new Audi A5, over 80 percent of the material volumes in the body shop are now provided automatically.

Virtually smokeless fixing is a world-first in car body construction. It involves attaching glued components, such as doors with small soldering points, to prevent the inner and outer parts from slipping. Previously, numerous soldered fixing points had to be cleaned, as smoke is corrosive. The new process almost eliminates residue build-up thanks to a rotating gas flow. Audi works more than twice as fast with the new method compared to previous techniques.

State-of-the-art quality monitoring in the body shop

Quality control measurements in the body shop are mainly carried out inline, i.e., without removing a vehicle from the line. New measuring technology is used at two stations. Four robots at each station use measuring sensors to determine the components' dimensional accuracy. The measurement result is evaluated using software, visualized, and made available to the employees. With this new technology, every vehicle produced can be measured directly on the line. Consequently, Audi significantly increases the number of measurements and can react faster to any deviations. Continuous, interruption-free quality control is also possible thanks to the high degree of automation.

Employees use innovative technologies such as augmented reality (AR) to inspect car bodies. An AR app on commercially available tablets with an integrated camera shows the connection points to be checked in real time. This makes it possible to check and directly document whether, for example, weld seams or points are present and executed according to target specifications. The increase in efficiency through digitalization is enormous. For example, inspectors once had to go to great lengths to determine the specifications for a bonded seam. With the tablet, this work is now done in just a few seconds.

1 Audi defines balance sheet CO₂ neutrality as a state in which, after exhausting other possible reduction measures with regard to CO₂ emissions caused by Audi products or activities, CO₂ emissions that are still present and/or currently unavoidable in the supply chain, production, and recycling of Audi vehicles are offset, at least in terms of quantity, by voluntary compensation projects carried out worldwide. CO₂ emissions occurring during the use phase of a vehicle, i.e., from when a vehicle is handed over to the customer, are not taken into account here.

Article source: www.audi-mediacenter.com