Press Release
Compared to the predecessor, the number of components on the further developed Audi Space Frame (ASF) has been reduced from 334 (including add-on parts on the previous model) to 267. This is achieved through the use of large-format panels such as the single-piece side-panel frame, of extruded sections such as the three-meter long hydroformed roof frame and multifunctional large castings such as for the radiator tank or B-post. The reduction in parts and weight on the new ASF is well represented by the last two mentioned components: whereas the radiator tank on the A8 still consists of seven different parts and weighs over five kilograms, it will be cast in one piece as a multifunctional part on the successor model. The weight: around three kilograms. The same is true of the B-post: whereas it was composed of eight parts till now (4,254 grams), it is produced as a single component in the successor model with a reduction in weight at the same time of around 600 grams. There are a whole range of other lightweight construction measures that have been adopted on the new A8: the aluminum rear auxiliary frame alone enables a weight reduction of around nine kilograms. Components such as the instrument panel support made of aluminum and magnesium, cast-rolled wheels or the sprayed-on acoustic insulation in the underbody area signify a weight saving of one kilogram in each case. Compared to a conventional steel body of this size, around 40 percent of the weight can be trimmed off in the new A8. !The Audi flagship is, as its predecessor already, a benchmark in terms of lightweight construction combined with exceptional stability,! according to Production Director Heizmann. At the end of the body production line, a computer-controlled CNC milling machine mechanically processes the connecting zones for suspension and front-end module. At the same time, the position of the vehicle is determined via mechanical sensors and the machining correspondingly controlled through a computer programme. It is possible to achieve a perfectly adjusted assembly of the front-end module and the suspension through the high precision of the milling process. The precision with which the running gear is connected to the body is a basic prerequisite for the new top model's excellent handling properties. The finished body shell of a new A8 is then transported to a height of 26 metres by a conveyor belt over a 315-meter long, completely covered over bridge into the paint shop. The paint shop, one of the most up-to-date in the world, was already prepared for the launch of the luxury-class vehicle following completion of the third building phase in October 2000. The third building phase enabled the introduction of segmenting or painting in various part sections separated according to the model series. Audi also took into account the increasing demands on the paint shop brought about by the growing number of aluminum vehicles. The total amount of investment for the paint shop was over EUR 300 million. above photo caption:
Inline measurement of the body: using laser measurement sensors, the body's dimensional stability is monitored at 14 stations in the ongoing process
