The new 911 Carrera Technology Workshop Body and manufacturing The - PowerPoint PPT Presentation

The new 911 Carrera Technology Workshop Body and manufacturing

The new 911 Carrera – Agenda 1 2 3 4 5 Warm-up Development Production Finish Body highlights

The new 911 Carrera – Highlights Design Lighting and assistance Driving dynamics and systems driving comfort  Exterior even more muscular and contemporary  LED matrix headlights  New Porsche Active Suspension  Even wider body Management  Night Vision Assist  New wheels and tyres with  Porsche Wet Mode different dimensions Performance & efficiency Individualisation (Front: 20-inch; rear: 21-inch)  Optimised three-litre six-cylinder  Lightweight carbon roof  New engine mounts flat engine with 450 hp  Sport Design Package  New eight-speed Porsche dual- clutch transmission (PDK)

The new 911 Carrera – Development weight-to-power ratio 1800 10 1600 Weight-to-power ratio in kg/hp 8 1400 1200 Weight in kg 6 1000 800 4 600 400 2 200 0 0 Original 911 G-Series 964 993 996 997 991 992 (2018 - ) (1963-1973) (1973-1989) (1988-1994) (1993-1998) (1997-2006) (2004-2012) (2011-2018)

The new 911 Carrera – Agenda 1 2 3 4 5 Warm-up Development Production Finish Body highlights

The new 911 Carrera – The eighth generation of the 911

The new 911 Carrera – Dimensions 992

The new 911 Carrera – Challenges Process  Derivatives development without prototypes  New multi-story body manufacturing plant at brownfield site  Methods development  Up to nine body variants and two platforms on one MMB* platform production line  Group modular platform  Platform users Product  Drive technologies  Systematic lightweight design  Multimaterial body  Innovative joining technologies * Modular mid-engine platform

The new 911 Carrera – Modular Mid-Engine Platform MMB MMB platform 911 718 … … Coupé Cabrio Targa Coupé Cabrio … Carrera Turbo GTx Carrera Turbo GTx Base GTx Base Spyder

The new 911 Carrera – Modular platform concept

The new 911 Carrera – Agenda 1 2 3 4 5 Warm-up Development Production Finish Body highlights

The new 911 Carrera – Reversal of the upward weight spiral 300 +10 % -11 % -5 % +20 % 250 200 Body weight in kg 150 100 50 0 993 996 997 991 992 (1993-1998) (1997-2006) (2004-2012) (2011-2018) (2018 - )

The new 911 Carrera – Material concept (0 %) (-37 %) (+4 %) 1 % 12 % 13 % Steel sheet (cold) (+4 %) Steel sheet (hot) 17 % Aluminium sheet 991 Extrusion profile 25 % (+22 %) Cast aluminium Cast steel 32 % (+7 %)

The new 911 Carrera – Development of joining technology 911 (Type 997) 911 (Type 991) 911 (Type 992) Steel sheet (cold) Steel sheet (cold) Sheet steel (cold) Steel sheet (hot) Steel sheet (hot) Aluminium sheet Aluminium sheet Extrusion profile Extrusion profile Cast aluminium Cast aluminium Cast steel Cast steel Resistance spot welding Resistance spot welding Resistance spot welding MAG welding MAG welding MAG welding Adhesive bonding Adhesive bonding Adhesive bonding Clinching Clinching Clinching Semi-tubular rivets Semi-tubular rivets Flow-drilling screws Flow-drilling screws MIG welding MIG welding Solid punch rivets Roller hemming Friction welding

The new 911 Carrera Lightweight design of exterior side panel using aluminium Weight reduction per vehicle 12 kg

The new 911 Carrera – Approach to the use of casting materials over time 997 991 992 0 % 9 % 13 %

The new 911 Carrera – Process optimisation in the manufacture of cast parts Process optimisation  Eliminates need for heat treatment at manufacturer  Finished mechanical properties by input of heat in CDC process Benefits  Improved CO 2 footprint due to elimination of heat treatment at manufacturer  Lower part costs  Improved punch rivet process

The new 911 Carrera – Load class control of front body Two load beams, one variant  Lightweight coupé vehicles  Heavy cabriolet/targa/turbo vehicles Differentiated by wall thicknesses of the extrusion profiles with  the same fastening points to the higher-level structure  same joining technology to the higher-level structure Goal  Weight- and function-optimised structure for absorbing different levels of energy while conforming to mounting space limitations

The new 911 Carrera – Transfer stiffnesses: front suspension Improvement of local dynamic transfer stiffnesses by  optimised double-shear joints of the strut tower  weight- and package-optimised braces concept Goals  Reduced rolling noise at front wheels  Improved driving stability of front body

The new 911 Carrera – Stiffnesses Torsion Bending Dynamic stiffness > 53 Hz > 76 Hz Body-in-white Dynamic stiffness > 27 Hz > 29 Hz Trimmed body Static stiffness > 39,000 Nm/° > 25,000 N/mm Body-in-white

The new 911 Carrera – Modular roof concept Magnesium Sheet metal sliding Aluminium sunroof (base version) CFRP Glass sliding sunroof

The new 911 Carrera – Agenda 1 2 3 4 5 Warm-up Development Production Finish Body highlights

The new 911 Carrera – Pressed part competence at Porsche Zuffenhausen, 1963 Schwarzenberg, 2018

The new 911 Carrera – Universal process from design to part Design Quality Tool Tool Simultaneous engineering engineering building process

The new 911 Carrera – Requirements for an exterior side panel Porsche DNA Strategic goals Business requirements Aluminium Dynamics Impression Legal requirements Highly precise fit and repeatability Higher Increasing tool complexity Lightweight Design requirement design Shorter manufacturing times and reaction times

The new 911 Carrera – Technical challenge of the side panel Crack Restraining force Good part Folding Part complexity

The new 911 Carrera – Assuring manufacturability by simulation Example of exterior side part > 1200 tonnes  Forming force > 45 tonnes  Weight of drawing tool > 325 mm  Blank holder travel ±0.02 mm  Forming precision up to 300 mm  Drawing depths

The new 911 Carrera – Body manufacturing in Zuffenhausen Zuffenhausen,1963 Zuffenhausen, 2018

Karosseriebau Zuffenhausen

The new 911 Carrera – Flexible body manufacturing over four storeys 2nd Upper level Front lid Structure Doors Body Rear lid 1st Upper level Side panels Roof frame Platform Body Ground level Front body Middle floor Rear body Platform Basement 911 Taycan

The new 911 Carrera – Flexible and innovative production systems technology Flexibility  Shared body manufacturing for 911, 718 and Taycan  Up to nine side body variants Innovation  Energy and control technology  Human-robot collaboration  Digital planning tools Automation  280 robots  404 m travel axis  approx. 1,000 system components Conveyor  2,200 m skid conveyor technology technology  1,500 m overhead conveyor technology  1,800 m chain conveyor technology

The new 911 Carrera – Porsche Group Framer Flexibility  Shared production line for 911 and 718  Up to nine plus two side panel variants Innovation  Implementation of highly flexible framer concept in compact construction  Automated part feed in “wild mix”  Clamping frame transport Automation by framer portal  Camera-guided roll hemming  Variant changeover: no cycle time loss Production area  Structures 1 and 2

The new 911 Carrera – Flexible side panel manufacturing Flexibility  Shared manufacturing island for exterior side panel of 911 and 718  Flexibility for seven plus two side panel variants Innovation  Use of storage and retrieval machine with 18 spaces (cycle time neutral) for provision of tools  Automated part feed in “wild mix” Automation  Fully automated changeover of tools  Automated process monitoring (with cameras) of derivative-specific parts Production area  Exterior side panel

The new 911 Carrera – Human-robot collaboration (MRK)  Use of innovative technologies in Flexibility production applications  Ergonomic work processes  Working without safety fence Innovation  Human-robot collaboration  “Grab in the box”  Flexible component feed Automation  Heavy-duty robot with capacitive skin  Driverless transport system (FTS) for flexible changeover of load carriers Production area  Rear body

The new 911 Carrera – Management architecture Customer orders  All data is saved 0 1 0 1 1 0 from the first 1 1 0 0 1 1 production step Order sequence 0 0 1 0 0 1 1 1 1 1 0 0  Quality data, measurements 1 1 0 Formulation 1 0 1 and information on joints are 0 1 0 0 1 1 available throughout the 1 1 0 Production control 0 0 1 Shop floor process chain. Production orders 1 0 1 0 1 1 Physical production 1 0 0  This database assures that 1 1 0 1 0 1 high Porsche quality 0 1 0 0 0 1 1 2 3 requirements are fulfilled at 1 1 0 0 1 1 all times 1 0 0 Vehicle configuration 0 0 1 1 0 1 document 0 1 0 1 1 0 Quality data 1 1 0 0 1 1 0 0 1 0 1 1 Systems messages 1 1 1 1 0 0 1 0 1 1 0 1 Fault messages 0 1 0 1 0 0 1 0 0