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How to check cars Porsche — report ZR

A premium car must not only go perfectly and to look cool, but not break. How do manufacturers? In Leipzig, the Porsche factory Maxim Sachkov learned some of the secrets.

The perfect body of the Panamera, which is cubing. Try to layout the parts to eliminate defects before they reach production vehicles. Sometimes fine-tuning and the search for compromise solutions leaving to one and a half years and more than ten times modify the design of one element.The perfect body of the Panamera, which is cubing. Try to layout the parts to eliminate defects before they reach production vehicles. Sometimes fine-tuning and the search for compromise solutions leaving to one and a half years and more than ten times modify the design of one element.

Surprises I did not expect, because he was at the plant in 2014, when it launched production of the Macan crossover — it was the third Porsche model (after the Cayenne and Panamera), which is collected in Leipzig. At the time, I carried around the plant, showed a testing ground and even gave a try a few laps on the factory ground on Makana. Interestingly, however, this level of movies “to unload the head” — I looked once and don’t want to. But it turned out that I was watching a stripped-down version. After all, not so long ago, here has opened a centre of quality management. And this is interesting!

A guide volunteered Dr. Andreas Schmidt is Director of the center and former head of the Dresden “Glass factory” of Volkswagen. He explained to me, what is your need to have filled six thousand square meters of expensive equipment and scored highly skilled professionals:

— Production volumes are growing, cars are becoming more complex, and it does not help to improve the reliability. So we opened this centre.

To replace the line

Measurement laboratory — the heart of the new center. In the adjacent premises located logistics services and pilot production, where daily produce two prototype, which is still at the stage of flight tests reveal shortcomings. Until the car went into production, eliminate errors easier, cheaper and faster. And most importantly: they will never find buyers.

Before the start of serial production of all of the collected body primeryayut and compared with a reference computer model. The deviation of half a millimeter — is marriage.Before the start of serial production of all of the collected body primeryayut and compared with a reference computer model. The deviation of half a millimeter — is marriage.

But got in the pipeline model is not left alone. All vehicles undergo a test drive on the factory track. Every tenth car arrange a more thorough test of diagnostic equipment. In addition, daily one off the conveyor car is stripped down to the cog and considered almost under the microscope — to early detect failures in the process and not to allow the mass marriage.

For example, at one of the stands primeryayut control points of the body due to wear of the dies, they can “float away”. Ultra-precise measuring equipment in the automatic mode scans the entire vehicle, compares the received data with three-dimensional computer model and gives a conclusion. It remains only to transfer the information to the appropriate Department — if necessary, replace the stamp or reconfigured equipment.

The old-fashioned places on the details that need attention, noted by the markers. Appropriate comments are entered in a separate Protocol.The old-fashioned places on the details that need attention, noted by the markers. Appropriate comments are entered in a separate Protocol.

Next to it, the towering aluminum the layout of the Panamera. On all sizes it exactly matches the design data, all the mounting points on the zero position. In General, the ideal body type. To establish various components that Porsche produced for third parties: lighting, interior elements, buttons and switches, actuators. Very similar to meccano. This process is called Bubinga (eng. cubing — stacking). Try to body components are checked for compliance with geometric parameters, functional parameters, esthetic criteria. To get the maximum information, the layout of the electrified — you can light up the backlight in the cabin, turn on the headlamps and flashlights to nominate a spoiler. Then check whether the tactile sensation to be expected — pleasant to the touch the steering wheel or the selector machine, as snap switches and buttons.

A complex acoustic system is similar to a hedgehog, it picks up all the sound vibrations in the car. A computer program processes the results and indicates the sources of noise and vibration.A complex acoustic system is similar to a hedgehog, it picks up all the sound vibrations in the car. A computer program processes the results and indicates the sources of noise and vibration.

Prints

Porsche is testing eleven new stands and systems for quality control of parts and assemblies. One such innovative technology called “optical fingerprint”. Initially this project was developed for the insurance company to assess the damage to the vehicles affected by hail. In Porsche decided to adapt the technology for themselves. In lighting the cockpit of the car from all sides illuminate at certain angles in different light sources, thus identifying deviations from the norm. After processing, the program “imposes” information about the defect directly into detail: specifies the location, size and type — a violation of varnish, bad fit of parts or the shade. This “fingerprint” will help to quickly eliminate the shortcomings.

The technology of the near future based on augmented reality. All technical documentation will be attached to the part. Thus it is possible to quickly detect an error, indicate the discrepancy between the required parameters and, if necessary, immediately send the information to all involved in the final design engineers and companies.The technology of the near future based on augmented reality. All technical documentation will be attached to the part. Thus it is possible to quickly detect an error, indicate the discrepancy between the required parameters and, if necessary, immediately send the information to all involved in the final design engineers and companies.

Other equipment enables you to take acoustic “fingerprint”. In the head of the driver fix installation, fixing noises and vibrations at different points of the salon. By itself, the measuring instrument is not new, these “balls” used by many manufacturers during the development and debugging of machinery. Know-how includes hardware and software, which processes remove the signals. The display shows a panoramic picture of the interior with colorful spots: blue indicates minimal deviation from the norm, yellow — critical, red — that the source of the noise should be eliminated.

The results of removing the “fingerprints” may be displayed on the computer monitor or the tablet producers and technologists either be projected directly on the body of the car, pointing to a place that needs work.The results of removing the “fingerprints” may be displayed on the computer monitor or the tablet producers and technologists either be projected directly on the body of the car, pointing to a place that needs work.

Before the visit to the factory in Leipzig my idea of quality control was limited to a minimum set of tools: eyes and ears of an expert to handle the Protocol. But as it turned out, and this trend is long out of the stone age — there is something to see and something to tell.

How to check cars Porsche — report ZR

Photo: Porsche

How to check cars Porsche — report ZR

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