German OEM Audi has officially initiated series production of electric motors for the e-tron in Gyor, Hungary. The electric motors are being produced on a floor space of 8,500m² using a modular production method.
“Our Hungarian subsidiary is now entering a completely new field of expertise with the production of electric motors,” said Peter Kössler, board member for Production and Logistics at Audi. “This exclusive know‑how makes Gyor our main plant for electric motors and embodies our strategic transformation into a provider of sustainable mobility.”
For the production of electric motors, the Audi Hungaria facility installed the innovative production equipment and islands within just one year. The departments for the development of electric motors and for production planning cooperated closely with the prototype manufacturing/ production technology center in Gyor to develop the required expertise.
The current production capacity is estimated to be 400 electric axle motors each day and can be gradually increased. At present, about 100 people are employed in this new area, to be increased to more than 130 by the end of the year.
The electric motor offers numerous new features. With the stator – one of the core components of the motor – the aim is to insert as much of the thin enameled copper wire as possible into the casing: the tighter the winding, the more efficient the power delivery. A new winding and inserting center at Audi Hungaria makes it possible to wind the optimal amount of enameled copper wire particularly compactly and then insert it into the casing.
The electric axle consists of other large components such as the power electronics, which are located in their own housing, the gearing and two flange shafts that transmit the power to the wheels. Employees produce two electric axle drive systems for each Audi e-tron, as both the front and rear axles are driven.
The production equipment, the robots and the bolting and measuring station are set out in fixed positions but are not linked together by a linear band. Instead, the employees produce the drive systems according to a modular method in production islands.
Despite a predefined assembly sequence, the modular system allows branched paths and more free scope in the production process. Driverless vehicles, controlled by an intelligent IT system, transports parts to the workstations.
In parallel to the production facility, Audi Hungaria has installed three test benches for electric motors in the engine/motor development department for testing and continuous load operation. Facility staff have undergone further training to become electrical experts in the production of electric motors.