Germany Volkswagen Group launched the industry 4.0 model, 30,000 robots can build a car in 50 seconds

[Introduction]: Using a machine to build a car can save a lot of human capital, and it is not harmful to the car factory. The world-renowned automobile group Volkswagen Group started its own industry 4.0 era, and 30,000 robots can build cars in 50 seconds.

A small robot "squeaked" the crisp light music and passed it "lightly" from the workers on the spot, smoothly transporting several auto parts to the next station. This is not the future scene portrayed by the famous science fiction writer Isaac Asimov. The reporter’s real-life production method based on Industry 4.0 when he visited the Volkswagen factory in Bratislava, Slovakia. Here, from the Volkswagen Touareg, the Audi A8 to the production of the Porsche Cayenne, there are robots involved in it.

Volkswagen's Industry 4.0 trial

In the 2017 Fortune Global 500 list, Volkswagen ranked sixth. At present, Volkswagen Group has 12 brands including Volkswagen, Audi, Porsche, Lamborghini, Bentley and Mann. It has 120 factories, more than 620,000 employees and more than 10 million vehicles. Although it experienced the "diesel door" storm before, the Volkswagen Group did not count special project expenditures in 2016, and the group's profit reached 14.6 billion euros, a record. The public is still a "aircraft carrier" for the global automotive industry.

However, in the face of fierce competition in the automotive industry, especially from the serious challenges of digital, autonomous driving and electric vehicles, this "aircraft carrier" is also seeking active change. According to the public's latest plan for journalists: By 2025, all production facilities of the Volkswagen Group, including production plants in China, will achieve digital planning and seamless network switching to ensure self-control, self-optimization and sustainability. Production.

“Technically, digitalization involves many technologies, such as cognitive computing and learning, artificial intelligence, mastery of new skills and technologies, and processes related to machine self-optimization and self-learning.” Volkswagen Group Management Board Member, Volkswagen China President and CEO Heizman said in an interview with reporters at Wolfsburg headquarters. Digitization is a general concept, going deeper, that is, the digitization of the entire production process, and the elements related to "Industry 4.0."

In Hezman's view, "Industry 4.0" is a very integrated concept. Under this concept, digital, robotic and artificial intelligence are included, and these are being integrated into all aspects of the day-to-day business operations of the Volkswagen Group.

The 4.0 in the production process is subordinate to the overall concept of “Industry 4.0”, and the concept of “Industry 4.0” includes Production 4.0. Production 4.0 From the beginning of R&D to every aspect of design and production, it includes digital management tools, digital technology and the application of automated processes.

Production 4.0 or Industrial 4.0 is a digital process that runs through the entire enterprise operation and production process: such as VR (Virtual Reality) technology, smart devices, some applications of wearable devices, and some 3D The application of printing technology. In addition, there are special application areas such as automatic transportation in logistics, logistics process management with artificial intelligence, maintenance of production equipment, maximization of the entire production process and so on.

The so-called Industry 4.0 or Production 4.0 concept is not limited to the production flexibility, but also in the aspects of product development, production, logistics, sales and after-sales service, and customer experience improvement, optimization and improvement. Industry 4.0 is closely related. "Some technologies have to be taken step by step, and it is impossible to achieve overnight and overnight. It takes time."

30,000 industrial robots

At the corner of the Volkswagen workshop assembly line in Wolfsburg, where the Volkswagen Group is headquartered, a first-line German female worker and her workers are busy installing the internal components of the car, such as dashboards, and she is busy with her and a huge robot around her. Hands and robots are familiar with the road and reach into the window. In just a few minutes, the instrument panel is installed in a cloud-like manner. Here, with the help of robots, workers can stop to listen to music, relax themselves, and even talk to reporters for a while.

Different from the space where machines and people are separated from each other, it is no longer a luxury for intelligent robots to realize direct cooperation between humans and machines. The reason behind this is that robots can respond to every gesture of human beings. The intelligent production laboratory of the IT department at the Volkswagen Group headquarters is developing solutions for future automotive production. One of the projects is the intelligent robot. For the first time, humans and machines will really work together. The reason for this is that robots have the ability to recognize and consider human thoughts.

Dr. Wolfgang Hackenberg, director of the Intelligent Production Laboratory of the Group's IT department, is leading his team with experts from the renowned Artificial Intelligence Research Center, the German Centre for Artificial Intelligence (DFKI). Together we develop this technology.

Dr. Hackenberg explained to reporters that before this, the working steps or working spaces of humans and robots must be separated and independent, which is not a true cooperation. In the intelligent production laboratory, the situation is completely different. “We integrate robots and sensors through software, enabling humans and robots to avoid danger, work in the same space, and even collaborate with each other. So, for the first time, we have achieved direct collaboration between humans and machines.”

In addition, the use of ergonomic principles to improve the physical fitness of human beings is also expected to be overcome. For industrial robots, this means huge energy savings potential. Dr. Dieter Geckler, a member of the Volkswagen Group's Digital Factory Working Group and head of the energy efficiency team, told reporters: "In order to save energy, weightlifters change their feet. The way to find the ideal balance before starting weightlifting. Like the weightlifter, the robot can save a lot of energy if it is in the right position."

But this easy-to-use software is not the final product, location optimization is only the first step, and the team is currently researching robot path optimization to save more energy. This step will calculate the most energy efficient action of the robot. The third and final step is that the software will be able to optimize the acceleration and speed of the robot. This optimization software optimizes the robot's position, path and speed and will save up to 30% of energy and is expected to be operational in 2018.

Volkswagen factory

At Volkswagen's Slovak factory, it currently takes only 2.5 minutes to produce 3 cars, which means that the production time of each car is 0.83 minutes, about 50 seconds. Producing cars in seconds, really entering the second-speed car phase. However, from the perspective of the public, this efficiency is still not enough. Their ultimate goal is to achieve complete autonomous production. The so-called independent production does not mean that human beings are not needed at all, but people tell what needs to be produced, and then by the factory. The robots are combined into a production line for production.

According to the public's vision, there are at least two key points to achieve this kind of independent production: First, the production robot can move by itself. The second is a central nervous system based on big data and AI processing techniques.

In the Volkswagen SPL intelligent production laboratory, the reporter saw the prototype of these two technologies. The self-propelled robot is a small car with two robotic arms that use the lidar and 3D depth camera to achieve positioning and navigation functions, allowing it to move around the factory. The latter is a super system that tracks all production data. It analyzes which robots and components are needed to produce each model, and then automatically deploys robots and components according to production tasks. More importantly, through manual labor. The introduction of intelligence and other technologies, in the process of organizing the production process, can also learn independently, so as to continuously optimize the production process in the next production, and further improve production efficiency.

In the car assembly line, a worker and a robot sit in the body to complete the various operations required for assembly. The production system is operated by a number of social machines, automatically connected to the "cloud" platform, looking for experts who can solve different problems. Experts hold a full range of maintenance techniques and virtual tools. The robot automatically integrates all the information to continuously improve its performance. The above scenario is a similar hard sci-fi future automotive industry production scenario described in Roland Berger's 2016 report, and some of it has now been implemented at Volkswagen's factory.

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