When it comes to car production, Porsche is using robots to help build its cars, particularly in the assembly of rear axles. The company’s Leipzig plant, where the Macan and Panamera are produced, utilizes robots for checking the rear axle assembly, while still maintaining a human touch.
Rear axles are complex components that play a significant role in driving comfort and performance. Porsche notes they are one of the most complex assemblies in their cars. The type of complexity varies depending on whether the axle is passive, as in front-wheel drive, or ‘live’, as in rear-wheel or four-wheel drive.
The company has developed an ‘automated end-of-line inspection’ system, which combines human expertise with robot assistance. Robots handle the repetitive inspection tasks, scanning the entire axle assembly, identifying connectors, measuring distances, and checking components are installed correctly based on stored information.
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Each inspection point is photographed and analyzed, and the image data stored for three years. This allows Porsche to check the condition of the axle at the time of its production if anything goes wrong. The effectiveness of such validation work during the manufacture of a new car will have a bearing on how reliable it’s going to be.
The system was developed during series production, and each inspection point was deliberately “manipulated” to ensure faults would be corrected and the number of false alarms reduced. If the image processing system incorrectly flags an error, the system is fine-tuned to make sure it doesn’t happen again.
Despite the march of AI, Porsche still considers humans indispensable in this role. Human technicians work in sync with the robots and perform the jobs that require experience and human sensitivity. Not everything can be checked visually, and, for example, the robotic system is unable to pick up a rubbing noise from a brake disc.
Although much of car production is automated, there are some aspects of a new car for which only a good old-fashioned ‘spanner check’ will do. This highlights the importance of human involvement in the production process, even as technology continues to advance.
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In the context of the automotive industry, the use of robots in car production is not new, dating back to the early 1970s. However, Porsche‘s approach to combining human expertise with robot assistance is notable. By leveraging the strengths of both humans and robots, the company can ensure the quality and reliability of its vehicles.
The quality control process is a key part of ensuring the reliability of Porsche‘s cars. They use robots and human technicians to identify and correct faults during the production process. This, in turn, can help to reduce the number of issues that may arise after the car has been sold.
It is notable that Porsche is striking a balance between technology and human expertise. As the automotive industry continues to evolve, other manufacturers will likely approach the use of robots and human technicians in their production processes in a similar manner.