- Tram Ho
CEO Elon Musk understands that in order to win against the competition in electric cars, battery technology and self-driving mode are not enough, but superior manufacturing technology is required. That is why he has equipped his factory with the latest industrial robots – this is also the reason for the delay in orders when Tesla transforms the way cars are built.
But even these amazing robots have failed to meet Musk’s expectations when, according to a recent Reuters report, in Tesla’s new super plant in Berlin, the company has eliminated hundreds of robots to prepare for a “revolution in body engineering” when making Tesla Model Y in Germany – something Musk said earlier this September.
More specifically, the replacement for these modern robots will be a fairly classic manufacturing method: Casting – or more precisely, Die-casting.
The orange part is the rear part of the Model Y that will be produced by molding method instead of using a robot as is usual.
As Elon Musk explained on the “Third Row Tesla Podcast” podcast, the car’s rear end ” is essentially just two large, high-pressure cast aluminum panels attached to each other and with it a bunch of other things. is attached to “(the orange part in the picture above). Attaching these two large aluminum plates together, although supported by modern robots, is still a very time consuming process.
That’s because the contact surfaces between these two aluminum castings need to be CNC machined in order to be correctly joined, and the ” other things attached ” that Musk said are about 70 other components. each other is glued together with glue or spliced with studs.
This is why Tesla chose to manufacture molds for the rear of the car. It will be molded into a single piece attached to the car’s rear bearing frame, instead of being assembled from two pieces together as before.
The Giga Press is about to be used in the production of the Model Y
According to a report from Automotive Engineering, the machine used to cast this part was once considered by Musk as ” the largest die casting machine in the world “: a “Giga Press” high-pressure molding machine with a size equal to the whole house was made by Italian high-pressure molding equipment manufacturer, IDRA Group.
Each of these machines weighs more than 400 tons and each time, about 80 kg of molten aluminum will be pumped into the cold casting chamber at a rate of 10m / per second. As stated by IDRA Group, Tesla has been ordering the machines from June 2020.
Parts molding significantly shortens the production time and cost of each Tesla car. Instead of spending a lot of time and money on the production and pairing of these two aluminum sheets, with the giant machine above, this part will form after just one casting. The approach will also help reduce unnecessary weight of the chassis, making the Model Y lighter and more energy efficient.
According to a source from Tesmanian, a Tesla fan blog, Musk has ordered these eight Giga Press machines for Tesla’s new super plant in Berlin. Electrek news outlet reports in late August also showed that Tesla had begun installing the machine at its plant in Fremont, California.
The image of the Giga Press machine is being delivered to the Tesla factory in Fremont, California.
But it is possible that casting the car’s rear chassis is just the beginning of the automotive body engineering revolution that Musk is talking about. According to a recent Tesla patent, the company is developing a molding system for the entire body of a car by using many of the giant machines mentioned above to create an entire chassis in one go. – If you can cast the rear part of the car, why can’t you cast the whole car?
If that turns out to be true, Tesla’s production rate will reach a real leap that even automakers with decades of experience will hardly keep up with.
Refer to Core77
Source : Genk