Fender-Mounting with FDS

Technology and Examples of FDS-Application at Audi AG

PWT/VFT Material and Production

Technology
 Technology Project “Flow Drilling for Fender Mounting":
Description

Process description:

Forming
Heating Plasticizing Forming screw Tightening
thread

Fender Outside One sided access for joining

Fender

Current mounting system with FDS mounting system,

weld nut, screw and washer only a screw is required

Screw Side-Member
+
FDS
Weldnut Fender Inside Adjustment is possible
(or Drilling)
2
 Equipment for Screwing

Screw gun with feeding system

Revolution: 5000 rpm
Weight: 15 kg

3
Typical Screw curve

Screw: FDS M5x18

Material: Side member: DC04 1.5mm – Fender DC04 1.0 mm

Schraubkurve

8 6000

7
5000

4000
5

U in min-1
Drehmoment
M in Nm
F in kN

4 3000 Kraft
Soll-Drehzahl
3
2000

1000
1

0 0
0 200 400 600 800 1000 1200 1400 1600 1800
Zeit in ms

4
FDS-Application Audi AG

Audi A4
Joining wheel-house-half with FDS at Audi A4

FDS-Screws Description:
Automated screwing of the two wheelhouse-
Glue halves on Audi A4 Typ 8E in combination with
gluing.
Screws: 2x4 (right and left)
Volume: up to 320.000 per year
Production time: from 10/2000 until now
Production location: Ingolstadt Germany

System integrator:
Mr. Hornborstel Audi AG Germany Neckarsulm
Phone: 049 7132 31 1107
049 07132 31 72574
5
FDS-Application Audi AG

Audi A6

Automatic Screwing in longitudinal

member at Audi A6
Description: joining reinforcing panel of
wheelhouse on longitudinal member
with 2 FDS screws on both sides.

Volume: about 200000 per year

Production time: from 2004 until now
Production location: Neckarsulm
Germany

System integrator:
Mr. Hornborstel Audi AG Germany Neckarsulm
Phone: 049 7132 31 1107
049 07132 31 72574 6
FDS-Application Audi AG

Lamborghini Gallardo

Automatic Screwing of Floor

Panel at Lamborghini Gallardo
Description: Joining floor panels
on Aluminum space-frame with
108 Screws
Volume: about 1.500 cars per
year
Production time: from 1.Quarter
2003 until now
Production location: Thyssen-
Krupp Drauz GmbH
Heilbronn Germany
System integrator:
Mr. Hornborstel Audi AG Germany Neckarsulm
Phone: 049 7132 31 1107
049 07132 31 72574 7
Further Application

 Audi TT (next model): joining aluminum-profiles (similar

Lamborghini) Location: Ingolstadt
 Audi A8: Joining sheet steel on aluminum side member (6
screws)
 Opel Speedster, Lotus Elise, Opel- Vectra Astra- and
Corsa (plastic fuel pipe clamp on steel floor panel)

8
Repair concept

 For repair it can use a normally metric screw or the same

FDS-screw.
 If the thread is damaged, the next size of self tapping
screws can be used.
Note: Audi used the same methods