Volkswagen’s improvement in power steering production

While most of Volkswagen’s successful projects remain hidden to outside observers, there is one that is worth mentioning.

By simulating with CENOS engineers in Volkswagen reduced the induction heating time for the assembly of the power steering rack by a factor of five – from 9 seconds to 2 seconds. As a result, the productivity of the production line for power steering components is now almost 5 times higher.

Let’s begin with the challenge

Normally, it took 9 seconds to heat up the power steering rack with a process of induction heating. This might seem fast, but in car making, every second that can be saved is crucial for staying ahead.

In Braunschweig, Germany, Marcel Ruthmann, a dedicated engineer at Volkswagen Group Services, teamed up with Fabian Bauer from Volkswagen in Wolfsburg. They were set on making a big improvement in how car parts are made, focusing on the power steering rack, which is a key piece of the car.

The solution

Marcel and Fabian used CENOS simulation software. This tool lets engineers try out ideas on a computer before doing them in real life. This saves time, money, and materials because they can see what works best without any waste.

By using the software to test and adjust their ideas, they managed to cut down the heating time dramatically. To be precise, from 9 seconds to just 2 seconds. This wasn’t just a small improvement. It multiplied the speed of their production line by nearly five times.

In technical terms, Marcel and Fabian used the software to fine-tune parameters like the coil design and the power output of the induction heater. They ran simulations to see how changes in these areas could improve heat distribution and reduce heating time. Their success came from pinpointing the optimal settings that maximized efficiency while maintaining product quality.

In conclusion

This improvement is very important for Volkswagen and for any engineer or manufacturing manager who wants to speed up production without sacrificing quality. Marcel and Fabian’s work shows how integrating advanced simulation technology can lead to huge gains in manufacturing processes.

Volkswagen’s innovative use of simulation technology in their production lines shows that by using the right tools, big challenges in production can be turned into opportunities for improvement and leadership in efficiency.

Marcel and Fabian’s project at Volkswagen is a clear example of how creativity and technology can come together to make significant improvements in the automotive industry. It’s an inspiring story for engineers everywhere, showing that with the right approach, even the most routine processes can be transformed to set new standards in efficiency.