After a $2 billion investment to transform this historic facility, Ford’s Electric Vehicle Center in Cologne is now able to build a Ford Explorer every 54 seconds
The new, purely electric Ford Explorer comes to inaugurate a new era for Ford in Europe, being the first of a series of new EVs coming to the Old Continent to change the data not only with their advanced features, but also with their high environmental performances. It is therefore only natural that such a capable and technologically advanced car as the new Ford Explorer is “born” in one of the most modern, automated and green vehicle manufacturing plants in the world: the new Ford Electric Vehicle Center based in Toilet water.
This particular factory, transformed by a $2 billion investment from Ford, is capable of producing an Explorer every 54 seconds, with a brand new production line, the most advanced battery assembly facilities, and state-of-the-art tooling and automation that overall occupy an area of ​​125 hectares.
Did you know that: Over 18,000,000 Ford vehicles have been built at Ford’s Cologne plant over the past 90 years
The production process of the all-new, all-electric Ford Explorer in Cologne begins with automated guided vehicles transporting various materials and finished parts to the plant’s workstations. In order to ensure the highest levels of quality and precision in manufacturing, Ford has created a specially designed enclosed space in which the laser welding of the car’s roof to the main body is completed with the help of Artificial Intelligence (AI). In this department, a multitude of robots take on tasks for everything – from picking and placing individual parts, to transporting large sheets of metal.
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Did you know that: Over 600 choreographed robots work together to build each new Explorer
The Ford Electric Vehicle Center Cologne is also equipped with a mobile robotic system with cameras, powered by Artificial Intelligence to scan the body of each new car and detect any deviations, while at least 1 to 2 vehicles are randomly selected each day from production line in order to be scrutinized. At the same time, a high-precision measurement system that is also based on Artificial Intelligence and features a photonic crystal fiber sensor, checks key points of the vehicle.
Did you know that: One of the main pillars at the Ford Electric Vehicle Center in Cologne is the philosophy of “closed-loop production”, which is a continuous process of exchanging elements and data at all stages, with the aim of enabling rapid adaptations.
The paint shop is another technological jewel of the new Ford Electric Vehicle Center. Here the body of the new Ford Explorer is moved by dipping to ensure the necessary anti-rust protection and rotated 360 degrees within each ‘bath’ to prevent air bubbles. At this stage, the distilled water used is continuously filtered and then reused.
Did you know that: In the paint shop, the savings achieved in terms of CO2 emissions reach up to 1,000 tons
During the final assembly process, a new AI system with cameras checks all electrical connections, while a laser scanner scans for any unwanted particles before the high-voltage lithium-ion battery becomes one with the body of every new Ford Explorer. Then, immediately after the construction is completed, each vehicle undergoes a final quality control on all its individual components, as well as on all its surfaces, using a series of advanced scanners, but also with the help of the factory’s specialized staff .
Did you know that: All checks of the electrical connections to the battery are carried out with the help of Artificial Intelligence systems
Throughout the production process, the “digital twin” system acts as the central nervous system of the factory, using data to monitor the quantity of parts and the efficiency of each process in real time, as well as to control workload and forecast maintenance work. Everything is controlled via a central touch screen, which offers the ability to zoom into any workstation, as well as icons that provide current information about tools and equipment, material delivery, work safety, ergonomics and more.
Did you know that: The central control panel that depicts in every detail the production line of the new Ford Explorer has a total area of ​​25 sq.m.
See in the video below the choreography of the advanced robots and systems with the help of which the new Ford Explorer is manufactured at the Ford Electric Vehicle Center in Cologne.
Source: Skai
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