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ŠKODA AUTO has put a new processing line for plasma coating into operation. This technically innovative concept allows conventional cylinder liners to be replaced with a powder coating that measures just 150 μm (0.15 mm). This will now be used when producing the new EVO three-cylinder engines from the EA211 series and will reduce internal friction. As a result, the 1.0 TSI EVO petrol engines will be even more efficient and boast even lower emissions. ŠKODA has invested a total of around 29 million euros in preparing and converting its Mladá Boleslav-based headquarters. 

Christian Bleiel, Head of Component Production at ŠKODA AUTO, highlighted, “The technically highly innovative plasma coating makes our EA211 TSI EVO engines even more efficient. It reduces friction losses and thus also fuel consumption. What’s more, this type of coating also allows heat to be more evenly distributed within the cylinders and helps it to dissipate more efficiently, thus optimising the thermal load. We produce the plasma-coated engines at Mladá Boleslav in three shifts and are installing them in the FABIA, SCALA, OCTAVIA, KAMIQ and KAROQ.” 

This means that the engines featuring plasma coating are also used in the ŠKODA OCTAVIA e-TEC mild hybrids. The Czech car manufacturer has added an assembly line with two special fixtures for plasma coating at its main plant. Both of these include two torches. ŠKODA AUTO has invested a total of 28.8 million euros in upgrading the plant in this way; overall, the carmaker has spent 69.1 million euros on modernising engine production. 

During the production process, the cylinders are first bored on the machining line. A 1,500-watt laser then abrades the cylinder bores to ensure that the plasma layer will optimally adhere to the surface. This involves the laser beam creating ten grooves per millimetre, each measuring an average depth of 40 μm. This production step takes place in a controlled atmosphere filled with nitrogen to keep the laser’s optics free from contamination and to ensure the necessary level of accuracy. 

A mixture of hydrogen and argon is used to create plasma gas, requiring 4.5 l of hydrogen per minute during the process. The plasma reaches a temperature of 15,000° Celsius and is then mixed with various types of steel that have been ground into fine powder. This powder is made up of iron, carbon, silicon and manganese as well as other necessary elements. The individual powder grains measure no more than 50 μm. When sprayed onto the cylinder walls, the molten powder forms a layer measuring approximately 250 μm. During final processing, this layer is honed out, so that it measures just 150 μm. To put all of this in perspective: the wall of a conventional cylinder liner is 4 mm thick. 

Each cylinder is automatically measured at several stages throughout the process to assess its quality. Optical measuring instruments first record the surface abraded by the laser, before a second measurement is taken once the plasma has been applied. Finally, the structure of the plasma layer is tested using turbulent flow.

Article source: www.skoda-auto.com

50 years ago, the legendary ŠKODA 110 R Coupé celebrated its trade fair premiere in Brno. The elegant sports car with a rear engine was a huge sales success and served as the basis for the Czech car manufacturer’s legendary rally and racing cars. Alongside the ŠKODA 180 RS and 200 RS prototypes, the ŠKODA 130 RS, which later became known as the “Porsche of the East”, was also derived from the 110 R.

At the same time as celebrating the 125th anniversary of its founding, ŠKODA AUTO is also looking back in 2020 on the market launch of several models that have played a significant role in the automaker’s history. These vehicles include the 110 R, which added a dynamic sports coupé to ŠKODA’s model range at the beginning of the 1970s. 

In 1964 ŠKODA began producing the ŠKODA 1000 MB notchback saloon. With its self-supporting body, rear engine and rear-wheel drive, this model heralded a new technological era at the Czech car manufacturer. ŠKODA invested heavily in modern production facilities for the new series and soon concentrated fully on the production of this newcomer due to the sales success of the rear engine saloon in export markets. For this reason, ŠKODA discontinued production of the FELICIA convertible. However, demand for sports models remained strong, particularly in Western European markets. ŠKODA responded to its customers’ wishes with a vehicle that would give the brand an image boost despite remaining a niche product in terms of the planned number of units. While the development of the ŠKODA 100/110 L series was underway (the successor to the 1000 MB that received body upgrades, front disc brakes and improved safety equipment), work began on the two-door coupé version ŠKODA 110 R.

Article source: www.skoda-auto.com

The launch of the fourth-generation OCTAVIA sees ŠKODA reach new heights yet again: The brand’s bestseller is even more emotive and offers an even greater level of active and passive safety. Furthermore, it comes with plenty of new assistance systems and advanced infotainment. Available with an efficient petrol or diesel engine, or one of three alternative powertrains, the new-generation OCTAVIA is also significantly more sustainable. The OCTAVIA e-TEC is the first ever ŠKODA to feature mild hybrid technology. The OCTAVIA iV and the sporty OCTAVIA RS iV are modern plug-in hybrids and the OCTAVIA G-TEC is designed to run on eco-friendly natural gas (CNG). Thanks to the three sustainable powertrain variants, the new OCTAVIA’s CO₂ emissions have been considerably reduced.

In its fourth generation, the ŠKODA OCTAVIA is once again available as a hatchback and an estate; a rugged SCOUT and three sporty RS versions have also been added to the line-up. Fitted with a choice of front- or all-wheel drive and manual or automatic DSG transmissions, there is an OCTAVIA to suit every ŠKODA customer.

The fourth generation since the modern-day OCTAVIA’s launch in 1996 will further cement the model line as the brand’s heart and engine as well as its top volume model. With more than seven million produced, the OCTAVIA is the bestselling ŠKODA ever and a real icon in numerous international markets. In addition to its domestic market, the Czech Republic, the OCTAVIA tops the bestseller lists in seven other countries, including Poland, Austria, Switzerland and Finland. In its second-largest sales market, Germany, the OCTAVIA has been the most sought-after import vehicle for years. The OCTAVIA COMBI, Europe’s most popular estate, has played a major part in this. 

ŠKODA manufactures up to 400,000 units of its bestseller each year. The OCTAVIA is the brand’s only model to be made in four different countries: it rolls off production lines in the Czech Republic, China, Russia and India.

The reasons for the OCTAVIA’s success story are obvious: In addition to its ŠKODA-typical generous amounts of space and excellent value for money, the brand’s heart and engine provides an impressive level of safety too – as illustrated by its five-star rating in the Euro NCAP tests. In its fourth generation, the OCTAVIA offers numerous innovative safety and assistance systems. These include Park Assist with Area View whose four cameras create a 360-degree image of the vehicle’s immediate surroundings, Adaptive Lane Assist, which is able to identify roadworks as well as conventional road markings, and the Local Traffic Warning function that automatically warns of traffic hold-ups in the car’s vicinity, such as the end of a traffic jam. For the first time, ŠKODA is offering the new head-up display for the OCTAVIA; this projects information such as the car’s speed, navigation instructions, detected traffic signs and activated driver assistance systems directly onto the windscreen. 

The OCTAVIA offers a choice of three infotainment systems from the latest generation with screens measuring between 8.25 and 10 inches. Thanks to a built-in eSIM, the vehicle is always online – thus enabling the use of new ŠKODA Connect online services.

Three alternative powertrains: plug-in hybrid, mild hybrid and CNG

The three letter combinations – iV, e-TEC and G-TEC – make reference to the wide range of new alternative powertrain variants available for the new ŠKODA OCTAVIA. Both the OCTAVIA iV and OCTAVIA RS iV feature plug-in hybrid drive and provide an all-electric and therefore zero-emission range of up to 60 km in the WLTP cycle. The e-TEC designation is new to ŠKODA and is reserved for cars equipped with mild hybrid technology – another first for the brand. The TSI petrol engines in these models are electrified by a 48-V belt-driven starter motor and a 48-V lithium-ion battery. The OCTAVIA G-TEC primarily uses eco-friendly compressed natural gas (CNG). This type of fuel boasts cleaner combustion, meaning that CO₂ emissions are approximately 25 per cent lower than when running on petrol.

Article source: www.skoda-auto.com

ŠKODA AUTO has manufactured its 13 millionth transmission from the current generation. At present, the Czech carmaker makes MQ/SQ100 and MQ200 gearboxes for Volkswagen Group at its main plant in Mladá Boleslav, whilst the DQ200 direct-shift transmission is built at the Vrchlabí factory. These are fitted in various ŠKODA models as well as vehicles made by other Volkswagen Group brands. 

Michael Oeljeklaus, ŠKODA AUTO Board Member for Production and Logistics, stressed, “Today we have reached the impressive mark of 13 million current-generation gearboxes built. This production milestone is the result of our team’s high level of expertise and formidable team spirit. Due to these strengths, ŠKODA AUTO’s component production has continuously gained in strategic importance and developed into a key pillar of the group’s cross-brand production network.” 

Christian Bleiel, Head of Component Production at ŠKODA AUTO, added, “Our Mladá Boleslav and Vrchlabí plants are among the most modern and efficient production sites in the entire automotive industry. Our gearboxes meet the highest quality requirements. Manufacturing these transmissions using our complex, high-tech equipment requires many years of experience and a high level of skill from the team. Through innovation, continuous optimisation, automation and – most importantly –digitalisation, we are resolutely developing component production at ŠKODA.” 

At present, ŠKODA AUTO makes a total of three types of gearboxes, which are used in ŠKODAs and other Volkswagen Group cars. At its main plant in Mladá Boleslav, ŠKODA has been manufacturing the MQ200 five-speed transmission for vehicles with a 1.0- to 1.6-litre petrol engine since 2000; since 2011, the MQ200 has also existed as a six-speed gearbox. More than 7,590,000 of this transmission type have been built to date since their manufacturing began in 2000. The daily production volume currently amounts to 2,000 gearboxes. 

The MQ100/SQ100 transmissions built in Mladá Boleslav since 2011 were originally designed for ‘New Small Family’ models from Volkswagen Group and were initially fitted in the ŠKODA CITIGO, the VW up! and the Seat Mii. With the exception of the VW up!, these models are now exclusively available with an all-electric powertrain and as a result, the gearboxes are now mainly used in the ŠKODA FABIA and other small Volkswagen Group cars powered by a 1.0-litre petrol engine. In August 2020, the two millionth MQ100/SQ100 transmission left the factory in Mladá Boleslav. 

Since 2012, ŠKODA has also been building the DQ200 automatic 7-speed direct-shift gearbox (DSG) at its component plant in Vrchlabí. At a rate of 2,300 units per day, more than 3,300,000 DQ200s have already been manufactured to date. This transmission is also installed in ŠKODAs as well as cars made by other Group brands. 

In 2019 alone, ŠKODA AUTO built approximately 1,125,200 transmissions; the average daily production volume across all models was around 4,800 units.

Article source: www.skoda-auto.com