From what I have seen of the Austin and Berlin construction so far casting machines are in rows, with overhead bridge cranes.
My understanding of the patent was that casting machines would need to be at right angles?
The patent and Jerome's comments do imply what you stated, but perhaps that is a future development, not Berlin phase 1,
Berlin has 8 Gigapresses, previously I was using a Wikipedia run rate of 90 seconds per cycle.
However, recent live video at Fremont shows a 3 minute cycle, there are 3 possibilities:-
- Wikipedia was just plain wrong.
- As machines get bigger cycle-time increases
- Fremont was not cranked up to max speed.
My first question on Berlin was:- Are they doing 2 or 4 castings per car?
IMO using 4 machines to produce 4 castings, which are then joined, gains most of the benefits of using 4 machines to produce a single cast body.
My solution would be 2 new castings:-
- front top - including A-Pillar and roof rail, looping back to B-Pillar
- rear top - including C-Pillar and roof rail, looping forward to B-Pillar
Add a structure to link B-Pillar to the structural pack, add on stamped side body panel, that is essentially the car body built.
With 8 casting machines, 4 castings per car and a 3 minute cycle time that is around 1,000 car bodies per day.
Casting probably determines the run rate regardless of any downstream processes.
Using 4 machines to cast the while body is the same run rate 1,000 bodies per day, but a single machine needing maintenance halves the run rate. Using 4 castings per car and bridge cranes, they can juggle around molds to keep the run rate up, especially if they have a stockpile of already cast sections..
We will have to see what pans out, I agree a single whole body casting at Berlin is possible, a body made from 4 joined castings is also possible,