Porsche: Electric Macan ready for the road
FIRST VIRTUAL, THEN REAL After initial test drives on the proving ground at the Porsche Development Center in Weissach, the well-camouflaged prototypes of the next generation of the compact SUV leave the factory premises for the first time. By the time the all-electric Macan is launched on the market in 2023, around three million test kilometers will have been completed worldwide under various conditions. The prototypes already incorporate the experience gained from countless [...]
By the time the all-electric Macan is launched on the market in 2023, around three million test kilometers will have been completed worldwide under various conditions. The prototypes already incorporate the experience gained from countless test kilometers - driven in virtual space.
Cost-saving and resource-saving
Instead of real vehicles, the engineers use digital prototypes. These are computational models that reproduce a vehicle's properties, systems and assemblies with a high degree of accuracy.
There are 20 digital prototypes for simulations in the various development categories such as aerodynamics, energy management, operation or acoustics.
It started with a flow around model
Among the first engineers to work with a digital prototype are the aerodynamics specialists. According to Dr. Thomas Wiegand, head of aerodynamics development, they already started with a flow-around model when the project was launched around four years ago.
With a view to a long range, low aerodynamic drag is elementary for the all-electric Macan. Even small improvements in the flow can have a big impact.
The engineers are currently still fine-tuning detailed solutions such as the cooling air ducts with the help of the simulation. The calculations not only take into account various component arrangements, but also the temperature differences that occur in reality.
Virtual tests with new display and operating system
New methods now allow very precise simulation of aero- and thermodynamics. While a temperature window of 90 to 120 degrees is the target for combustion engines, electric drives, power electronics and the high-voltage battery require a range between 20 and 70 degrees, depending on the component.
The critical scenarios do not occur while driving, but during fast charging with high power at high outside temperatures. However, the Porsche developers can precisely calculate and digitally optimize position, flows, and temperatures.
New display and operating concept
Virtual prototypes can be combined with the real world at an early stage. The best example: the development of a completely new display and operating concept for the next Macan generation.
By using a so-called seat box, which represents the driver's environment, the display and operating concept can be made tangible in an early development phase in conjunction with the digital prototype.
The "test drivers" are not only the experts themselves, but also test subjects from outside the field. In this way, all interactions between driver and vehicle can be examined down to the smallest detail and optimized in a targeted manner, even before the first physical cockpit is created.
Development goal: the sportiest model in its segment
Based on the data obtained, the first physical prototypes of the all-electric Macan were built - in some cases elaborately by hand or with special tools. They are regularly adapted to further virtual development.
Conversely, the findings from road testing flow directly into the digital development process. The demanding test program under climatic and topographical boundary conditions for the all-electric Macan includes disciplines such as charging and conditioning the high-voltage battery. This has to meet high standards. The all-electric Macan is set to be the sportiest model in its segment.
Another Macan with combustion engine
The market launch for the all-electric Macan, which will be the first Porsche to be built on the Premium Platform Electric (PPE), is planned for 2023. Porsche is positioning itself flexibly for the transition to all-electric mobility.
Michael Steiner, Member of the Executive Board for Research and Development at Porsche AG: "In Europe, demand for electric vehicles is rising continuously. However, the pace of development in the world's regions with regard to electromobility varies. We are therefore launching another successor model to the current Macan with conventional drive in the course of 2021."
In the future, the new Macan models with combustion engines will be offered alongside the all-electric Macan. Before the latter is launched on the market, it still has millions of test kilometers to complete - both real and virtual.
