Through the all-new electric Cayenne Electric, Porsche demonstrates how digital development and engineering expertise are revolutionizing vehicle creation.
It’s the first project developed virtually from whole-vehicle testing through pre-series production. Before, the construction stage of testing required about 120 individually built prototypes, a process that consumed a significant amount of time. In the making of the Cayenne Electric, these were replaced by digital counterparts. Beginning in the design phase, engineers were able to send these virtual prototypes on digital test drives.
Cutting-Edge Virtual Simulation & Test Bench Validation
With the rapid advancement of AI and simulation, vehicle testing has been greatly shortened.
Porsche’s capability to not only visualize the Cayenne virtually but also to conduct direct digital simulation was based on three important pillars: accurately digitized routes ranging from the Nürburgring to standard traffic scenarios and road conditions; the unmatched expertise of Weissach engineers from field testing; and the elevated computing capacity of modern systems for real-time simulations.
Engineers were able to modify the digital forms easily in the development process, then used virtual reality (VR) to execute initial tests. The outcomes of the digital tests were validated later through a state-of-the-art test bench with actual, physical components. Newly developed for this purpose, the test bench enables integrated testing of the drive, energy management, battery, and charging systems under realistic conditions. The test bench has four powerful synchronous motors, configurable to precisely replicate road and environmental conditions, acceleration resistance, and the forces experienced during braking and energy recuperation. The machines can even show different asphalt surfaces or tire slip.
Refined for Maximum Performance
Porsche’s test programs for the Cayenne were very stringent. This included a lap simulation at the Nürburgring-Nordschleife – at the limit. The input from this test was fed into the composite test bench in real-time, ensuring consistent power delivery, and optimal battery conditioning under all conditions and temperatures. The goal is for the Cayenne to display heating and cooling systems more powerful than in any preceding electric Porsche. At every point during the lap, the values measured on the test bench have been evaluated against the results of the digital counterpart to ensure that there is no discrepancy in the simulation.
Pushing Final Drives to the Extreme
Despite the digital testing advancements, the human factor is still indispensable. During the final drives, the Cayenne Electric was tested in all realistic driving situations in the real world—in the city, on the highway or off-road.
Porsche’s demanding testing included extreme climatic conditions. The vehicles were tested in scorching heat, with temperatures reaching up to 50 degrees Celsius in regions such as the Gulf States and Death Valley in the U.S., and in freezing cold, with temperatures dropping to minus 35 degrees Celsius in Scandinavia.
The tests evaluated fast-charging capabilities, thermal management, handling, traction, and braking performance.
Making the process more efficient, precise, and fast, the combination of digital preparation and real-world testing is proving its value. Compared to the traditional development strategy, the timescale for developing the Cayenne was reduced by 20%. Additionally, material consumption was reduced.
The breakthrough vehicle will be revealed toward the end of the year and will be offered alongside the current combustion-engine and hybrid models.
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