Porsche Cayenne Electric Undergoes Rigorous Real-World and Virtual Testing

Porsche is pushing the boundaries of vehicle development with the upcoming Cayenne Electric, integrating advanced digital simulations with extensive real-world testing. This innovative approach aims to accelerate the development process and enhance precision, with the all-electric SUV slated for unveiling later this year.

Key Takeaways

• Porsche's new Cayenne Electric leverages virtual testing to replace a significant portion of physical prototypes, streamlining development.

• A state-of-the-art composite test bench simulates extreme conditions, validating digital models with physical components.

• The development timeline for the Cayenne Electric has been reduced by 20% compared to conventional methods.

Digital Transformation in Vehicle Development

Porsche is pioneering a new development methodology for the Cayenne Electric, moving directly from digital whole-vehicle testing to pre-series production. This strategy has largely replaced the need for approximately 120 time-consuming physical prototypes with digital equivalents. Engineers utilized virtual prototypes for digital test drives during the design phase, significantly shortening the testing cycle.

Advanced Simulation and Testing Infrastructure

The testing process is built on three core pillars: precisely digitized routes, the extensive experience of Weissach engineers, and enhanced computing power for real-time simulations. This allows engineers to not only visualize the Cayenne virtually but also to test it directly within a digital environment. Initial component tests were conducted using virtual reality (VR), with results later verified on physical components via a newly developed composite test bench. This bench can simulate various road conditions, acceleration resistance, and recuperation forces, even replicating different asphalt surfaces and tire slip.

Testing at the Limit and Extreme Conditions

Porsche's test programs are exceptionally demanding, including simulating a Nürburgring-Nordschleife lap at the limit. The data from virtual prototypes is fed into the composite test bench in real-time, ensuring the vehicle consistently delivers maximum power. This rigorous testing extends to extreme climatic conditions, with vehicles tested in scorching heat (up to 50 degrees Celsius) in regions like the Gulf States and Death Valley, and in freezing temperatures (down to minus 35 degrees Celsius) in Scandinavia. These tests focus on thermal management, charging capabilities, traction, handling, and braking performance.

Efficiency and Precision Gains

This integrated approach of digital preparation and real-world validation is proving highly effective across all testing areas, leading to a more precise and efficient development process. Porsche reports a 20% reduction in the development timeline for the Cayenne Electric compared to traditional strategies, alongside reduced material consumption, making the process more resource-efficient.

Embracing Electromobility

The development of the Cayenne Electric is part of Porsche's broader commitment to electromobility. The Volkswagen Group is actively promoting this transition through cross-brand communication campaigns, highlighting advancements in electric vehicle technology.