Porsche is combining advanced simulation technologies with extensive engineering expertise to achieve more efficient and effective development as it prepares to unveil the all-new electric Cayenne.
The company is leveraging artificial intelligence and digital testing to reduce the number of physical prototypes, reducing costs and speeding up the development process by up to 20%.
This project marks the first direct transition from comprehensive digital testing to production, without the need to build individual prototypes as previously practised. Virtual models have replaced around 120 test vehicles, and are now subjected to rigorous testing in a digital environment.
Porsche relies on three key elements: realistic driving track simulations, the extensive experience of the Weissach engineers, and significant advances in real-time computing capabilities. Virtual reality environments are used to test components early, allowing for rapid modifications before the actual parts are produced.
The company has developed an advanced test platform that simulates realistic driving conditions to ensure the utmost accuracy, including loads, road resistance, tyre behaviour, and even climate effects. This platform enables the complete electric drivetrain to be tested, including motors, batteries, and energy and charging management systems.
The platform is capable of representing various road conditions, from paved roads to off-road, as well as extreme climate conditions, such as desert temperatures in the UAE, which can reach 50 degrees Celsius, or extreme cold in Scandinavia, which can reach -35 degrees.
Despite the rigour of virtual testing, the human touch remains essential, as driving engineers are the ones who finalise performance tuning, particularly regarding driving dynamics and handling strategies, whether on the race track or in everyday traffic conditions.
The testing phases also include testing the vehicle’s ability to charge rapidly in various conditions. Regardless of the driving style, the battery must always be ready for an efficient and rapid charging process before stopping. Even scenarios such as long stops or traffic jams have been taken into account to improve energy efficiency.
Finally, by testing the vehicle under extreme conditions beyond those of everyday use, Porsche ensures that it performs well even in the harshest environments. This approach, which combines the digital and real worlds, is a significant step toward developing more precise, efficient, and sustainable vehicles.
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