Developed virtually, proven in real life – Porsche has leveraged digital tools and engineering expertise in the development of the new Cayenne Electric, which is set to debut later this year
“This project was the first in which we moved directly from digital whole-vehicle testing to pre-series production,” explains Dr Michael Steiner, deputy chairman and member of the executive board research and development. Much of the traditional prototype testing, which previously involved 120 custom-built vehicles, was replaced with digital methods.
Initial component tests carried out virtually
Porsche’s simulation and AI testing is built on three pillars: digitized test routes, insights from field testing, and powerful real-time computing systems. These enabled engineers to begin development and initial component testing entirely in a virtual environment using VR. The digital findings were later validated on physical test benches.
Composite test bench simulates real-world loads
A new composite test bench was developed to simulate real-world loads. It enabled the drive, battery, energy management and charging systems to be tested together under realistic conditions. The test bench features four synchronous motors that can be programmed to simulate different road conditions, acceleration resistance and forces experienced during recuperation and braking. “The machines are so sophisticated that we can even display different asphalt surfaces or tire slip,” says engineer Marcus Junige. Environmental conditions can also be fully simulated.
Permanent comparison with the digital twin
“Our test programs are unique in terms of their requirements,” Junige adds. For example, a full lap of the Nürburgring-Nordschleife was simulated using a virtual prototype, with real-time impulses fed into the test bench.
“Under all conditions, the vehicle must always deliver full power as soon as the driver demands it,” Junige continues. That level of performance demands exceptional thermal management, prompting Porsche to design the most powerful battery conditioning system ever used in an electric Porsche.
During the Nürburgring simulation, real-time test bench data was continuously compared to digital twin predictions — with minimal deviations, which confirmed the accuracy of the simulation model.
Testing at the limit and in all situations
“In reality, only humans can perform the finishing touches,” says Sascha Niesen, team leader for overall vehicle testing at the Porsche Development Center in Weissach. The importance of test drivers’ experience in perfectly balancing driving dynamics and control strategies is particularly evident on racetracks. A particular focus is on the management of charging. “No matter how the Cayenne is driven before stopping, it must always be conditioned for fast charging,” explains Junige.
In hot climates, the systems were tested under extreme conditions up to 50°C. In cold regions, down to –35°C, engineers evaluated cold starts, traction, climate control, handling and braking. In all cases, the Cayenne Electric had to maintain full charging capability.
Endurance testing simulates a vehicle’s life under conditions so harsh that customers would only experience them in extreme situations. Under everyday conditions, the vehicles cover more than 150,000km in shifts within a few months.
The combination of digital preparation and real-world testing makes the development process more precise and efficient. Compared to a conventional development strategy, the timescale for developing the Cayenne Electric was reduced by 20%. At the same time, state-of-the-art virtual testing is more resource-efficient too, thanks to reduced material consumption.
This is an edited version of an article originally published in the Porsche Newsroom.
