vehicle development Archives

All-electric Porsche Macan begins real-world testing, launch in 2023

After the Taycan, the next all-electric sportscar from Porsche will be the Macan. Developed with the usual secrecy, prototypes have been running around the proving grounds of the Porsche Development Centre and the next step is to take them into the outside world for road-testing.

Real-world testing on public roads and in a real-life environment are important stages in the development of a new model. In the case of the electric Macan, due to be launched in 2023, the testing will cover at least 3 million kms worldwide in varying conditions. This will add on to the experience gained from countless previous test kilometres – driven in a virtual space.

Digital development preserves resources
Digital development and testing not only saves time and costs but also preserves resources, so it enhances sustainability. Instead of real vehicles, the engineers use digital prototypes – computational models that replicate the properties, systems and power units of a vehicle to a high degree of accuracy.

There are 20 digital prototypes for the purpose of simulation in a number of development categories, such as aerodynamics, energy management, operation and acoustics. “We regularly collate the data from the various departments and use it to build up a complete, virtual vehicle that is as detailed as possible,” explained Andreas Huber, manager for digital prototypes at Porsche. This allows previously undiscovered design conflicts to be swiftly identified and resolved.

The aerodynamics specialists are among the first engineers to work with a digital prototype. “We started with a flow-around model when the project first started about 4 years ago,” explained Thomas Wiegand, Director of aerodynamics development.

Low aerodynamic drag is fundamental to the all-electric Macan with a view to ensuring a long range. Even minor flow enhancements can make a huge difference. The engineers are currently using simulations to fine-tune details such as the cooling air ducts. The calculations not only take into account different arrangements of the components, but they also reflect real-life temperature differences.

*Advanced and powerful simulation software allows almost all aspects of a new model to be viewed and tested before physical prototypes are built, saving time and money.*

Virtual testing
New methods now allow very precise simulation of both aerodynamics and thermodynamics. “The digital world is indispensable to the development of the all-electric Macan,” said Wiegand. ”The electric drive system – from the battery through to the motor – requires a completely separate cooling and temperature control concept, one that is very different from that of a conventionally powered vehicle.”

While a temperature window of 90 to 120 degrees is the target for combustion engines, the electric motor, powertrain electronics and high-voltage battery require a range of between 20 and 70 degrees, depending on the component. The critical scenarios don’t occur on the road but can occur during fast high-power charging at high outside temperatures. However, the Porsche developers are able to precisely calculate and digitally optimise position, flow and temperature.

Virtual prototypes can be combined with real-world scenarios at an early stage. The best example here is the development of a completely new display and operating concept for the next generation of Macan. Using what is known as a seat box to recreate the driver’s environment, the display and operating concept can be brought to life in an early development phase in conjunction with the digital prototype.

“Simulation allows us to assess displays, operating procedures and the changing influences during a journey from the driver’s point of view,” explained Fabian Klausmann of the Driver Experience development department. “Here, the ‘test drivers’ are not just the specialists themselves but also non-experts. This allows all interaction between driver and vehicle to be studied down to the last detail, enabling selective optimisation even before the first physical cockpit has been built.”

To be the sportiest model in the segment
The first physical prototypes of the electric Macan were built using data obtained from the simulations – in some cases elaborately by hand or using special tools. These are then regularly adapted based on the virtual refinement process. By the same token, the findings from road testing are fed directly into digital development.

“Endurance testing on closed-off testing facilities and public roads in real-life conditions is still indispensable to ensure that the vehicle structure, operational stability and reliability of hardware, software and all functions meet our high quality standards,” said Member of the Executive Board Michael Steiner.

*Prototype of all-electric Macan being tested at Porsche’s test track. Some cars, with camouflage over their bodies, are now being tested on public roads in different parts of the world.*

The demanding test programme for the electric Macan, carried out under the extremes of climatic and topographical conditions, includes disciplines such as the charging and conditioning of the high-voltage battery, which has to meet very rigorous standards.

“Like the Taycan, the all-electric Macan, with its 800-volt architecture, will offer typical Porsche E-Performance,” promised Steiner, citing development goals such as long-distance range, high-performance fast charging and reproducible best-in-class performance figures.

Combustion engine will still be offered
While Europe is accelerating into the era of pure electromobility with all-electric vehicles, Porsche understands that the pace of change will vary considerably across the world. In some regions, there will still be demand for vehicles with conventional combustion engines. Therefore, the next Macan will continue to have a variant with a combustion engine for markets which want it.

Entry-level Porsche Taycan available from March, priced from RM605,000

Porsche Taycan Cross Turismo in final stages of development, market launch by mid-2021

*Visit www.bhpetrol.com.my to know more about promotions at BHPetromart.*

With the Taycan – Porsche’s first production all-electric sportscar – successfully launched and progressively entering various markets, including Malaysia, the carmaker is now busy following up with final development work of the Taycan Cross Turismo. Prototypes have already covered more than 998,361 testing kilometres, a distance that equals almost 25 times around the planet (measured at the equator).

“When developing the Cross Turismo, we were of course able to build on our experience with the Taycan sports saloon. The biggest challenge was combining the requirements of sportiness with off-road capabilities,” explained Vice-President Model Line, Stefan Weckbach. “The Cross Turismo has to be capable of high performance on the racetrack and must also be able to handle mud and gravel.”

25 times around the planet
The latter conditions were simulated on the Endurance Testing Ground at the Development Centre in Germany. The conditions at this facility include a ‘Safari’ track that mimics terrain in Africa. Having completed a total of 998,361 testing kilometres, the Cross Turismo prototypes have circumnavigated the globe almost 25 times (measured at the equator).

The extensive Porsche testing programme has also taken place on racetracks such as the Nurburgring Nordschleife and the Grand Prix track in Hockenheim (both in Germany) as well as on testing grounds worldwide. The Cross Turismo has also been tested off the beaten track in the south of France and in the Pyrenees region.

‘Swiss army knife on wheels’
“The result is impressive. However, the Cross Turismo is not a hardcore off-road vehicle, but specialises in unpaved and dirt roads. It’s like a type of ‘Swiss army knife on up to 21-inch wheels’,” added Weckbach.

The new derivative, which features all the strengths of the Taycan sportscar, will have a chassis with all-wheel drive and height-adjustable air suspension. There is also significantly more headroom for the passengers in the rear and a large load capacity under the tailgate. The package and space conditions have been optimised down to the very last detail.

2021 Porsche Taycan Cross Turismo — *The mock-up – a faithful, physical representation of the interior – and the package function model alone took 650 design, electronic and coordination hours and 1,500 workshop hours to complete.*

Same test programme as other sportscars
At Porsche, electric cars have to undergo the same rigorous testing programme as all its other sportscars with combustion engines. In addition to displaying superior performance, this always includes proving unrestricted everyday usability in all climatic conditions. Particularly demanding tasks such as charging the battery, or controlling the temperatures of the powertrain and interior under extreme temperatures, are additional aspects that are tested in the battery-powered electric models.

Other development goals typical for Porsche include racetrack performance, the ability to perform repeated acceleration runs at full throttle, and a range suitable for everyday use. Extensive testing is also carried out in the laboratory and on test rigs, and includes development and validation of the aerodynamic design. The Cross Turismo braved the storm in the wind tunnel for around 325 hours, part of the 1,500 hours spent there during its development process.

The new rear bicycle carrier designed by Porsche for this model also underwent its own rigorous testing programme with rough road tracks and driving dynamics tests. It sets new benchmarks when to comes to handling, ergonomics, driving safety and stability. Several e-bikes can be transported on its generously spaced wide rails.

The Taycan Cross Turismo combines Porsche E-Performance with enhanced suitability for everyday use. It will go on sale in Europe in mid-2021. To date, more than 20,000 Taycans have been delivered worldwide.

2020 Porsche Taycan — *The Taycan was launched in Malaysia last September by Sime Darby Auto Performance.*

Click to know more about the Taycan and other Porsche models in Malaysia

Porsche Taycan does 165 km/h inside a building – a new Guinness World Record (w/VIDEO)

VR technology enhances vehicle development processes for Hyundai and Kia

Hyundai Motor Company and Kia Motors Corporation have debuted a new virtual reality (VR) design evaluation system at the brands’ global design headquarters. The new system, introduced to the Namyang Research and Development Centre in South Korea, demonstrates a heightened focus on enhancing vehicle development processes through the implementation of VR technology.

The technology uses several development applications, enabling teams of designers and engineers to carry out vehicle design quality assessments and development verification processes. It is part of the 15 billion won (about RM53 million) investment in the Namyang Research and Development Centre announced by Hyundai and Kia in March 2019.

Faster development times, reduced costs
Through the complete implementation of the virtual development processes throughout R&D and pre-production stages, Hyundai and Kia anticipate a 20% reduction in vehicle development times and a 15% reduction in annual development costs. In addition, these new virtual technologies are expected to increase profitability and trigger a cycle of continuously increasing R&D investment for Hyundai and Kia.

“The virtual development process is a necessary step for responding quickly and reacting with agility to the needs of customers and paradigm shifts within the automotive industry,” said Albert Biermann, Head of Research and Development Division for Hyundai Motor Group. “Through reinforced virtual processes, we will enhance quality and profitability, ultimately increasing investment in R&D to secure competitiveness in future mobility.”

20 simultaneous users
VR headsets allow the brands’ vehicle designers and engineers to virtually enter developmental simulations, with 36 motion tracking sensors detecting and tracking the locations and movement of all users, enabling each to participate accurately in real time. The new VR design evaluation system can currently support up to 20 simultaneous users, enabling greater cross-team collaboration than ever before.

As a result, the new cutting-edge facility allows the designers to more efficiently review a multitude of design concepts earlier in the developmental process and in ways that were previously physically impossible. The system simulates interior and exterior design elements, lighting, colours and materials, and even virtual environments.

Testing individual components
VR also enables development teams to simulate operations of individual vehicle components, such as doors, bootlids, bonnets, and windshield wipers. Furthermore, the system enables testing of vehicle ergonomics and aerodynamics more efficiently.

Hyundai first used this system during the design assessment stages of the HDC-6 NEPTUNE Concept Class 8 heavy-duty truck that was revealed in October. Kia also plans to expand the design assessment capabilities of the facility for developmental use on future models.

Additionally, plans to establish remote VR design assessment capabilities will enable real-time virtual collaboration between each brand’s design centres in Europe, America, China and India, along with an enhanced virtual development process through the implementation of AR (Augmented Reality), among other technology. There are also plans to introduce VR technologies in production and assembly lines to create more ergonomic, efficient and safe working environments.

Kia’s Futuron concept is inspired by UFOs and flying saucers! (w/VIDEO)

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