Here, the 'test drivers' are not just the specialists themselves but also non-experts. “Simulation allows us to assess displays, operating procedures and the changing influences during a journey from the driver’s point of view,” explains Fabian Klausmann of the Driver Experience development department. 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. The best example here is the development of a completely new display and operating concept for the next generation of Macan. Virtual prototypes can be combined with real-world scenarios at an early stage. However, the Porsche developers are able to precisely calculate and digitally optimise position, flow and temperature. The critical scenarios don’t occur on the road but during fast high power charging at high outside temperatures.

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 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. “The digital world is indispensable to the development of the all-electric Macan,” says aerodynamics expert Wiegand.

New methods now allow very precise simulation of both aerodynamics and thermodynamics.

Virtual testing with the new display and operating system The calculations not only take into account different arrangements of the components, they also reflect real-life temperature differences. The engineers are currently using simulations to fine-tune details such as the cooling air ducts. Even minor flow enhancements can make a huge difference. Low aerodynamic drag is fundamental to the all-electric Macan with a view to ensuring a long range. “We started with a flow-around model when the project first started about four years ago,” reports Dr Thomas Wiegand, Director of aerodynamics development. The aerodynamics specialists are among the first engineers to work with a digital prototype.

Prototype 3 release