Macan prototypes tested thoroughly for performance and efficiency.
The new Porsche Macan will soon make its global debut. Until then, leading up to this launch saw Porsche putting Macan prototypes through gruelling tests in extreme conditions to ensure reliability, performance and efficiency.
Ten years after its launch, the Macan is now in its second generation in all-electric form. As the first Porsche model built on the new Premium Platform Electric (PPE), the SUV is a completely new development.
The test process to ensure the perfect coordination of all components and systems is accordingly meticulous. Naturally, camouflaged prototypes were deployed in various locations for testing.
“When we develop a new model, it’s always about the driving dynamics and precision. That’s Porsche. It’s in our DNA. But it’s always about efficiency too. And design,” said Jörg Kerner, Vice President, Product Line Macan.
One challenge was to maintain the product identity of the successful Macan model series while at the same time meeting the aerodynamic requirements needed to ensure high efficiency and therefore also a high range. Well, a drag coefficient of just 0.25Cd means the designers and engineers worked in lockstep to produce a slippery sports SUV. The previous generation Macan’s drag coefficient was 0.35Cd in comparison.
“Finding the optimal connection between our design principles and the specifications given to us by the aerodynamics engineers is certainly a challenge,” said Peter Varga, Director, Exterior Design at Style Porsche. “We’re working together on every millimetre to achieve the optimal balance between aesthetics and function.”
Through this teamwork, Porsche succeeded in combining its design DNA with range-optimised aerodynamics. This was achieved not only through a striking silhouette but also through the components of Porsche Active Aerodynamics (PAA) and other targeted measures.
“The active aerodynamic elements all significantly contribute to the range,” said Thomas Wiegand, Director of Aerodynamics and Aeroacoustics. “We have an automatically extending rear spoiler and active cooling flaps on the front air intakes.”
Variable elements also exist out of sight in the undercarriage. The vehicle floor is flat and closed like that of a racing car, even in the rear axle area. The fairings there are flexible and also ensure low air resistance when rebounding.
During normal cruising, the Macan automatically assumes its ideal streamline. The rear spoiler moves into the eco position, the air flaps close and the chassis level lowers. This, according to Porsche, allows for a WLTP range of more than 500km for all variants.
The Macan’s electric motors are powered by a lithium-ion battery pack with a gross capacity of 100 kWh, of which up to 95 kWh can be actively used. The battery’s 800-volt architecture enables high-performance fast charging at up to 270kW, which is being tested worldwide as part of the development process.
According to Porsche, the battery pack can be charged from 10-80% in less than 22 minutes at a 150kW 400-volt charging station. This is because a high-voltage switch in the battery enables bank charging by effectively splitting the 800-volt battery into two batteries, each with a rated voltage of 400 volts.
Prototype testing doesn’t just involve driving around in different conditions. “There are different charging standards in our main markets. A major focus of the testing has therefore been on checking these different framework conditions in the different locations with our prototypes and adapting the technology accordingly where necessary. Charging simply has to work, wherever and whenever,” said Kerner.
However, driving around in different extreme conditions is, naturally, par for the test process. Through the various test stages, the objective is to coordinate the newly developed components and systems and to ensure the operational stability and smooth functioning of their interaction.
In endurance tests, a vehicle’s service life is simulated under the kind of harsh operating conditions that will later only be experienced by customers at the absolute limit. To date, the camouflaged prototypes of the all-electric Macan have completed more than three and a half million test kilometres on test tracks and public roads.
To test the interaction of all active driving components under extreme climatic and situational loads, the test cars are used all around the world. “We cover all temperature ranges. From minus 30 degrees Celsius in Scandinavia to plus 50 degrees Celsius, as we experienced in Death Valley in California,” continued Kerner. “Of course, an SUV also has to work on any surface. That’s why we test not only on roads but also off-road, on gravel, snow and ice.”
Any Porsche, even in SUV form, has to be an engaging drive. The rear-focused all-wheel drive in the all-electric Macan models is always on home turf in this regard. Porsche exclusively uses the latest generation of permanently-excited PSM motors on the front and rear axles. They provide an overboost power of more than 612hp, offer excellent efficiency and enable optimum reproducibility of the power output.
The electronically controlled Porsche Traction Management manages the distribution of more than 1,000Nm of torque with Launch Control in the top model in almost real-time.
A Porsche SUV needs to handle well and also be comfortable.
To this end, Porsche’s engineers have deployed a Porsche Active Suspension Management system with two-valve damper technology, air suspension, rear-axle transverse lock and, for the first time, rear-axle steering with a steering angle of up to five degrees.
Prototype-testing successfully completed and signed off, the new Porsche Macan will soon be launched. Excited yet? More to come. Stay tuned.
Photo Credits: Porsche
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