The New Porsche Macan EV
In order to get the all-electric Macan ready for its impending global debut, Porsche is subjecting the prototype to a rigorous and demanding testing regimen. The car is an entirely original creation. Porsche's engineers didn't cut any corners when creating the new Macan EV.
The Macan, which debuted ten years ago, is about to introduce a second model generation that will be entirely electric. The SUV is an entirely new creation, the first Porsche model constructed on the new Premium Platform Electric (PPE). As a result, the testing procedure is rigorous in order to guarantee that all systems and components work together flawlessly. Porsche values in-the-real-world testing with prototypes that are disguised. Simulators are becoming more accurate and have a bigger function in both the virtual world and wind tunnel at the same time. This is especially true when it comes to increasing the efficiency and sportiness of a new Porsche.
Cd value of 0.25 – designers and aerodynamics engineers in lockstep
“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,” says 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. It was accordingly important to ensure close cooperation between the leaders of the two teams during the development stages in the Design department and the aerodynamic testing in Porsche’s state-of-the-art wind tunnel. “Finding the optimal connection between our design principles and the specifications given to us by the aerodynamics engineers is certainly a challenge,” says Peter Varga, Director Exterior Design at Style Porsche. “We’re working together on every millimetre to achieve the optimal balance between aesthetics and function.”
Porsche was able to blend range-optimized aerodynamics with its design DNA thanks to this collaborative effort. This was accomplished by means of a visually arresting silhouette in addition to additional focused measures and the elements of Porsche Active Aerodynamics (PAA). The Director of Aerodynamics and Aeroacoustics, Thomas Wiegand, states that "all the active aerodynamic elements significantly contribute to range." "We have active cooling flaps on the front air intakes and an automatically extending rear spoiler."
Variable elements are also included on the underbody. Even in the region of the rear axle, the vehicle floor is closed and flat like that of a racing car. Together with the streamlined, mostly closed wheels and the aerodynamically optimized tire outlines, the fairings there are flexible and guarantee little air resistance during rebounding—an inventive solution. When driving on a rural road, the Macan naturally transitions into its optimal streamlining. The air flaps close, the chassis level drops, and the rear spoiler goes into the eco position. Wiegand and his team found that the drag coefficient in this case was 0.25 (formerly 0.35). Because of all of this, the new Macan is among the most aerodynamic SUVs, which significantly improves efficiency.
Fast charging with up to 270 kW – for all markets
The 100 kWh gross capacity lithium-ion battery located under the car powers the new Macan's electric motors. Of that amount, 95 kWh can be utilized actively. High-performance quick charging is made possible by the 800-volt PPE architecture in the new Macan and is currently undergoing global testing as part of the development process.
“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,” says Kerner. The DC charging capacity for the new Macan at 800-volt charging stations is up to 270 kW. The charge level can be increased from 10 to 80 per cent in less than 22 minutes at 400-volt charging stations, 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. This enables particularly efficient charging, without an additional HV booster, at up to 150 kW. AC charging is possible with up to 11 kW.
Driving dynamics testing under extreme conditions
Porsche developed the new Macan with a keen focus on the driving dynamics typical of the brand, and a familiar steering feel. These core competencies of the sports car manufacturer are a particular focus during testing. 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,” continues 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.” 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 overboost power of more than 450 kW, offer excellent efficiency and enable optimum reproducibility of the power output. The electronically controlled Porsche Traction Management manages the distribution of the more than 1,000 Nm of torque with Launch Control in the top model in almost real time. To offer the broad spectrum between high performance and comfort for which the Macan is known, the 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.
