Porsche Engineering Magazine

CUSTOMERS & MARKETS Special features of the Chinese automotive market PORSCHE UP CLOSE The new Cayman GT4—Rebels, race on ENGINEERING INSIGHTS New method for measuring component temperatures ISSUE 1 / 2015

www.porsche-engineering.com End. e d To Th To e d ee r Comprehensive Vehicle Development Engin Engineered To The End. MagazinE

Porsche Engineering Porsche Dear Readers,

_____ always looking at things from a holistic perspective is in our genes. Whether it’s an individual part, component, or system, we don’t simply focus on the individual func- tion, but ensure its intelligent integration in the right environment. As an engineering services provider of Porsche, we cover all areas of vehicle development, always consider individual processes comprehensively, including all pre- ceding and subsequent steps, and also provide supporting activities. In this issue’s focus theme we present in detail our comprehensive approach to vehicle development.

“Rebels, race on.” is the apt slogan for the new Porsche Cayman GT4. In this article we present the new GT racer with its own unique mid-engine concept in a bit more Malte Radmann and Dirk Lappe, detail. We also talk with two industry experts about the Managing Directors of Porsche Engineering Chinese automotive market and future challenges in vehicle development.

We would like to congratulate the Nardò Technical Cen- ter on its 40th anniversary! In our special supplement About Porsche Engineering “40 Years of Future-Oriented Testing,” the proving ground It’s nice to see is presented with interesting articles and fascinating photos Creating forward-looking solutions was the standard from years gone by and today before yielding the floor to great ideas gain ground. set by Ferdinand Porsche when he started his design customers and friends to share their personal experiences office in 1931. In doing so, he laid the foundation for and stories about this unique venue. today’s engineering services by Porsche. We renew our commitment to that example with each new project A variety of exciting topics awaits—enjoy the read! that we carry out for our customers.

The scope of services provided by Porsche Engineering Sincerely, ranges from the design of individual components Malte Radmann and Dirk Lappe to the planning and execution of complete vehicle developments, and is also transferred to other sectors beyond the automotive industry.

Editorial Porsche Engineering MagazinE 3

150521_PEG_Anzeige_210x280_Porsche_Engineering_RZ_EN_v1.indd 1 28.05.15 10:44 14 20 30

Measures Exhaust Valve Temperature and Valve Lift, n = 7000/WOT

700 11

680 9 E (°C)

660 7

B

640 5 A C D (2) Valve Lift (mm) (2) Valve 620 3 Exhaust Valve Temperature (1)

600 1

Valve open 580 -1 0 30 60 90 120 150 180 210 240 270 300 330 360

Cam Angle (Deg) 34 40 (1) Exhaust Valve Temperature (2) Valve Lift (3) For explanations of A–E, see page 44

Comprehensive Customers & Markets Engineering Insights Vehicle Development 28 nardò Technical Center 40 o ptical Measurement 10 Well Considered 40 years of future- of the Valve Temperature The product development process oriented testing New method for measuring A special supplement component temperatures 14 precisely Developed An innovative chassis component 30 individual, Networked, Efficient Special features of the Chinese 20 Exactly Calculated automotive market 03 Editorial Simulation and calculation in 06 News engine development 27 Imprint

24 optimally Supported Porsche Up Close Supporting services 34 the New Cayman GT4 Rebels, race on.

SPECIAL SUPPLEMENT cayman gt4 40 YEARS OF future-oriented Fuel consumption TESTING IN NARDÒ city: 14.8 l/100 km 28 highway: 7.8 l/100 km combined: 10.3 l/100 km

CO2 emissions: 238 g/km Since its founding in 1975, the Nardò Technical Center has established Efficiency class: G itself as the partner for complete testing services and high performance.

Contents Porsche Engineering Magazine 5 News News

Successful Start Girls’ Day Opens up Relaunch of the Porsche Takes Over Inaugural Ceremony in Shanghai New Perspectives Company Website Climatic Wind Tunnel

___ The inaugural ceremony for Porsche Engineering (Shanghai) Co., Ltd. in De- cember of last year turned out to be a very auspicious beginning for the new loca- tion in China. The subsidiary of Porsche Engineering Group GmbH, Weissach, invited guests from the worlds of busi- ness, science, and politics to join in the festivities. The two managing directors of Porsche Engineering, Malte Radmann and Dirk Lappe, were pleased to receive the congratulations of longtime customers and political representatives. ___ Once again this year, interested ___ Informative. Compact. Current. ___ With the acquisition of a climatic With regard to current and future chal- schoolgirls had the opportunity to get a These are the watchwords of the new wind tunnel specially designed for the lenges in automotive development, Dirk closer view of the engineering profes- company website from Porsche Engi- areas of air conditioning, safety and Lappe promised to offer sustainable con- sion at Porsche Engineering as part of neering. The website presents the emissions from Modine Europe GmbH cepts that would fulfill the requirements of Germany’s nationwide “Girls’ Day company’s comprehensive range of ser- in Filderstadt-Bonlanden, the sports car Chinese customers. “We develop solutions 2015” campaign. The 22 girls were vices clearly structured and in detail, manufacturer has further expanded its for the future—a future that we‘re very treated to detailed introductions to the with impressions from the company development capabilities. The facility much looking forward to,” said Dirk technical departments such as electrics/ and working world of a globally active will continue to be made available by Lappe in his speech. n electronics, body, complete vehicle, engineering services provider. The web- Porsche Engineering to other vehicle drive technology, and engines. The girls site is optimized for mobile devices and manufacturers and suppliers for devel- also gained practical experience in the was adapted to current internet use pat- opment tests. The proximity of the cli- technical environment in small groups. terns. Thanks to a clear design language matic wind tunnel to the Porsche devel- For example, CAD designs were created and the lean structure, relevant infor- opment center in Weissach will further and temperature measurements taken mation is available in a clear and com- promote the efficient development of on the thermal test bench. During a pact form. n sophisticated projects. The acquisition joint lunch, the girls were able to talk is part of an investment package aimed to the engineers about their everyday at equipping Porsche’s development work lives as developers. n location for the future. The highly mod- ern facility is suitable for all vehicle variants from sports cars to commercial www.porsche-engineering.com vehicles. n

NEWS Porsche Engineering Magazine 7 Comprehensive Vehicle Development

____ Less is more. These three words sum up the challenge and solid experience. Porsche has all of those things. As the with the customer’s core processes to create a custom project. lights the new paths being taken in the field of hybrid light- faced by the automotive industry today and the impetus for original core and integral subsidiary of Porsche AG, Porsche For all of our engineering services: in engine development, weight construction. Porsche Engineering also offers support- the massive efforts to find solutions. Less consumption, lower Engineering puts its OEM experience at the disposal of its our specialties include the intelligent and time-saving use of ing services that allow customers to focus on their core business emissions, less weight. But also more power, more variety, and customers. Vehicle development is our core competence. The modern simulation tools (page 20), which help us design even and leave the increasingly complex peripheral tasks to us. more customer benefits. And all this with ever-shorter prod- meticulous planning from the design and development of a more efficient engines. A cross member (page 14) designed for uct cycles and with requirements and conflicting objectives new vehicle is described in the Product Development Process the specific requirements of an electrically powered research that can only be resolved with new ideas, better technologies, section on page 10. Our engineers combine their experience vehicle that combines less weight with greater stiffness high-

Product development process

Concept & Styling Construction Design Calculation & Simulation Testing Industrialization

Engineering services Complete vehicle

Body

Electrics/electronics

Chassis

Powertrain

Supporting services Project management, procurement and supplier management, production planning, FMEA and functional safety, sales and after-sales planning, tolerance management, logistics planning, launch management and series support, change management, weight management, information systems, legal regulations, approval management

8 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 9 PRODUCT DEVELOPMENT PROCESS

ENGINEERING SERVICES

SUPPORTING SERVICES

ation of the project. The PDP contains interfaces between the expertise in using it. Porsche engineers have a wide range development, project management, quality, procurement, pro­ of technological expertise in this area as well as many years of Well Considered duction, and sales. Thus the PDP forms a detailed procedural experience across the entire vehicle spectrum as well as in the model for mapping the simultaneous engineering process and, non-automotive field. in terms of methodology, represents the ideal process for cre­ ating a vehicle. The product development process Concept development and assurance

By Steffen Rudert and Jens Trumpfheller Pre-PDP and product definition The concept development and assurance stage involves the design and production of digital prototypes as well as detailed The pre-PDP step precedes the actual product development pro­ planning and finalization in the specifications. Beyond simu­ cess and serves to flesh out the product idea and integrate pre- lation, initial testing with unit carriers takes place. Following ____ The foundation for the success of a product is laid in the product development process (PDP). development topics in the project. The outlines are defined in a selection of the final styling model, refinements begin that will It includes all phases of development and describes the core processes involved in launching a product profile and work begins on a rough assessment of feasibility and continue into series production of the vehicle. Typical project on schedule, on budget, and with the desired quality. Porsche Engineering makes its process capa­ the specification of requirements. In addition, the positioning requests in this PDP phase, as well as in pre-development proj­ bilities and experience from sports car series development available for a wide variety of development of the product with respect to the competition and in the tar­ ects, concern the development and creation of a demonstrator projects in the automotive industry and beyond. This experience allows to take account of get markets is determined. Project management gets under way or prototype. The starting point is rough drafts or product preceding and subsequent PDP phases in every development. Porsche Engineering can cover the entire in this phase and establishes the project organization, rough profiles provided by the customer. Based on them, Porsche scheduling and initial resource and budget planning. Engineering takes over all development processes from design product development process itself, work within the framework of customer-specific PDPs, enhance to calculation and trials as well as the setup, application and existing PDPs, or develop completely new ones. In the product definition, the departments define their require­ testing. Moreover, all development-related functions such as ments of the product based on the profile. In addition to devel­ procurement, logistics, and quality management are handled oping styling designs, this phase also includes analyses of the internally and contribute massively to the successful imple­ competition and elaborations of the concept. Ultimately, the mentation of the project. Porsche Engineering can also count result of this phase is a design for the overall vehicle, including on reliable partners specialized in prototypes, limited-run, the rough concept, the package, safety considerations, produc­ and pre-series. After assembly, the prototypes can be tested tion technology, and aerodynamics values. Thus both technical on test benches. objectives and an economic outline have been defined. When a prototype is being created, many of the PDP process­ During the early phases of pre-PDP and product definition, the es are conducted in a concerted manner. Porsche Engineering core processes take place under the aegis of the manufacturer. has developed its own processes and systems to accompany Porsche Engineering can provide technical expertise and ad­ and control the creation of prototypes. This includes not visory services for processes. The spectrum of services ranges only devising and maintaining the bill of materials but also from concept studies to concept evaluations and benchmark a multi-level approval system and an in-house system for test The product development process (PDP) is a living con­ As a rule, each automobile manufacturer has its own specific studies. Existing concepts are evaluated in terms of technical plans. But this is no immutable apparatus; instead, the entire struct and is always the result of continuous learning and on­ PDP, yet there are some basic commonalities that take on feasibility, decisions regarding producibility and production system is designed to react flexibly to customer requirements going development based on known and new challenges. The different shapes according to the company’s philosophy and technology are made, and styling recommendations are pre­ and, if needed, to work together with customer systems. strong market orientation of automobile manufacturers (Orig­ circumstances. There might be differences in the length of the sented. Porsche Engineering provides support in integrating inal Equipment Manufacturers or OEMs) and the increasingly concept phases, for example, or in the placement of individual long-term development trends in the concepts such as down­ fast reaction times that this requires mean that development design-freeze milestones. sizing, e-mobility and lightweight construction, as well as Series development times are growing ever shorter. At the same time, the rising modern assistance systems and connectivity options. Alterna­ degree of individualization in combination with exacting qual­ Fundamentally, the overall PDP process is divided into main tive concept proposals may also be developed. In series development, the creation of prototypes and the con­ ity demands leads to great technical complexity. Moreover, the phases with milestones known as quality gates between them. struction phase, the design of the series vehicles and the start PDP must ensure effective networking between internal and As synchronization points, these quality gates are used to In many cases, Porsche Engineering is involved in such pre- of testing all occur in parallel. At the end of this phase, all external resources from the development stage onwards and check the status of predefined criteria which, once fulfilled, development and research projects because the customer suppliers have been selected and start-up management takes integrate development partners and system suppliers. trigger the approval of the preceding phase and the continu­ lacks or has limited experience with a new technology and up its work to prepare the next phase. ›

10 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 11 Like in the conceptual design phase, Porsche Engineering tion process. The focal points are procurement and supplier also frequently assumes responsibility for components and management, quality management, production and logistics

Series modules in this phase. This involves assuming responsibility planning, as well as start-up management. This includes sam­

management for components from the concept and sample phases through pling inspection, checking series capability at the suppliers’, Series production the pre-series and on into series production. Associated with FMEA workshops in the production field, developing equip­ this task is responsibility for all interfaces between the dif­ ment, controlling change management processes, as well as ferent development areas as well as with procurement, pro­ series management following the start of production. launch Market duction, logistics, quality, and sales. Moreover, they have the requisite skills from a process and methodology perspective, Full-scale production Change such as functional safety (FuSa), FMEA (Failure Mode and Ef­ Conclusion management

Production start-up Production fects Analysis), and tolerance management. With their well- Series Press Press

launch founded knowledge of many customer-specific processes and Porsche Engineering is well-versed in development work Optimization systems, the engineers from Porsche Engineering can easily across a broad range of different contexts. Detailed processes Approvals

Finalization of occupy an overarching role within the customer’s develop­ and specifications are implemented with great expertise,

VFF/PVS/0S ment organization. often directly in the customer systems. At the same time, the Start-up management engineers demonstrate great flexibility and creativity in de­ VFF: pre series release vehicle; PVS: production “try out” series; 0S: zero series vehicle; PVS: production VFF: pre series release

planning Responsibility for components can cover an entire field of ap­ veloping custom solutions, both in terms of technology and All Market launch Series preparation plication—for instance the complete bodyshell—or indeed process, even where the specifications are less precise. While suppliers the entire vehicle. It can also be highly specific, such as the the focus is clearly on the technology, when needed processes Physical BST/prototypes

Series development of a high-voltage battery or the use of innovative can be adjusted pragmatically to bring the projects to a suc­

Series materials (see the article “Precisely Developed: Hybrid cross cessful conclusion.

BST: construction phase; BST: member made of fiber-reinforced plastic” on page 14). When Digital

BST/prototypes it comes to testing the construction phase as well as pre-series In addition to development work with customer-specific PDPs, testing, the Porsche testing grounds in Nardò in southern Italy Porsche Engineering can also add elements to existing PDPs or

Unit carrier represent the ideal complement to the development expertise develop them from scratch. Regardless of what type of devel­ Series development in Germany, Prague and, since late last year, the new location opment or the phase of the PDP that engineers are currently BST/prototypes Refinement BST/prototypes in Shanghai. working on, the preceding and subsequent process steps are always taken into account, or otherwise incorporated into the overall process, in order to ensure smooth integration with Unit carrier Final model

Detailed Series preparation and full-scale production the customer environment. description, finalization in specifications Digital Primary suppliers and assurance pre-prototypes Series preparation involves moving closer to series production- Porsche Engineering is always enhancing its own capabilities Design development readiness through a sequence of staggered pre-series. With and expertise. Its ever-growing expertise in the field of simu­ the first vehicles in series and series-like facilities, the vehicle lation is perfectly in step with the increasing digitization and Definition of models Multiple requirements manufacturer not only stabilizes its production and logistics virtualization of PDPs. And the use of modules and platforms processes internally, but also externally as the entire process is an effective way to reduce development and procurement takes place throughout the supply chain as well. costs by increasing the number of shared components. n Concepts Initial

benchmarking When the run-up to series production is finished, the actual Definition phase designs Market analysis, development activity is at an end and the work of the proj­ ect organization as well as all development teams is com­

Profile plete. Emerging issues are handled by the series production team, which has already begun its work with the step-by-step hand-over and the finalization of approvals during the pre- Definition of competitors,

requirements, series phase. target markets target

In the final two PDP phases, the development scopes are Product idea Product

Pre-PDP (pre-development) Pre-PDP handed back and the core processes resume in greater concen­ tration with the customer. Porsche Engineering remains active

at this stage—in addition to continuing and finalizing devel­ opment packages from earlier phases—in the industrializa­

Objective definition Project management Sales Schematic representation of the product development process Styling Design Assurance Trials Tools Suppliers Testing Prototypes Prototypes Pre-series Full-scale production Comprehensive Vehicle Development Porsche Engineering Magazine 13 PRODUCT DEVELOPMENT PROCESS

ENGINEERING SERVICES

SUPPORTING SERVICES Precisely Developed

Hybrid cross member Reference component Mount for the power unit carrier made of fiber-reinforced plastic

By Markus Hofmeister and Andreas Tegtmeier

developed hybrid cross member made mined. A topology optimization in the component as well as simulation of the of fiber-reinforced plastic (FRP) is construction space did, however, enable tensions while taking into account non- ____ Lightweight construction and electrification of the drivetrain are also used to mount the motor of the the creation of a new basic design opti­ linear considerations. important objectives in modern vehicle development. In combination, electric drive unit and serves as torque mized for the load flow. they present development engineers with new challenges that call for support. As the properties of fiber-reinforced innovative solutions. Porsche Engineering employs intelligent development As with the optimization of the topol­ composites strongly depend on the methods to meet those challenges. One example is the creation of a The development of this component, ogy, the virtual assurance of the compo­ orientation of the fibers, they have to structure-stiffening suspension component with composites. which was led and largely shaped by nent to be developed was conducted in be aligned in a load flow-appropriate Porsche Engineering, ranged from the part with specialized finite element (FE) manner to exploit their full potential. concept phase to design, optimization programs and the components were cal­ Thus the orientation of the composite and simulation as well as production culated by the developers together with fibers was optimized through simula­ and testing. software experts. This involved the use tion and designed to maximize the ma­ of software for linear predesign of the terial properties. ›

The development methods

In the development of the innovative cross member, the aim, beyond achiev­ ing the defined requirements, was to use In 2012, Porsche took the lead in the electric-powered concept car. Over the as little material as possible. The cost e-Generation (see info box on page 16) course of development, nearly all of the angle was also a consideration from research project with the Volkswagen car’s combustion engine components the outset with the potential for series Group research division as a consulting were removed to make space for other production in mind. To achieve these partner. In the project, leading German components. Among other elements, a objectives, the engineers at Porsche En­ companies and renowned universities structure-stiffening suspension compo­ gineering employed state-of-the-art de­ are developing a new generation of com­ nent in the area of the rear axle was velopment methods for the design and ponents for electric vehicles. developed. The task of the reference material selection processes. component slated for replacement was The platform for integrating these to increase the torsional rigidity of the By selecting the Porsche Boxster mid- groundbreaking components was the rear as well as the connection stiffness engine sports car as the base vehicle, current Porsche Boxster, whose basic of the rear-axle wishbone to the body. the usable construction space for the structure as a mid-engine sports car The newly developed component is design and the defined force-transmis­ The engineers employ state-of-the-art development methods makes it especially suitable for a purely also subject to other requirements. The sion points in the body were pre-deter­ for the design and material selection.

14 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 15 Structure optimization of the construction space Areas with different characteristics FRP hybrid cross member Individual parts of the cross member

Requirements and material selection decreased driving resistances or by al­ for the right area of application. Use­ 1. A flat area that is determined by the 3. A section that can handle the signifi­ For the second section, a design was lowing a larger battery. ful in this context is a comparison of surrounding components; it is im­ cant forces of up to ten kilonewtons selected that would enable maximum Over the course of initial research, it the materials available for selection perative that this part be capable of from the power unit mount. stiffness at the lowest possible weight. became clear that the welded sheet- Material selection is the decisive fac­ with regard to the specific stiffness, handling the major shear forces that The choice was a profile made of car­ metal construction used in the reference tor here. Aluminum alloys, high- i.e. the relationship of the E-module can be expected to emanate from the In the first area, steel is the perfect bon fiber-reinforced plastic. This was component was not ideal under the new strength steels and fiber-reinforced [N/mm²] and the density [g/cm³]. wishbone. material owing to the low available perfect for increasing the stiffness of conditions. Weight was the primary composites form a ground floor for construction height of just a few milli­ the rear. consideration in the development of a components with this purpose in The results for the future component 2. A middle area with a high flexional meters. It is the best-suited material for new component. Every kilogram saved mind. It is very important, however, revealed three different areas, all with resistance generated from the con­ passing on the high shear forces without To best handle the loads in the third enables increased range, either through to select the right material as needed rather different requirements profiles: nection points with the body. buckling or warping. section and support surrounding com­ ponents, aluminum was selected. In this application, aluminum guarantees high specific stiffness while offering great freedom to shape the material.

A two-component adhesive was used to e-Generation connect these different materials opti­ mized for their respective tasks. Thus In the current environmental and climate situation, new solutions vehicles, the costs of the requisite e-mobility components and systems mentation. The aim of the research results is also to improve the three in themselves essentially optimal in the field of vehicle-based mobility are urgently needed. Leading must be reduced drastically. With this in mind, the project is examin- competitiveness of the automobile and supplier industry in conjunc- subcomponents were combined to form German companies and renowned universities and research insti- ing the possibility of a module for electric drivetrains. tion with research institutions in Germany and thus pave the way a single component. In short: the best tutions joined together to advance the cause of e-mobility as part for Germany to assume a leading role in the global marketplace. of three worlds. of the e-Generation project sponsored by the Federal Ministry of To increase the range, the use of energy resources must be optimized. Education and Research (BMBF). Beyond the fundamental reduction of consumption, research efforts in this area also focus on new means of vehicle air conditioning. Reducing Characteristics and The joint project supports the goal of the federal government to the overall weight also contributes to increased ranges, which is why production-appropriate design establish Germany as a leading market in the field of electro- lightweight construction and efficiency-focused measures are also being mobility with the aim of improving the range, cost, and day-to-day examined. New generations of drive components coordinated with All elements of the cross member were usability of the vehicles. other components in the overall vehicle composition should result in also designed with a mind to subse­ new potential for greater efficiency as well. quent series production. The produc­ Electric vehicles are currently still significantly more expensive tion method therefore also influenced than conventional vehicles. In spite of the many innovations that The close collaboration between the vehicle manufacturers and im- the design. Common processes in series electric vehicles require, potential customers expect a good and portant suppliers and universities ensures the market-relevance of the production were taken into account. easy-to-use vehicle. To increase the market appeal of electric research results and thus creates the basis for rapid market imple- The first area, also known as the clos­ ing panel, was manufactured out of ›

16 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 17 10 Before being used for the first time in After all of these assurance measures, The untapped potential for lightweight

9 9.33 the vehicle, the FRP hybrid cross mem­ all vehicles in the e-Generation project construction within the field of hybrid 8 ber had to prove its long-term robust­ were outfitted with the component. component design opens up the possi­ 7.85 7 ness on the test bench. This involved bility of using innovative development 6 Density (g/cm3) simulating an endurance test at the approaches to build lightweight and sta­ 5 Specific stiffness (E/rho) Weissach testing grounds that approxi­ Evaluation and completion ble components at relatively low costs. 4 mates the strains of a vehicle lifetime in An entirely lightweight construction- 3 2 2.68 2.65 2.64 GFRP – glass fiber-reinforced plastic a very compressed format. The compo­ The development of the FRP hybrid cross oriented design of the cross member 2 2.23 1 1.5 CFRP – carbon fiber-reinforced plastic nent went on ultimately to pass the test member shows what can be achieved could enable additional weight savings 0 without any significant damage being with an intelligent material mix com­ of up to 30% without compromising in Steel Aluminum GFRP CFRP detected. bined with new component development terms of the requirements. n Comparison of density and specific stiffness methods and established production To check the cross member after the procedures. This opens up an alterna­ exacting ordeal on the test bench, vari­ tive to the existing more expensive and ous methods of examination were used, time-consuming methods such as the cold-forming micro-alloyed high-strength running lengthwise in the profile direc­ Thanks to the use of modern develop­ including computerized tomography. ones used in the motor-racing context. steel and given a cathodic coating to tion are shaped through a thermosetting ment and production methods, the cross protect against corrosion. A positive matrix and saturated with an epoxy member that emerged from this process side-effect of this is a coated component resin. To incorporate fibers crosswise to is twice as stiff as the reference compo­ suitable for adhesive application without the profile direction in the component nent. It also integrates the function of further preparation. as well, the continuous fibers are ad­ the unit carrier and yet weighs five per­ ditionally wrapped in fibers at an angle cent less than the reference component. This material and coating are frequently deviating from the pultrusion direction. used in the automotive sector, which aside from having the desired character­ This makes it possible to generate al­ Assurance and production istics, also results in low material costs. most any fiber orientation or config­ uration without breaks for joints in To ensure proper functioning in the Through two screw connection points, the fibers. Thanks to this production vehicle, the cross member and all join­ the closing panels form the lower inter­ method, the profile used in this com­ ing techniques were simulated and eval­ face to the body. ponent demonstrates greater robustness uated with calculation programs. One and stiffness than a comparable part particular challenge in this regard was The consoles—i.e. the third section— made of high-strength steel—at a quar­ validating the FRP profile and the ad­ are made of aluminum. Die cast mold­ ter of the weight. hesive connection. ing is preferable for the manufacture of the part because this method, compared The subcomponents are joined with After proving the requisite robustness to other casting methods, allows smaller a two-component adhesive from the and calculating the stiffness, initial pro­ wall-thicknesses and a great deal of bodyworks. The adhesive procedure totypes of the cross member were cre­ freedom in shaping. The material was was specially developed and tested for ated. This was always done with a view one used in the suspension area for sub­ this cross member. to potential series production: even the frames and suspension arms. Each of the first components were produced and aluminum consoles has a fixed mount The adhesive alone is enough to ensure joined so as to be as similar as possible for the drive unit and together they form an absolutely adequate bond between to cross members produced automati­ the upper interface to the body. the components. Since suspension cally in any later production process. components, as in the present case, are The aluminum consoles were designed The heart of the cross member is a usually safety-relevant components, the in a cast-compatible fashion and the square profile that emerges as a pultru­ aluminum consoles are additionally fas­ closing panels were manufactured in sion profile via the pullwinding method. tened to the closing panels with screws. line with the envisioned series produc­ The pultrusion method is currently the This ensures that even in the case of a tion method. The process safety of the most cost-effective means of manu­ hypothetical failure of the adhesive joining process was also subjected to facturing fiber-reinforced elements in bond, limited functionality would be continuous examination and optimiza­ To check the cross member, various means of examination were used, larger unit numbers. Continuous fibers assured. tion throughout the process. including computerized tomography.

18 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 19 PRODUCT DEVELOPMENT PROCESS time losses. In fact, the simulation pro­ and the risks of the model conversions. a great deal of experience is required to

ENGINEERING SERVICES cess consists of a series of necessary se­ Furthermore, it facilitates the work load interpret the calculation results properly quential steps from the meshing to the distribution between the simulation and derive the right conclusions. For this SUPPORTING SERVICES calculation and finally to the post pro­ and design groups, enabling the team task, the engine department is supported cessing, each of which requires a certain to handle larger projects without ad­ by a vast database of similar projects amount of time. Moreover, the results ditional support. Here again, the aim that have already been calculated with of the simulation may determinate de­ is to reduce development loops, limit­ the same methodology. Even if a wide Exactly Calculated sign modification; the time necessary ing the time and cost intensive fully- range of fully-fledged CAE tools is me­ for this activity must also be planned. fledged simulation to the final design. thodically employed, the backbone of a Staggered component release can only The relatively simple-to-operate CAD- development strategy is not represented mitigate the problems: in a complex me­ based simulation tools have been inten­ by the software capabilities, but rather by chanical system, such as a combustion sively validated by Porsche Engineering the expertise of the engineers who con­ Concept and CAD-based simulation engine, the components are mutually through calculation comparisons and tinuously question the output of artificial interdependent and must be developed component tests; they can be reliably intelligence and systematically proof the in engine development simultaneously. The key word to solving used for preliminary calculation up to plausibility of the simulation results. the issue is frontloading. a certain degree of accuracy. By Matthias Penzel The third pillar consists of fully fledged Structural optimization of Time saving through frontloading simulations that are executed in a dedi­ components and assemblies cated software environment and run on ____ Shortened product life cycles and thus significantly reduced development times In the near future, no major calculation- powerful computers. Yet, again using The last pillar is structural optimization. on the one hand, highest customer expectations in terms of development quality on time reduction for highly sophisticated such high sophisticated software, there This practice is particularly effective at the other: the engine development process of Porsche Engineering proves that computer-based simulation, is expected. is potential for project schedule tighten­ the very beginning of the development these demands are not necessarily mutually exclusive, thanks to the early integration Thus, in order to optimize the efficiency ing. In particular, for structural ques­ process, in the concept phase. Especially of the simulation activities in the development process. of the development process, it is crucial tions, for example the cylinder head and for innovative components, with no to accurately coordinate the design and block system, an early FE calculation can comparable predecessors, the structural simulation activities. For years, engine help identify critical areas and provide optimization makes it possible to design development at Porsche Engineering has additional information for the cylinder solutions that lie in close proximity to resolutely followed the path of front­ head gasket design. Since, at this stage, the theoretical optimum from the be­ loading, through an early integration of the maturity of the design is typically low, ginning. › simulation in the development process as well as the systematic implementa­ tion of CAD-based calculation.

The frontloading strategy is based on four pillars. The first stage consists of simple math-based programs for the For decades, components and mod­ time-consuming development loops, preliminary component dimensioning. ules were developed on the basis of the based on the trial-and-error process, At Porsche Engineering, these programs experience and simplified calculations can be therefore dramatically reduced are often developed during an intern­ of the designers. Until the first proto­ and the mechanical and durability tests ship or a master’s thesis and they offer type was tested, it remained an open can be limited to the validation of the the students the possibility of coupling question whether the theory would final design. the theoretical knowledge to the practi­ work in practice. cal application. In the early design stage, however, the With the introduction of computer- simulation has to cope with a critical The second pillar is represented by the aided engineering software, the devel­ trade-off: on the one hand a reasonably CAE tools—finite-element (FE) meth­ opers have been provided with power­ mature design status is the prerequisite ods or computational fluid dynamics ful tools that enable them to push the for starting the calculation activities; on (CFD)—that are embedded in the CAD design to the limits of the physical laws the other hand, waiting until the final environment and operated directly by Using CAE tools minimizes the effort required for and material properties. The traditional design is ready would lead to enormous the designer. This minimizes the effort and the risks of the model conversions.

20 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 21 The conceptual design of completely the stiffness of the component can be beginning of each engine development Various application options new components and systems is both improved by the same factor. However, project, the potential components for in engine development the most rewarding, and the most chal­ the related drastic design changes are structural optimization are identified Intake port optimization lenging, task for an engineer. Assum­ only possible in the early concept phase. and scheduled for calculation. The The applications of structural optimiza­ ing a certain set of expected loads, the Later design changes generate major ad­ systematic use of this method makes it tion in engine development at Porsche The optimization tool is used to evaluate the sensitivity of the intake task is to find the best possible mate­ ditional costs and increase development possible to perform a structural opti­ Engineering are usually related to the port geometry with reference to pressure loss and tumble. rial distribution within a given design risks: test results from previous design mization within a single work day, if improvement of component mass and/or space. Recalculations of older designs stages are, often, no longer relevant to the boundary conditions are defined stiffness as well as the NVH behavior, proved that very experienced engineers the improved design. This is the most and available. This makes it possible targeting specifically defined compo­ can achieve impressive results even important argument in favor of the use to work on unplanned components on nent eigen-frequencies. The dedicated Sensitivity to pressure loss Sensitivity to tumble without CAE support. The die-cast of structural optimization right at the short notice, if necessary. At best the software allows production-related crankcase of the original 911, for ex­ beginning of the development process. simulation is run overnight, so that the ­issues such as ensuring a defined mini­ ample, represents a perfect example of next morning the results can be directly mum wall thicknesses and avoiding un­ harmonious design and homogeneous Structural optimization can also be use­ implemented in the design. dercut for cast and forged components stress distribution. But, even if stiffness ful in the context of further develop­ to be taken into account. and deformation behavior can be cor­ ment of existing products. New vehicle The term structural optimization refers rectly imagined by experienced design­ generation or periodical updates usu­ to and summarizes different techniques The concrete application options for ers, more complex topics, such as the ally aim towards vehicle mass reduction, such as structural optimization in engine de­ acoustic behavior of complex structures, each area having to provide its contri­ velopment are extremely varied. The lie beyond the limits of intuition. Using bution. For engine and transmission, – topology optimization, which typical examples are load-bearing com­ simulation-based structural optimiza­ structural components frequently offer ­focuses on achieving the maximum ponents such as engine mountings and tion, it was also possible to lighten the optimization possibilities, which are stiffness with the minimum use of brackets, but also geometrical details old 911 block by several hundred grams, particularly interesting when the parts ­material, in a given design space, such as oil return passages, connection without compromising the functional can be considered as closed systems of the main bearing walls to the block Push in Pull out characteristics and acoustics. and when the mounting points remain – form optimization, which is par­ structure and camshaft bearing cap unchanged. ticularly appropriate for high-stress designs are systematically optimized. Structural optimizations generally im­ component details, Beyond the actual technical improve­ pact component design significantly. In the context of structural optimiza­ ments of the components, an additional By pulling out the red areas and pressing in the blue regions, the With reference to the initial design, a tion, it is crucial to perform the simula­ – cross-sectional optimization, which side-effect has been noticed: through pressure loss in the port can be reduced while increasing the tumble. weight reduction of 10 to 20 percent can tions in a systematic and standardized represents a valuable support for the the constant practice with structural be typically achieved or, alternatively, fashion. At Porsche Engineering, at the surface design (such as tailored blanks). simulations and results analyses, the designers develop an improved sensibil­ ity to estimate load cases and predict structural behaviors. These experiences produce, therefore, a beneficial effect in completely different components and CAD-based simulation applications and, in particular, they Lightweight design through structural optimization help the engineers to quickly identify weight, and crankshaft stiffness have ther shorten development times, while critical areas and recognize structural been evaluated and the results have improving, at the same time, the quality weaknesses. been compared against comparable ex­ of the development process. isting engines. But even with all this, the uses are far The time and quality benefits of the from exhausted: in a recent example, early integration of CAE simulations during the concept definition of an en­ Enormous development potential in engine development—and not only gine family with a high degree of com­ there—are plain to see. To fully exploit monality, structural optimization was At Porsche Engineering, simulation and this potential, the users are required used for a DOE (design of experiments) design methodologies are continuously to have a great deal of experience in cascade focused on concept-related updated in coordination with each other. order to properly assess and interpret Design space Optimization result Production feasible FE validation questions. To put that in more detail, New methodologies, such as the recently simulation results based on early, and design the effects of the bore-to-stroke ratio developed adjoint-based intake port therefore not fully mature, component on engine overall dimensions, engine morphing, show great potential to fur­ design. n

22 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 23 PRODUCT DEVELOPMENT PROCESS

ENGINEERING SERVICES

SUPPORTING SERVICES Porsche Engineering not only performs pure engineering Having the right materials at the right place at the right time work but also takes on additional tasks and qualifies the is the key function of logistics. The basis for smooth series respective component or product according to the applicable production is detailed logistics planning covering all steps of Optimally Supported requirements. The customer can therefore focus on the core the product development process. Porsche Engineering sup­ development work that is its actual area of expertise. Farming ports customers in the concept, evaluation and implementa­ out supporting tasks makes the customer’s job easier. Porsche tion of all logistics processes and thus guarantees a smooth Engineering also offers these types of services to industries integration process for new developments. Supporting services outside of the automotive sector and is flexible in providing the services—development and qualification work is done There’s a lot of ground to cover before a new development By Peter Weidenhammer according to the required standards. has reached production maturity and production is stable. With regard to launch management and series support, valu­ The portfolio of supporting services is divided into various able experience from series production can be applied to the thematic areas ranging from project and supplier management customer’s processes and establish long-term improvements. ____ The spectrum of expertise offered by Porsche Engineering covers the entire to various planning activities and assessing compliance with Supplier management and cross-departmental quality control, product development process. But the know-how of the engineers is increasingly legal regulations. but also tool tracking and work instructions, help ensure a in demand for supporting services as well. The reason is that dealing with the smooth start for a new product in series production. constantly growing complexity of such tasks sometimes requires additional capacities. In the project management area, the engineers support the In such cases, Porsche Engineering assumes the role of a partner that maintains planning and execution of tasks. They concentrate not only Adjustments are frequently necessary to achieve perfectly de­ an overview of activities in the respective field of supporting services, provides on the development of new technologies, but also pay close signed products. That’s why it’s important to establish inter­ attention to the frameworks in which the projects take place. nal processes for change management which clearly define the requisite expertise and performs the task in its entirety. Together with clients, they draw up detailed plans and reli­ when a modification can take place and how it must be docu­ ably monitor and optimize factors such as cost, quality, and mented. Customers are supported and advised in this process. milestones. Implementation is closely tied to the customer’s To reduce costs and keep delays to a minimum, cross-model product development process. collaboration is a fundamental component and one of the goals of optimization. With regard to procurement and supplier management, the engineering services provider can draw on its many years of Failure Mode and Effects Analysis (FMEA) is an established experience in Porsche series production; Porsche Engineering instrument in the product development process for identify­ knows what it takes to secure a robust supply chain. Porsche ing and correcting errors or potential sources of errors at Engineering identifies, selects, and audits suppliers and pro­ an early stage in the design of products and the associated vides expertise if problems arise. It also includes the planning manufacturing and assembly processes. Due to the distinction and execution of projects to improve supplier performance between system, design, and process FMEA, Porsche Engi­ and quality assurance for purchased parts. The customer can neering takes all potential error sources into account. With therefore count on finding the best partners and suppliers for regard to functional safety (FuSa), the risks associated with the manufacture of their products. the function to be implemented are determined, thus further reducing potential dangers. With years of experience as a series manufacturer of sports cars under our belt, Porsche Engineering is well acquainted In vehicle development, dimensional management is used as with the challenges in production planning as well as produc­ a preventive quality assurance method to ensure fulfillment tion processes and methods. Over the years, the company has of visual and functional requirements. This also makes it always developed successful solutions by creating innovations possible to avoid potential problems before they occur. The and making continuous improvements. This knowledge is overriding objective of dimensional management is to achieve brought into the design of assembly lines. Beyond the re­ high product quality without rework. Together with a ref­ duction of production times and costs, the focus is also on erence point system (RPS), this is achieved through precise increasing process security and identifying the potential for specifications on functional dimensions and the joint plan. improvements. This is then rounded out by tolerance calculations and a ›

Comprehensive Vehicle Development Porsche Engineering Magazine 25 three-dimensional tolerance simulation (see also Porsche With the growing diversity of variants and derivative models Drawing on its series production experience, Porsche Engi­ IMPRINT Engineering Magazine 1 / 2013: “Dimensional Management in vehicle development, the demands on information systems neering also handles approval management. Regardless of in Vehicle Development”). are growing as well. The engineers are familiar with these which stage of development the product is in, this encom­ Porsche Engineering requirements from a variety of assembly and module develop­ passes approval management and tracking and thus compre­ MAGAZINE With legal regulations and market demands calling for ve­ ments and approach them with innovative and lean solutions hensive control of the approval process for components and hicles with ever lower consumption and emissions, the impor­ for tasks such as product data management, BOM systems milestones. ISSUE 1 / 2015 tance of effective weight management has never been greater. and approval management. With the intelligent lightweight construction of the current Porsche customers expect not only premium quality, but also Porsche Engineering generation of sports cars, Porsche is once again the reference Developments do not simply need to fulfill technical require­ exceptional service. The brand is thus an exacting standard MAGAZINE point. An optimal weight assessment depends on recording ments and functional demands, but also comply with for sales and after-sales planning. What that means is that in

CUSTOMERS & MARKETS Special features of the Chinese automotive market PORSCHE UP CLOSE The new Cayman GT4—Rebels, race on and evaluating vehicle mass and center of gravity data. The additional legal regulations. Porsche Engineering provides not every development, service concepts are taken into account ENGINEERING INSIGHTS New method for measuring component temperatures ISSUE 1 / 2015

www.porsche-engineering.com

key is to balance opportunities and risks and continually only the expertise to ensure that the products are compliant from the very outset. This ensures that the client’s customers Comprehensive Vehicle Development COMPREHENSIVE VEHICLE DEVELOPMENTCOMPREHENSIVE VEHICLE check whether weight objectives are being achieved through both in their manufacture and characteristics, but also covers will be satisfied with developments even when servicing is ENGINEERED TO THE END. the development process. proprietary and patent rights for the developments. required. n MAGAZINE

Porsche EngineeringPorsche

Production planning Logistics planning Functional safety Launch and series management Approval management Publisher Porsche Engineering Group GmbH Porschestrasse 911 71287 Weissach Germany Tel. +49 711 911 0 Fax +49 711 911 8 89 99 Internet: www.porsche-engineering.com

Editor-in-Chief Frederic Damköhler Procurement and supplier management Change management Legal regulations Weight management Editing | coordination Nadine Guhl Advertisement Frederic Damköhler Design VISCHER&BERNET, Stuttgart Translation RWS Group Deutschland GmbH, Berlin Printing Kraft Druck GmbH 76275 Ettlingen All rights reserved. Reprinting, incl. excerpts, Project management Sales and after-sales planning Information systems Dimensional management only with the permission of the publisher. No responsibility can be taken for the return of photos, slides, films, or manuscripts submitted without request. Porsche Engineering is a 100% subsidiary of Dr. Ing. h.c. F. Porsche AG.

26 Porsche Engineering Magazine Comprehensive Vehicle Development Comprehensive Vehicle Development Porsche Engineering Magazine 27 40 Years of Future-Oriented Testing

____ The Nardò Technical Center perfectly unites tradition and the future like no other proving ground. Without losing its original character, from the very outset Nardò has planned ahead and left room for innovation. This is where testing for top performances takes place. For the entire automotive industry. Innovative and ready for the future.

Come and join us in the south of Italy! Individual, Networked, Efficient Future trends on the Chinese automotive market Professor Zhuoping Yu Jianying Wang

In addition to serving as assistant After studying automotive president of Shanghai’s Tongji engineering at Tongji University, University and dean of its auto­ Jianying Wang started her career motive department, Professor Yu is in the Chinese automobile industry. director of the Shanghai Automo­ In 1995 she joined Porsche and ____ China represents one of the largest and most interesting markets for the automobile industry. tive Industry Corporation (SAIC). since then she was managing Thorough knowledge of this market, the ability to innovate, and new technologies are all of great He is also the chairman of the Porsche Engineering’s sales activi­ Collaborative Innovation Center ties with Chinese customers. importance in meeting the demands and requirements of Chinese customers. Porsche Engineering has of Intelligent New Energy Vehicle She was appointed director of the at Tongji University. newly founded site of Porsche been working with Chinese customers for more than 20 years now, and has recently strengthened Engineering (Shanghai) Co., Ltd. its activities yet further in the country by founding a subsidiary in Shanghai. We spoke with Professor in January of 2015. Zhuoping Yu, an automotive expert at the city’s Tongji University, and Jianying Wang, the director of Porsche Engineering Shanghai, about trends and technologies on the Chinese market.

Interview: Frederic Damköhler and Nadine Guhl

What will Chinese customers expect Jianying Wang I think that Chinese cus- opment poses new challenges in terms from mobility in the future? tomers have especially high expecta- of traffic and the environment. In order tions with respect to safety and comfort, to reduce energy consumption and pol­- Prof. Dr. Zhuoping Yu Just like in Europe while low emissions and affordable lution, it’s crucial to pursue further and the USA, individual mobility has prices continue to be very important development on alternative drive con- become ever more important for Chi- as well. To achieve these aims, promis- cepts. As for traffic safety, ever greater nese people. The number of motor ve- ing solutions might be found in ways significance is being attached to intel- hicles per 1,000 in the country currently of combining individual mobility with ligent technologies such as driver assis- stands at around 100. But this figure public transportation. tance systems. will increase approximately threefold over the next several years. This enor- What technologies will have an Wang Lightweight construction will mous rise in the number of cars will especially strong influence on the auto­ play an even more important role in require the right kind of infrastructure. mobile industry over the coming years? the future, especially when it comes Given the well-known problems related to reducing fuel consumption and for to emissions and space, this will not just Yu In my view, electromobility, light- electric vehicles. The challenges we’re be a matter of building new roads and weight construction, and intelligent facing here have to do with high pro- parking lots. Intelligent traffic systems driver assistance systems will be impor- duction costs as well as vehicle safety. or new ways of organizing traffic will tant topics in the future. Mobility is A number of technologies and systems be needed. Ideas on how to limit the use not yet a given in our country. More and have to be developed further if we of cars are currently being considered— more people have the means to buy their want to be able to combine different such as allowing only certain license own cars these days, and want to do materials safely in cars. We at Porsche plates to drive on certain days—as are so because of the new type of flexibility Engineering are working on various different models of car sharing. and freedom they offer. But this devel- ways of doing this. ›

30 Porsche Engineering Magazine Customers & Markets Customers & Markets Porsche Engineering Magazine 31 ners, which means joint projects and How does Tongji University differ ever increasing number of students and communications, will lay the founda- from other universities? the feedback we get from companies tion for the successful completion of confirm that we’re on the right track development processes. Yu Compared to other Chinese univer- with this approach. sities, Tongji maintains intensive rela- Non-automotive companies, par­ tions with leading German universi- Wang Those are the reasons why we ticularly technology companies like ties and companies. Ever since it was work with Tongji University too, and Google and Apple, have entered the founded in 1907, it has been in close especially why we support the auto- automobile market. What effect will contact with the medical and mechani- motive engineering department. Ex- that have on how the sector develops? cal or civil engineering departments of perienced employees from Porsche German universities. We started offer- Engineering hold guest lectures at the Wang A new competitive environment ing a degree program in automotive en- university and also propose topics for is arising. Joint ventures with these gineering at the end of the 1980s. Our students to work on. types of technology companies could courses and programs are very prac- be helpful in the future, and enable all tice-based and future-oriented. Tongji And now to conclude with a very partners to benefit in the best possible has studied industrial developments in different question, Professor Yu: assum­ ways from their respective experience China from the very beginning and has ing you could take a test drive as part and developments. continually adapted its programs to of series development work at Porsche, meet the needs of industry. Internships which model would you choose? Yu The way I see it, the roles will be re- are also required—as is often the case assigned. Google will become a major in Germany—in order for students to Yu A Porsche Cayenne S E-Hybrid! supplier and partner in the future. Car start gaining practical experience. An When can we start? n makers will have to master a lot of challenges or lose their favorable mar- ket positions to these ambitious tech companies.

New tools or front-loading mecha- Professor Yu, to what extent does nisms are constantly being set up in the demand for sustainable mobility Lightweight construction will play an even order to keep pace here. influence your work at the university? more important role in the future, Yu Development processes will be in- Yu Our university, or rather our courses Car makers will have to master a lot fluenced all the more by supplier in- and programs, are being further de- especially for reducing fuel consumption dustries and other sectors. Car makers veloped to address the demands as- of challenges or lose their favorable will be concentrating more exclusively sociated with sustainable mobility. In and for electric vehicles. on the core process of development. 2010 we formed a working group on e- market positions to these ambitious Wheel-hub drives for electric vehicles mobility with members from Tongji Jianying Wang and batteries, for example, are not part University and the Technische Univer- tech companies. of the core business for car makers. sität München as well as from two ad- Development processes will be split up ditional Chinese universities and the Prof. Dr. Zhuoping Yu to a greater extent, and parts of these Shanghai Automotive Industry Corpo- processes will be delegated to service ration (SAIC). This in turn led to the providers. Sales, or sales systems, will launch of a cooperation and integration also change. Car use no longer neces- center for electric vehicles. The goal is What will be key for development everything is moving much faster. It’s sarily means car ownership. These ap- to advance the preliminary development processes in the future? more important than ever to keep a proaches will require well thought-out of innovations in this area. We need to constant eye on the market, but it’s systems of use and information tech- incorporate the topic of sustainability Wang Individual development cycles becoming harder to do so at the same nology, which in turn will influence the into the educational system. In connec- are becoming shorter, which means time. What is innovative today will be development process and need to be tion with electromobility, another ma- that development processes as a whole obsolete tomorrow. And this gives rise taken into account right from the start. jor topic that the university will need to CAYENNE S E-HYBRID – Fuel consumption (combined): 3.4 l/100 km, CO2 emissions: are also becoming shorter and that to new organizational requirements. Successful integration of systems part- address is intelligent traffic control. 79 g/km, Power consumption: 20.8 kWh/100 km, Efficiency class: A+

32 Porsche Engineering Magazine Customers & Markets Customers & Markets Porsche Engineering Magazine 33 cayman gt4 Fuel consumption city: 14.8 l/100 km highway: 7.8 l/100 km combined: 10.3 l/100 km

CO2 emissions: 238 g/km Efficiency class: G

Rebels, Race On. The new Cayman GT4: Maximum driving dynamics combined with day-to-day usability

Porsche up close Porsche Engineering Magazine 35 A new member of the GT family—the Porsche Cayman and thus protects the aerodynamic downforce against rocks. GT4—celebrated its world première in March of this year The traditionally wide Porsche wing encompasses the bi-xenon at the Geneva Motor Show. This marked Porsche's first GT headlights with their black interior design. sports car based on the Cayman that bears components of the 911 GT3. The engine and suspension, brakes and aerodynam- The side inlets behind the doors are also a prime example of ics are trimmed for maximum driving dynamics; yet the top performance-oriented design: Sideblades with the “GT4” logo model retains the typical versatility and day-to-day usability generate additional dynamic pressure. The result is better air of the two-seater Porsche Coupé. intake and more efficient cooling of the engine. The body sits 30 millimeters lower than that of the Cayman, bringing the Cayman GT4 even closer to the asphalt. The benefit: a lower The design: an aerodynamics package center of gravity for even sportier driving behavior. Optimal contact with the road is ensured by the 20-inch, platinum- Every element of the exterior has a function. Thus the GT4 colored alloy wheels. They sit well on the outside and with impresses not only with its design, but also puts in an excep- their large dimensions nearly completely fill the wheel wells. In tional performance on the track as well: With a lap time of combination with the standard sport tires, the wheels improve 7 minutes and 40 seconds on the Nürburgring's famed North traction and cornering performance. The V-shaped design of Loop, the GT4 took its place at the front end of the pack. the spokes is also taken up by the standard SportDesign ex- The GT4 impresses with its water-cooled flat-six engine. The suspension is designed for uncompromising performance. terior mirror. The sleekness of the front is as effective aerodynamically as it is attractive to look at. The pronounced front spoiler The origins of the new Cayman GT4 are most evident in the lip extends across the entire width of the front end and the rear. The fixed wing with aluminum supports stands for pure additional spoiler flows in front of the wheel wells gener- motor racing culture. In combination with the integrated rear ate aerodynamic downforce on the front axle. The large air spoiler beneath it, it generates unmistakable downforce on the intakes enable excellent ventilation of the water coolers. The rear axle. The sideplates of the wing are designed for optimal central air intake also directs the air flow upwards through aerodynamics: Yet more proof that every detail is designed to the exhaust opening in front of the luggage compartment lid harmonize perfectly with the whole. The powerful conclusion is the black rear apron in diffusor look with two centrally The suspension: for optimal agility, stability and precise tracking the vertical vibrations of the engine while accelerating at full positioned tailpipes, also in black. The sound charges ahead throttle are reduced. The result is a more uniform and greater forcefully—thanks to the standard sports exhaust system. The entire suspension is designed to meet the rigorous require- propulsion force on the rear axle, higher traction and better ments of oval track racing. To achieve agility, stability and acceleration. And with a moderate driving style, the driving precise tracking, the front axle is equipped with a reinforced­ comfort is enhanced thanks to a softer configuration of the Engine and transmission united to form a drive unit MacPherson spring strut axle with oval track-tested kinemat- dynamic engine suspension. ics as well as individually mounted wheels on the longitudinal In the new Cayman GT4, the typical Porsche GT perfor- and track control arms. The rear axle is also adapted to the Furthermore, the standard Porsche Torque Vectoring (PTV) mance meets the exceptional agility and cornering dynamics sporty high-performance of the new Cayman GT4 with including rear-axle differential lock also improves the driving of a compelling mid-engine concept. Its drive unit is a flat- additional reinforcements and specific wheel carriers. Individual dynamics of the GT4 additionally. The rear-axle differential six engine derived from the 911 Carrera S engine. Its power ball joints on both axles also create an especially stiff bond lock enables greater traction as well as significantly improved transmission is handled by a six-speed manual gearbox with with the body and thus enable even more precise wheel con- lateral dynamics and driving stability during load changes in dynamic gearbox mounts. With its specially tuned gear ratios, trol. The height, camber and track, as well as the stabilizers corners and when changing lanes. Moreover, with a dynamic the precise-handling and strikingly light manual transmission of the chassis, can be tuned individually for track use, where driving style, targeted braking interventions on the inside rear puts the engine's outstanding power on the pavement. The every millimeter makes a difference for shaving hundredths wheel are initiated as soon as the car starts to steer into the engine features direct fuel injection (DFI), VarioCam Plus of seconds off a lap time. And more adrenaline in the blood. corner—this generates an additional turning impulse in the and integrated dry-sump lubrication. In addition, a variable turning direction. resonance intake system keeps the engine well-ventilated. The Cayman GT4 has dynamic gearbox mounts. The elec- For its part, the engine draws a stately 283 kW (385 hp) at tronically controlled system minimizes vibrations throughout 7400 rpm from 3.8 liters of displacement. The maximum the entire drivetrain, and particularly the engine; on the other PSM and PCCB for optimal braking performance torque of 420 Nm is available over a range from 4,750 to hand, however, it also adapts the damper force and stiffness 6,000 rpm. Together with a low power-to-weight ratio of to the driving style and road surface. This makes it possible to Porsche Stability Management (PSM) is an automatic control 4.7 kg / kW (3.5 kg / hp), the result is a veritable explosion of enjoy the benefits of a hard as well as a soft engine suspension. system for stabilization when driving at the limits of the car’s power, and a 0-to-100 km / h time of just 4.4 seconds. The car With load changes and in fast corners, the driving behavior driving dynamics. In addition to the anti-lock brake system Cayman GT4: the aerodynamics posts a top speed of 295 km / h. becomes notably more stable and precise. At the same time, (ABS), it includes the Electronic Stability Control (ESC) and ›

36 Porsche Engineering Magazine Porsche up close Porsche up close Porsche Engineering Magazine 37 the Traction Control (TC) systems. Sensors continually deter- mine the driving direction, driving and yaw velocity as well as lateral acceleration. PSM uses that data to determine the actual direction of movement. If it deviates from the desired lane, it initiates targeted braking interventions on individual wheels. The special thing about PSM in the new Cayman GT4 is the sporty tuning with exceptionally sensitive and precisely dosed control interventions. The systems can also be com- pletely deactivated in two steps.

The Cayman GT4 embodies the highly emotional connection between daily life and the race track.

With its especially large brake disc diameters of 410 milli- meters in the front and 390 in the rear, the optional ceramic brake system offers even greater brake performance. The de- cisive advantage of the Porsche Ceramic Composite Brake (PCCB) is its extremely low weight. The brake discs are some 50 percent lighter than gray cast iron discs of a similar build and size. That makes a noticeable difference not only in terms of driving performance and consumption, but also reduces the unsprung and rotating masses, which provides better grip as well as enhanced driving and ride comfort, particularly on uneven road surfaces.

Conclusion

The new Cayman GT4 was not made to stand still; it was made to go all out. The aerodynamics are downforce-oriented, the engine performance enhanced. The chassis and brakes are designed for uncompromising performance. As a GT sports car from Porsche, the Cayman GT4 embodies the highly emotional connection between daily life and the race track and thus the sporting core of the brand: Intelligent Performance. n in the material hardness. This procedure or with other applications cannot be at- available to the test engineers in real is well established, but the measurement tained in a single measurement. time at the test bench or in the vehicle. Optical Measurement of values are only available much later: This would make it possible to sig- The engine must first be dismantled and In special cases, thermocouples are also nificantly increase the efficiency of the the valves analyzed in the lab, which integrated in the valves and monitored development process both in terms of from a time perspective is difficult to through telemetric signal transmission. the mechanics and the application. The the Valve Temperature incorporate into today’s dynamic devel- This procedure is expensive and critical specifications defined: opment processes. It is still only possible in terms of reliability and has therefore to use certain materials, which means not established itself as a standard. ____ Modern engine development demands ever more flexible and dynamic processes. The core aspects that the measurement valves may not are the speed and precision of the measuring methods. Porsche Engineering has developed a method for reflect the actual state. Furthermore, > Measurement range of up to ap- contactless transient online measurement of component temperatures that can be used directly on the the results only indicate the maximum Requirements and motivation prox. 500 degrees Celsius for intake engine test bench or in the vehicle. This new tool provides a substantial foundation for further increases temperature reached with the applied valves and approx. 900 degrees for application state in a measured oper- The focus of the development by Porsche exhaust valves, with a sensor both in specific engine power as well as future CO and consumption optimizations. 2 ating point. Information regarding the Engineering was the generation of a ambient temperature of max. valve temperature in other load points measurement signal that could be made 125 degrees Celsius. By Johannes Wüst and Maximilian Fischer > Measurement accuracy comparable to or better than thermometric valves (<10 kelvins) > High dynamic range of the signal and availability of the measurement signal in real time > Resistant to reflections and slight soiling > Small size Legal regulations and customer de- ments in the turbocharger field, injec- haust valves: One option is to limit the Protective glass Focus Glass mands for lower-consumption vehicles tion technology and combustion pro- exhaust-gas temperatures in the upper optics fiber have led to major changes in the engines cess development, will continue to rise load range through mixture enrichment of new vehicle generations in recent in the near future. and thus also reduce the component years. Three primary tendencies have temperatures of the exhaust valves. From initial deliberations to mar- shaped the technological development: These performance optimizations lead This makes it possible to use cheaper ket launch in 2013, the project went first, the introduction of direct fuel in- directly to a significant increase in the materials for the exhaust valves, albeit through multiple development cycles. jection, which is meanwhile practically specific heat energy, which in turn in- with higher fuel consumption in these Since that time, the measuring method universal in Europe. Now developers are creases the thermal load for many en- load ranges. On the other hand one can has been successfully used in some cus- faced with the question of implementing gine components. It primarily affects use higher-quality materials, e.g. replac- tomer projects. It was used, for example, the future Euro 6 emissions limits with the pistons, gas exchange valves, cylin- ing a common steel alloy such as X50 to examine the causes of valve damage the lowest possible additional produc- der heads, the exhaust manifold and the with Nimonic, or using sodium-filled and excessive wear on valve-seat rings. tion costs. Second, naturally aspirated turbocharger. The most common reme- valves. Both options lead to a signifi- Other uses included a comparison of engines have been replaced by turbo- dial measures are to modify the engine cant increase in part prices. In general, IR different valve designs with and with- charged engines with a smaller displace- cooling, design means such as an inte- however, the focus is on completely ex- Detector out sodium filling as well as different ment, a shift referred to as downsizing. grated exhaust manifold, piston cooling hausting the thermomechanical poten- Controller engine applications in order to select Third, further optimizations such as or higher-quality materials. As a rule, tial of the material and the design. the most cost-effective valve material thermal management, start-stop func- however, this results in additional costs. for every application variant. tions, hybridization and friction reduc- Data tion have come into play. In any engine development process, one State of the art for measuring Acquisition The development tool is currently in use must continuously take account of the valve temperatures at Porsche Engineering in its 4th stage Direct fuel injection and downsizing in the conflict between technical objec- of evolution. › particular have resulted in rising spe- tives such as reduced consumption To determine the valve temperatures, Measurement cific engine power. Values between 90 and the marketability of a vehicle, i.e. thermometric valves have been used for object and 100 kW / l are now the state of the cost thresholds. A typical example is many years from which the valve tem- art and, in view of continuous enhance- the fuel selection and the design of ex- perature can be deduced from changes Technical setup

40 Porsche Engineering Magazine engineering insights engineering insights Porsche Engineering Magazine 41 Soiling of the optics and solutions ranges. The fiber optics still receive Concept validation to this problem the signal and direct it in the sensor Glass fiber housing to the two sensors through a To demonstrate the capabilities of the One neuralgic issue is the soiling of prism. The specific signal intensity of system, in early 2014 an extensive in­- the protective glass by soot from the each wavelength analogous to the tem- ternal series of tests was conducted exhaust gas. In particular where valve perature makes it possible to compare with two test vehicles in Nardò, Italy. temperature measurements are to be the signals in the controller by deriving Both vehicles withstood the two-day, carried out over lengthy testing periods, coefficients. This increases the preci- 1,600 km outbound trip as well as the the deposits of certain fuels in differ- sion of the measurement and any signal return on their own steam to demon- Focus optics ent countries can substantially shorten attenuation is compensated for. This strate the robustness of the measuring Protective glass the potential measuring period. To re- also makes it possible to determine the system through long-term data logging. solve this issue, the engineers developed intensity loss and thus also the degree two different measures: a design that of soiling. Specifying a maximum per- The measurements at Porsche Engi- Water jacket enables fast cleaning of the protective missible signal attenuation value causes neering’s Nardò Technical Center were glass and a two-color pyrometer. the controller to switch off the sensor conducted as part of an extensive test- Exhaust valve when the threshold value is reached; ing program. Both test vehicles were The principle of two-color pyrometry is the optics must then be cleaned. This equipped with direct-fuel-injection, based on the use of two infrared detec- procedure ensures the uniform quality flat-six naturally aspirated engines in tors that measure in different wavelength of the measurements. two different performance classes. ›

Beam measurement position Intake valve

Measures exhaust valve temperature and valve lift, n = 7000 / WOT

700 11

Sensor integration in cylinder head of a Porsche 911 engine 680 9 E (° C ) 660 7

The measuring system the vehicle, the signal can alternatively the cooling water causes significant dif- B be recorded in the application computer ficulties here, which was resolved using The central component in valve temper- to detect direct reactions to the applica- an elaborate welding procedure. This 640 5 A C D ature measurement is a pyrometric in- tion status. enables the procedure to be used on al-

frared sensor. In pre-trials, appropriate ready developed cylinder heads. lift (mm) (2) Valve 620 3

sensor types were selected on the basis The construction design must be tested xhaust valve temperature of their suitability for the application. individually for each engine type. The In the current stage of evolution, an- E purpose and reason for the measurement other sensor type is in use that can be (1) The measurement chain consists of the can impact the placement of the sensor. mounted completely separately from 600 1 infrared sensor, a controller and a mea- the engine via a fiber-optic cable. In ad- surement PC. The sensor is protected One challenge of this design—assuming dition to even greater dynamics, this Valve open against the high exhaust-gas tempera- that it cannot be included in the cast part design is even more resistant to thermal 580 -1 0 30 60 90 120 150 180 210 240 270 300 330 360 tures and exhaust backpressure with in prototype cylinder heads—is creating loads, soiling and mechanical sensor sapphire glass. The measurement signal the sensor access through the oil cham- loads. Possible optical reflections are Cam angle (Deg) can easily be integrated into the conven- ber, the cooling water jacket and into avoided by means of black matte coat- (1) Exhaust valve temperature (2) Valve lift (3) For explanations of A–E, see page 44 tional systems in engine test benches. If the outlet port. One problematic issue ings and an optimal incidence angle of the measurement is to be conducted in was that the sealing of the sleeve against the “measurement beam.” Valve lift and valve temperature at 7,000 rpm and full load

42 Porsche Engineering Magazine engineering insights engineering insights Porsche Engineering Magazine 43 Measurement raw data and definition of data analysis segments

Speed profile for measurements on NTC ring track 900 T3—Exhaust gas temperature 800

1st lap 2nd lap 700 T_AV3_S (°C) T_AV3_S

sea level 600 T_AV—Exhaust valve temperature (m)

500 75.77 T3 (°C) 400 28.06 0 50 100 150 200 250 300 Time (sec.)

km km km km km km km km km km km km km km km km km km km km km km km km 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12 600 500 km 0 km 12.5 km 0 km 12.5 400 300 Engine load

240 km / h 260 km / h 280 km / h vmax 280 km / h 260 km / h 240 km / h MO_Mom_ist (Nm) 200 100 0 50 100 150 200 250 300 Time (sec.)

300 280

Off throttle Off throttle Off throttle 260 Acceleration Acceleration Acceleration 240 Constant speed Constant speed Constant speed Constant speed Constant speed Constant speed Constant speed 220 Vehicle speed ESP_v_Signal (km / h) 200 0 50 100 150 200 250 300 Time (sec.)

Vehicle speed profile on the circular track in Nardò Individual measurement and definition of the static evaluation ranges, taking a 1 km journey as a reference

The exhaust valves to be tested were 7,000 rpm under a full load but not yet – Expansion effects and gas-pressure Under a load, the highest exhaust valve Conclusion itself over a total deployment duration sodium-filled, hollow-shaft valves. steady conditions. In addition to the oscillation in the exhaust channel (C), temperature (T_AV) measured in this of over 25,000 defect-free kilometers. temperature, it also shows the valve lift. – Cooling due to heat transfer from test series was 805.6 °C. This was With this new measuring methodology, In early 2014, the procedure was suc- Testing included varying fuel types, the surface to the inside of the reached while using the poor-quality Porsche Engineering has created a valu- cessfully used for the first time for tem- driving profiles and sensors as well as We see extremely high temperature gra- valve, the valve seat and the valve fuel in conjunction with a slight ap- able tool for the development of engines perature measurement on the turbine alternating application values for igni- dients that are only visible with mass- guide (D). plication modification. The highest that are more efficient, lighter and yet wheel of a VTG turbocharger. As an tion angle, oxygen value, exhaust back- less measuring methods. The interpre- recorded exhaust-gas temperature T3 more powerful and robust. The mea- enhancement, a water-cooled infrared pressure and coolant temperature. The tation of these temperature gradients Another effect may be a rise and fall of 893.8 °C was determined using a surement results are directly available sensor was used. n scope of the test matrix alone shows is not easy, however. The curve of the in temperature due to passing over the conventional thermocouple while us- during the test and the effect of remedial the data acquisition potential of this locally measured valve temperature is hottest point on the valve (E). ing Super Plus 100 in conjunction with measures can be represented in a direct measuring technology. interpreted as an interaction of at least only a slight application modification— comparison of “before and after” values. four different effects: To evaluate the test matrix, the entire a lean adjustment in the composition of This significantly shortens development dataset was highly compressed through the mixture. The highest exhaust valve and testing times. Another advantage Results – Heating by means of exhaust escap- statistical analyses of average and max- temperatures overall were recorded in of the contactless measuring method is

ing at high pressure from the com- imum values. A uniform driving profile the fired thrust. Here the new non-in- that it offers additional means of CO2 Even a small sampling of the results bustion chamber (in the figure on (top figure) ensured directly compa- ertial measuring system was able to re- and fuel savings by better exploiting the underscores the capabilities of the mea- page 43, item A), rable results. For the statistical evalua- cord temperatures of over 900 degrees thermomechanical limits of the valves. suring system. One example is the high- – Apparent cooling due to movement tions, in each case the engineers looked Celsius, the upper temperature limit of resolution temperature signal. The fig- of the measurement position towards at a one-kilometer section of the sec- the sensor calibration selected for this The robustness and reliability of the ure on page 43 shows a load point at the colder valve shaft (B), ond measurement lap (figure to right). test series. measuring system has already proven

44 Porsche Engineering Magazine engineering insights engineering insights Porsche Engineering Magazine 45 MHP_AZ_Lenkrad_2015_220x280_3mm_ENG_ISO_uncoated.indd 1 beaufort8.de Why shoulditbeanydifferent whenitcomestoyourprocesses? You wouldn’t letjustanyonebehindthewheelofyourvehicle. Germany I Switzerland I USA I China IRomania China I USA I ISwitzerland Germany Excellence inManagement- andIT-Consulting forAutomotive. You canfind additionalinformation at:www.mhp.com capacity, the majorityofwhomare among thetop50automotivecompanies. 1,250 employees, can shape the direction of 250companiesinanadvisory management and IT consulting. It is no wonder that we, with our currently more quicklyandreliably. Ourdrivingforce istheperfect symbiosisof MHPasyourprocess supplier,With youwillgetwhere youwanttobe MIESCHKE HOFMANNUND GESELL PROJECTEXCELLENCE IT UND IT-BERA – PRÄMIER -MANAGEMENT SCHAFT FÜRMAN TUNG MBH 22.05.15 17:16 T AGEMENT- – PA RTNER

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