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Special Issue 2006

Porsche Magazine

Porsche engineering services Porsche has placed its extensive knowledge at the disposal of external cus- tomers from the automotive and other branches of indus- try for more than seventy- five years.

Complete The complete devel- opment has always been a strength and passion of .

Excellent design Turning design dreams into reality for customers and for Porsche: such as the 911. Contents

Porsche Engineering is a Porsche modular systems; we also take on Whether you require a general Group subsidiary specializing in planning and implementation of automobile developer or specialized contract development services. complete vehicles all the way to system-provider, Porsche When contracted to support series production. What makes our Engineering can bring you the best manufacturers or original equip- offerings unique is our proven of both worlds. ment suppliers, we offer design and expertise as a volume vehicle development services, from in- manufacturer. dividual components to complex

Editorial Page 4

Complete Testing Vehicle

Insights Decades of engine power Seventy-five years Page 19 of Porsche engineering services System Porsche From theory to Page 5 Page 13 confirmation Page 16 Complete vehicle competence at Porsche Page 10 Contents

The entire knowledge base of If you would like to know more Porsche Engineering converges in about Porsche Engineering, please Weissach, . Yet it is avail- send an e-mail requesting our able globally. Which also means: image brochure to the following Special directly on-site with you. Wherever address: our competence is required, it’s [email protected] Page 33 Milestones in Customer always Porsche. Development from 1931 – 2006

Electrics & Industrial Body and Production Styling Electronics Engineering Safety Engineering

Unconventional ways Expertise from auto- for body concepts motive development Page 30 for other branches of Hardware, soft- industry The shape of ware and system Page 26 the future development Page 22 from one source Accelerated power From designing Page 24 of innovation to the start of Page 28 production Page 32 Editorial

Dear Readers,

The secret to the success of the managed centrally by the Porsche Dr. Ing. h.c. F. Porsche AG is based Engineering Group GmbH (PEG), on decades of experience that founded in 2001 and based in extends far beyond the develop- Weissach. Thanks to the mature ment of sports . Seventy-five development network of Porsche, years ago, PEG can call on the services of started his own independent engi- other subsidiaries within the group. neering office in , which Where necessary, the resources of

The story of Porsche Engineering’s success is based on decades of develop- ment experience in the automotive

sector. Porsche has the reputation of being Company founder Ferdinand Porsche with his son Ferry at the drawing board with a one of the world’s most versatile providers construction drawing of the Porsche Type 60. of engineering services since 1931.

was to become a cradle of automo- the Porsche Research and phase to series production, with the bile technology. He used customer Development Center in Weissach customer continuing to receive cus- orders to develop vehicles such as are available for customer develop- tomized solutions for his project. the racing car and the ment work. By networking all its VW Beetle and made the name of locations and having a close Porsche a synonym of technical exchange of information between We wish you an enjoyable read. excellence. Porsche has continued its engineers, Porsche Engineering the tradition established by com- offers interface competence and The Editorial Team pany founder Ferdinand Porsche in across-the-board thinking for the 1931 up to the present day, and smooth and productive manage- does not only develop sports cars, ment of customer projects. but also implements technical projects for customers around the The area of contract development globe. services gives Porsche a unique position in the automobile sector. Developing on behalf of car manu- No other independent car manufac- facturers, suppliers, and other turer makes its know-how and test industrial companies from around facilities available to external in- the world has always been an inte- dustrial customers. Porsche gral part of the services provided Engineering also supports its con- by the Porsche AG. All contract during the entire product development projects worldwide are creation process, from the concept

4 Porsche Engineering Magazine Special Issue 2006 From back then until today Insights

Seventy-five years of Porsche engineering services

Long before sports cars bearing The young Ferdinand Porsche had the Porsche name caused a sensa- already been occupied with con- tion among car enthusiasts on structing cars at the turn of the and race tracks around the century. On behalf of the Lohner world, the name of Porsche was Coach Factory in , a purvey- already synonymous in specialist or to the Austrian Royal Family, he circles with innovation and technolo- built cars with a combination of gical competence. When Ferdinand gasoline and electric drive – the Porsche dared to go independent first hybrid cars in the world. This on April 25, 1931 with “Dr. Ing h.c. was followed by pioneering activi- F. Porsche GmbH, Konstruktion und ties such as the all- drive and Beratung für Motoren- und Fahr- the four-wheel , which he zeugbau” (“Dr. Ing h.c. F. Porsche introduced as innovations into the GmbH, Construction and Consulting world of automobile production. Company for Engine and Vehicle This technical prowess did not go Ferdinand Porsche founded the construction office in the Kronenstraße 24 in Stuttgart in Production”), he had already many undiscovered: In 1906, Ferdinand 1935. years of experience as an automo- Porsche was appointed Technical tive engineer. Director of Austro-Daimler, making

Porsche has a long tradition of providing development services for other companies around the world. Regardless of whether these developments concern cars, , commercial vehicles, shipping technology, or agricultural machines.

him responsible at the age of just 31 for the entire model range at one of ’s largest car makers. Following the victorious launch of his “Prinz Heinrich Car” at the race named after the prince in 1910, Porsche developed the “Sascha”, a lightweight that made its international debut at the in 1922. Just one year later the by now well-known auto- motive engineer joined the Daimler- Motoren-Gesellschaft in Stuttgart. There it was above all the super- Door plate of the Dr. Ing. h.c. F. Porsche GmbH in 1931. charged sports and racing cars

Porsche Engineering Magazine Special Issue 2006 5 Insights From back then until today

development of a sixteen-cylinder racing car for the new 750 kg rac- ing formula. The first test drives of the P racing car (the “P” stands for Porsche) were conducted as early as January 1934, and the new car wrote automobile history with its numerous racing victories and speed records.

When Ferdinand Porsche began designing an inexpensive compact car on behalf of NSU in 1933, this The , the first contract development of Porsche (Type 7). was already the seventh compact car he had constructed in the that continued to strengthen his twelve people was enormous, even course of his career. With the air- reputation as a truly outstanding by today’s standards. In its first cooled four-cylinder horizontally automotive engineer. Ferdinand year the engineering office devel- opposed engine in the rear and the Porsche left the Daimler-Benz AG oped a new midrange and Porsche in 1929 and decided to crown his an eight-cylinder engine for the on the rear , the prototypes career by establishing his own engi- German car maker Wanderer. These already showed clear leanings neering office in December of projects were followed by a com- towards the later Volkswagen 1930. pact car on behalf of Zündapp, Beetle. In June 1934, Porsche offi- which paved the way for the later cially received the order from the The pace of work initially endured . Auto Union “Reich Association of the German by Ferdinand Porsche’s team of commissioned the construction and Automobile Industry” to design and build the Volkswagen or “People’s Car”. The first prototypes were assembled in the garage of Porsche’s private villa in the north of Stuttgart in 1935. The decision to build a special Volkswagen plant was born in 1936, and Ferdinand Porsche was given the assignment to plan this new production facility. The Type 64 with its aerodynamic alloy body was created in 1938/39 for the long-distance race from Berlin to Rome. Although the start The Porsche Type 64 is considered the ancestor of all Porsche sports cars. of the war prevented the Type 64

6 Porsche Engineering Magazine Special Issue 2006 From back then until today Insights

drive. The Porsche Engineering Office was also requested by the Armament Authority of the German Army to develop , but these saw limited regular use in the war, due to technical problems and material bottlenecks.

Following the war, the Porsche Engineering Office, which had moved to the Austrian town of Mercedes-Benz record-breaking racing car T 80 in 1939. Gmünd in in 1944, com- peted again for new orders from from being used in motor racing, the elegantly designed coupé is the ancestor of all Porsche sports cars created since 1948.

Alongside the extensive Volkswagen project, the Porsche Engineering Office, based in Stuttgart’s district Zuffenhausen since 1938, had been working on numerous other develop- ment orders. The Type 80 was a high-speed record-breaking car pro- duced for the Daimler-Benz AG. The Type 110 compact for farm use set the foundation for the sub- sequent “People’s Tractor” and the Porsche Type 60 (V3) at the exit of the Porsche-Villa in Stuttgart-Feuerbach around 1936. Porsche diesel tractor built after World War II. Following the outbreak of war in the . To begin 1939, further models based on the with, however, the company was Volkswagen were intended for mili- only able to develop water turbines, tary use. The company re-estab- cable winches, ski-lifts, mowing lished later in 1937 as Porsche KG rods, and various agricultural trac- now mainly developed off- vehi- tors that were now marketed for cles such as the VW “Kübelwagen” the first time under the name of and the VW “Schwimmwagen” Porsche. In 1946 the Italian compa- Workshop cabin of the Porsche factory in amphibian car fitted with all-wheel ny entrusted Porsche KG, Gmünd/Carinthia (1944). Porsche Engineering Magazine Special Issue 2006 7 Insights From back then until today

Ferdinand Porsche at the drawing board of the Porsche Engineering Office in the Kronenstraße 24.

now under the management of structed. This marked the birth of remained an important part of the Ferdinand Porsche’s son Ferry, with the Porsche brand, with company’s overall range of activi- a number of extensive development production of the rear-engined ties. Until the 1970s, Porsche’s contracts. Apart from a small trac- coupé and cabriolet versions of the most significant customer was the tor and a water turbine, the compa- 356 starting in the second half of Volkswagen AG. The close coopera- ny developed and built the all-wheel- 1948. After returning to Stuttgart in tion of the two companies has been drive Type 360 Cisitalia Grand Prix 1950, Porsche began regular setting the pace in the development racing car as well as a two-seater series production of the 356 with a process ever since 1948. mid-engine sports car. total production volume of some 78,000 units by the year 1965. Numerous detailed improvements In July 1947, the Porsche The successor model, the Porsche were therefore developed for the Engineering Office started working 911, helped the company make its VW Beetle built in under under its own steam on the Type final breakthrough as one of the a license fee paid to Porsche. 356 VW Sports Car. Based on the leading manufacturers of sports Porsche was also involved in the Type 64 Berlin-Rome racing car, the cars in the world not only in techni- development of various successor design concept bearing the internal cal terms, but also in design. models to the highly successful construction number 356 became Despite this successful start as a Beetle. The company developed reality in of 1948 and a car manufacturer, development numerous prototypes for the ready-to-drive prototype was con- assignments from customers which set the

8 Porsche Engineering Magazine Special Issue 2006 From back then until today Insights

trend for the wide range of passen- ger cars coming out of Wolfsburg for the coming years. The most famous customer developments were the VW- present- ed in autumn 1969, and the Volks- wagen Development Project EA 425, which made its appearance in 1976 as the .

The wide range of development at Porsche comprised nearly all areas Technical drawing of the Cisitalia Grand Prix race car (Type 360). of motorization over the last 75 years, including developments con- Research and Technology. The cus- The development on behalf of auto- cerning cars, motorcycles, com- tomer base also came from almost mobile manufacturers, suppliers, mercial vehicles, shipping technolo- the entire worldwide automobile and other industrial companies from gy, aircraft, agricultural machines, industry and used Porsche’s know- around the world is still far from agricultural vehicles, construction how ranging from individual techni- being finished, and this business machinery as well as comprehen- cal solutions to complete vehicle field continue to be an integral sive projects such as automotive developments. component of Porsche in the studies for the future on behalf of future. This is ensured by some the German Federal Ministry of 400 employees at the Porsche Engineering offices. Porsche Engineering also has access to the full range of facilities and test stands at the Weissach develop- ment centre, and can also rely on the 2,400 employees in the devel- opment department.

Powered by the combined know- how of Porsche in the background, PEG is able to consistently focus not only on the smallest compo- nents, but also on the complete vehicle as a whole. The supreme objective in the future is therefore also to optimize the overall system, Aerial photograph of the Porsche Development Centre in Weissach in autumn 2005. ensuring satisfied customers at all times. I

Porsche Engineering Magazine Special Issue 2006 9 Complete Vehicle From concept to series production planning

Complete vehicle competence at Porsche

Four-door sedan by Porsche (Type 542) developed for the American car maker .

Porsche has worked successfully on customer projects since the – from the concept phase to series production. The best example is the VW Beetle.

Since its beginnings in 1931, the range of tasks performed by the Porsche Engineering Office has covered the entire bandwidth of automotive technology. The work done by Ferdinand Porsche’s hand- picked team ranged from drivetrain and suspension components to the production-ready complete vehicle. Even in the early 1930s, fully-func- tional prototypes of compact and Alpine test drive in 1936 with two Volkswagen prototypes of the V3 range. midrange models were being creat-

10 Porsche Engineering Magazine Special Issue 2006 From concept to series production planning Complete Vehicle

ing masters of their trade such as Karl Rabe, and Josef Mickl – placed the VW Beetle’s characteristic air-cooled four-cylinder in the rear and divided the vehicle into base plate and body. The potential of this concept proved its reliability up to the end of the Second World War in numerous variants, such as the “Kübelwagen” jeep and “Schwimm- wagen” .

Test car of NSU (Type 32) in front of the Porsche Engineering Office at Kronenstraße 24 in After the war, Porsche remained Stuttgart. linked to the Volkswagen AG as a development partner for many ed on behalf of renowned car manu- vehicle would be built by 2003. The decades. Apart from countless facturers such as Zündapp, NSU design that became known as the detailed improvements to the VW and Wanderer. Porsche Engineering Beetle, due to its unmistakable Beetle, the Stuttgart-based sports still continues this inheritance from shape, became a symbol of mass car manufacturer repeatedly took the first days of Porsche. This motorization across the world. on complete vehicle development wealth of experience together with When designing the vehicle known projects from Wolfsburg, which the combined know-how of a series internally as the Type 60, Ferdinand went as far as the prototype stage manufacturer gives Porsche a Porsche and his engineers – includ- of whole model families. unique status in the automotive sec- tor. Porsche Engineering makes its 75 years worth of complete vehicle knowledge available to its custom- ers, and manages all areas of car making: from conception to design, prototype construction, testing, production planning, procurement, logistics, and production.

When Ferdinand Porsche presented his ideas on the design of a German “People’s Car” in an exposé in January 1931, not even the bravest optimists could predict that over 21.5 million units of this The VW 38 (Type 60) from 1938 already has the look of the later VW Beetle.

Porsche Engineering Magazine Special Issue 2006 11 Complete Vehicle From concept to series production planning

International customers, such as the American automobile manufac- turer Studebaker, also relied on Porsche know-how. From 1952 to 1954, Porsche used the Type 542 to develop a modern four-door sedan with an integral body-frame that did not make it to series pro- duction only because of a lack of capital of the American contractor. The Soviet state-run Avto VAZ also relied on the experiences of Porsche when a complete compact Development of the robust compact car “” with front wheel drive for the Russian state-run Avto VAZ in 1984. car was ordered in the form of the

Lada “Samara”, whose robustness was specially designed to cope with Soviet road conditions. For the Chinese market Porsche used the C88 to develop a vehicle study adjusted to Chinese require- ments, which was presented at the Beijing World Trade Center in 1994 as part of an international presenta- tion. The specification manual of the C88 demanded comfortable driving, even on poor roads. In 1994, Porsche Engineering received an order from the Adam AG to start on the complete vehicle development of the com- pact in line with a given concept. Presented for the first time at the Paris Motor Show in 1998, the Opel Zafira A was pro- duced from 1999 to 2005. I

Opel Zafira – Complete vehicle development to a given concept for the AG.

12 Porsche Engineering Magazine Special Issue 2006 From driving comfort to driving fun Chassis

System Porsche

The first construction order for Porsche comes from Wanderer (Type 7).

From the start, the Porsche Engineering Office has pursued the objective of con- stantly improving automotive technology with trend-setting solutions. In its very first year of work, Ferdinand Porsche’s team of technicians reached a milestone in the history of technology: the torsion-bar suspension known as the “System Porsche”.

The innovative wheel suspension about in connection with the August 10, 1931. In early 1931 the principle, which uses a torsion bar Engineering Office’s first contract German car maker Wanderer in as a suspension element, came development and was patented on assigned Ferdinand Porsche the project to construct a midrange sedan that was to become the Wanderer W21 and W22. Apart from having a new six- cylinder alloy engine, the vehicle known internally as Type 7 was noted for its special swinging axle system. The Porsche torsion bar suspension used here for the first time was to prove itself as one of the most significant detailed devel- opments in automobile production. One special feature was the small Drawing of the “System Porsche” torsion-bar suspension constructed under the Type 17 amount of space needed for the designation. Porsche Engineering Magazine Special Issue 2006 13 Chassis From driving comfort to driving fun

Test drive in 1937 with the W30 on the Katschberg.

torsion bar, which was arranged body – an important advantage in tem, the best known of these with- transversely below the vehicle with- cars without an integral body-frame. out doubt being the Volkswagen out affecting the size of the cabin – Much of the development work car- Beetle, which first demonstrated unlike a . The damping ried out by the Porsche Engineering its qualities during long test drives forces were also absorbed by the Office in the years that followed in the prototype phase in 1936. platform framework and not by the also had the new suspension sys- The system proved itself in motor racing in the Type 22 Grand Prix racing car developed by Porsche for Auto Union. After the war, the tor- sion bar suspension demonstrated its performance on all the world’s race tracks in the .

Since then, the “System Porsche” torsion bar suspension has been used worldwide by millions in count- less variations, and is still used today in passenger cars, commer- cial and special vehicles.

The chassis of the Type 22 Grand Prix racing car developed for the Auto Union.

14 Porsche Engineering Magazine Special Issue 2006 From driving comfort to driving fun Chassis

selves as technological trendsetters PASM is always active in the back- in the development of vehicle sus- ground and checks the style of driv- pension. ing in the currently selected pro- gram. This system gives the sporty The variable suspension system on multi-purpose vehicle outstanding the actively and driving properties for its class. continuously regulates the damping force by using acceleration sensors Besides the Porsche Cayenne, the to determine the conditions of the , Porsche Boxster, and The Porsche roadway and the individual style of Porsche Cayman models have also Management (PASM) electronic damping system actively and continuously regulates driving. For example, PASM kicks in benefited from this new suspension the damping force depending on the driv- during very dynamic driving with technology since 2004. Thanks to ing style and situation. heavy phases of acceleration and PASM, the sports cars from braking or on particularly uneven Zuffenhausen combine two suspen- All suspension developers hope terrain, in order to balance the sions in one: one with equal meas- to achieve the ideal adjustment of rolling and pitching movements by ures of sportiness and comfort for the car to the current driving situa- stabilizing the individual shock long-distance driving and a tighter, tion. Porsche engineers have absorbers. PASM also enables the markedly sporty one for the circuit. moved a step closer to this goal Cayenne driver to perform individ- This achieves additional active driv- with Porsche Active Suspension ual adjustments ing safety in all situations with a Management (PASM) introduced in while driving. The driver can select tangible increase in the level of the air-sprung Porsche Cayenne in one of three basic programs: comfort. 2002, and have again proven them- “Comfort”, “Normal” and “Sport”. Excellent driving dynamics are a feature of all Porsche sports cars. Porsche Engineering makes this core competence available to its customers and develops project solutions from conception to start of production in order to develop and optimize the handling of the vehicle in line with customer expec- tations. Porsche Engineering devel- ops complete chassis, including all components such as , , suspension and control sys- tems, , , pedals as well All suspension components in the Cayenne are 100% adapted to the Third Porsche, as axle and engine components. I in order to enable the typical handling of a Porsche on all roads.

Porsche Engineering Magazine Special Issue 2006 15 Testing The desire to test is in our genes

From theory to confirmation

Cayman S in the climate wind tunnel at the R & D Center in Weissach. Real stretches of road can be simulated here under real climate conditions, such as the Townes Pass in the USA.

The Porsche Research and Development Center offers an incomparable range of services. State-of-the-art test benches, workshops and laboratories can also be used by customers.

The “idea factory” of the Porsche measurement center, a wind tunnel, AG has been located in Weissach and the safety test stands including 25 kilometers west of Stuttgart a crash-test facility. The second since 1971. Alongside the skid pad phase of the development center in and – whose construction Weissach was finished in September started in 1961 – Porsche succes- 1974, and the new test stands, sively expanded the Research and workshops and laboratories official- (center) with Helmuth Bott, Ghislaine Kaes and Hans Tomala (from left) Development Center with additional ly opened. on a visit of inspection of the test track in large technical facilities such as a Weissach in 1962.

16 Porsche Engineering Magazine Special Issue 2006 The desire to test is in our genes Testing

Crash test of a Carrera GTS The new Development Center in Weissach was built in 1971. The test track is in the in 1966. background.

For example, the Porsche emis- the worldwide development cus- work environment with ultra-modern sions testing department has been tomers from the automotive indus- test stands was created for the testing the export vehicles of other try were calling for greater capacity emissions technicians over an area manufacturers on behalf of the to measure and improve emissions, of 5,500 square meters. Here, the American Environmental Protection the “Measuring Center for Environ- current emissions rolling test Agency on its own rolling test stand mental Protection”, which has its stands determine the real driving since 1967. As not only the own test building, was officially resistance of the respective car at Porsche engineers, but above all opened in late fall of 1982. An ideal any given moment using micro- processor-controlled systems, while the vehicles are driven automatical- ly using statistically guaranteed measurement accuracy and various country-specific emission test cycles that can be reproduced at any time.

A climate center with three test chambers and a climate tunnel with an all-wheel rolling test stand allow emissions and consumption tests, as well as many other development Porsche Type 911 T driving through the asphalt-patch curve on the test track at the tests, to be performed across a Weissach Development Center in 1970.

Porsche Engineering Magazine Special Issue 2006 17 Testing The desire to test is in our genes

tomers. Other trendsetting, detailed and safety-conscious solutions from the house of Porsche included auto- matic three-point belts, head restraints integrated in the and a safety steering wheel with a crumple section.

In 1987, the Weissach Development Center was expanded by adding a modern crash facility with perma- nently installed control and monitor- ing technology. Apart from Porsche Porsche vehicles in the climate pressure chamber at the Emissions Center of the sports cars, vehicles and com- Development Center in Weissach. ponents of other manufacturers are tested for their crash behaviors and wide range of climates and altitudes. from the outset as a safety cabrio- improved by Porsche engineers. I The high level of emissions research let, thereby meeting the enhanced at the Porsche Development Center safety requirements of Porsche cus- was also a reason behind the decision of Porsche, , BMW, DaimlerChrysler and Volkswagen to found a joint “Automotive Industry Emissions Center” (ADA) at Porsche in Weissach, which began operating in January 1996.

Investigations into the passive safe- ty of automobiles using crash tests has a long tradition at Porsche which reaches back to the 1960s. The knowledge accrued in count- less tests flowed directly into vehi- cle development, so that by 1964 Porsche was able to introduce a split safety steering system in the new Type 911. The Porsche 911 Targa presented in 1965 with its Porsche Study C88 for the Chinese market in the wind tunnel of the Development Center in Weissach. fixed roll-over bar was designed

18 Porsche Engineering Magazine Special Issue 2006 Powerful Engine

Decades of engine power

As the smallest independent German car manufacturer, Porsche has special competence when it comes to building . Porsche Engineering makes the experience it has gained over decades of series production and motor racing exclusively available to its cus- tomers. Since its early days as an independent engineering office, Porsche has written automobile history with its engines.

Back in 1931, it was a Porsche six-cylinder alloy engine with a dis- placement of 1.7 or 2 liters that powered the newly developed Wanderer sedan W21/22 as well as the well-known “”. The six- cylinder compressor engine of the The Porsche Type 550 Spyder with the Type 547 “Fuhrmann engine” constructed as a racing engine (1953). Type 22 Auto Union P racing car

Porsche Engineering offers all areas of modern engine development and develops units from the single-cylinder engine to the multi-cylinder, high-performance engine. From the application to the completely new development.

had a legendary reputation. During fewer than 30 Grand Prix victories air-cooled four-cylinder flatengine its season in 1934, the and 15 world records between that was not only used in millions V-shaped 4.36-liter engine of the 1934 and 1937. of VW Beetles, but was also to Grand Prix racing car generated serve as the basis for the engine 295 bhp and a powerful torque of When Ferdinand Porsche received of the subsequent Porsche 356. 55 mkg at just 2,700 rpm. Driven the order to develop the Volks- With a double system by motor racing legends such as wagen in 1934, designing a new and enhanced compression, the , and engine was also part of the project. Porsche engineers helped the , the Auto Union P rac- Following extensive tests, the 1,100 cc unit of the first Porsche ing car (P for Porsche) achieved no Porsche engineers developed an 356 achieve an output of 40 bhp.

Porsche Engineering Magazine Special Issue 2006 19 Engine Powerful

became a permanent standard in Another high-powered engine was international motor sports, in partic- created in 1988 for the American ular in the Spyder, but CART racing series. In the Indy- also in the Carrera versions of the Porsche, the methanol-fuelled V8 Porsche 356. racing engine was placed among the top four in eight out of nine With the launch of the Porsche races in 1989, and won the 200 911 Turbo in 1974, Porsche Miles Mid-Ohio. Porsche developed became a pioneer of engine charg- a 3.5-liter 12-cylinder naturally Technical drawing of the four-cylinder ing using turbochargers. The tech- aspirated engine for the Footwork engine with four overhead camshafts (Type 547). nology, which was previously tested Arrows racing team, which was in the racing car types 917/10, used during the 1991 Formula 1 Over the years, Porsche constantly 917/30 and the 911 Carrera RSR season. However, financial difficul- increased the potential of the flat Turbo 2.1, reached a highpoint in ties at the end of the season result- engine that would eventually be the 1977 /78 “Moby ed in a premature end to the coop- used in the until 1968 Dick”, whose 6-cylinder flat engine eration. by making numerous modifications was fitted with water-cooled four- and improvements. The engine in valve cylinder heads for the first Porsche engines not only made a the racing version, described as time. Aspirated by two turbocharg- name for themselves on roads and the “Fuhrmann engine”, was ulti- ers, the 3.2-liter engine generated race tracks – the compact units mately enlarged to have a two-liter up to 845 bhp. These comprehen- also convinced in the air, thanks to displacement and was fitted with a sive experiences became the basis their excellent power-to-weight four-camshaft control driven by a of one of the most important cus- ratio. Porsche presented an entire vertical shaft. The lively flat engine tomer development projects at range of aero engines in 1959. The Porsche Engineering: On behalf of units were used in light aircraft and the Saudi Arabian businessman helicopters and had an initial power Mansour Ojjeh, the engineers in output of up to 75 bhp. Weissach developed the “TAG-Turbo made by Porsche” for the British racing team McLaren. This Formula 1 engine generated over 1,000 bhp from a mere 1.5 liter displacement. The Porsche engine dominated the class of racing sport from 1984 to 1986, and helped McLaren win three World Championship titles. The Formula 1 engine “TAG-Turbo made by Porsche” was used for McLaren racing cars. Ferdinand Porsche next to the Auto Union P-racing car (Type 22) in 1936.

20 Porsche Engineering Magazine Special Issue 2006 Powerful Engine

The 12-cylinder-suction engine was exclusively developed by Porsche for the Footwork- Arrows racing team.

Harley-Davidson V-Rod V2 engine with 115 bhp. Considerably more powerful was simple handling and long mainte- the PFM 3200 aero engine devel- nance intervals. oped on the basis of the Porsche of a cooperation that reached back 911 flat engine. The 3.2-liter unit As a development partner, Porsche to the 1970s, the Porsche engi- drew public attention when it Engineering developed a new V2 neers constructed a water-cooled, proved its reliability during a round- engine under the development 1,131 cc unit based on a racing the-world flight in 1985. Used in name “Revolution Engine” for the engine, whose power and engine sports planes and airships, the PFM “V-Rod” model of the American sound enthused discriminating 3200 was noted for low fuel con- manufacturer Harley- Harley-Davidson customers in equal sumption, low noise emissions, Davidson. Against the background measure. Another focus of the development project was the highly dynamic drivetrain relationship between the and . Of course, the production- side improvement was part of the order, as the engine was produced under common responsibility in a joint venture between Harley- Davidson and Porsche. I

Porsche Type 3200 aero engine with 3.2-liter capacity.

Porsche Engineering Magazine Special Issue 2006 21 Styling From vision to form

The shape of the future

The Porsche 911, a unique and unmistakable design feature.

Design has been one of the core competences of Porsche ever since it started building sports cars. Porsche Engineering makes the skills of its stylists in the area of Automotive and Transportation Design available to its customers.

The styling that is so typical of design, thanks to its clear basic Porsche has evolved over decades. design concepts. The shape of this Sports cars such as the Porsche classic sports car has been careful- 356, the 550 Spyder and the 904 ly enhanced and interpreted in a Carrera GTS have written the histo- contemporary fashion by Porsche ry of design and exerted repeated stylists for more than four decades. influence on international car pro- The highest maxim of the in-house duction. The Porsche 911 in partic- designers has been and remains ular is considered an icon of classic the visualization of the innovative Porsche 356 Coupé in the year 1951.

22 Porsche Engineering Magazine Special Issue 2006 From vision to form Styling

offers international customers from machinery to agricultural machinery the automotive industry and various or aircraft and commercial vehicles. industrial sectors extensive experi- Porsche styling lends products their ence in the field of automotive and own personality through clear design. transportation design. A focal point of the company’s com- petence lies in the area of ergo- Designing in unfamiliar territory has nomics. Even in the early 1980s, Ferdinand Alexander Porsche working at long been one of the focal points of Porsche engineers helped design the drawing board. the work performed by Porsche the cockpit layout for Airbus pas- stylists. The transfer of automotive senger jets in cooperation with the technology found in the Porsche designs to other vehicles often Airbus industry, and set a trend by model family through its exterior results in completely new aesthetic using displays instead of conven- design. concepts. Consequently, the tional instruments. I Porsche designers consider feasi- Porsche sets a high design and bility and the necessary manufactur- quality benchmark for its customers ing processes right at the design and develops cars for them with stage. the same passion as it does its own vehicles. As a design partner, Pursuing new ways that go beyond Porsche Engineering Styling repre- the mainstream is a tradition at sents far more than just pure prod- Porsche. The diversity of the range uct design. The significance of of products Porsche designs is strategic design has long been almost unsurpassable: from cars to Porsche engineers designed the cockpit of the Airbus A 310 from an ergonomic per- known, and Porsche Engineering motorcycles, from construction spective.

Apart from designing cars, Porsche stylists work on everything that moves. The range of designs is covering commercial vehicles, motorcycles and for example.

Porsche Engineering Magazine Special Issue 2006 23 Electrics & Electronics From architecture to intelligence

Hardware, software and system development from one source

A fully networked system takes care of all electronic data exchange in the Cayenne.

In terms of complete vehicle development, automotive electronics are among the most important aspects of Porsche Engineering.

No other area of automotive tech- in the vehicle and the possibilities In the past the innovative power of nology has such a high rate of in- this presents, Porsche Engineering Porsche in the area of electronics novation that lets us talk about a is occupied with the development has manifested itself time and “ revolution”. In particular, the and integration of electrical and again in its own sports and racing intelligent networking of compo- electronic systems for the body, cars. In 1985 the sports car manu- nents and systems has a special drivetrain and chassis. Other areas facturer from Stuttgart showed significance that will continue to cover software and telematics, con- what was possible when it present- increase as time goes by. The core trol and display components, the ed the with an elec- competence of the Electrics & development of vehicle electrical tronically controlled chassis and Electronics area therefore lies in systems and networking, multime- program-controlled all-wheel drive. the system integration of electronic dia, HMI (human-machine interface) The technology platform 959 is still components and the exploitation of and EMC (electromagnetic compati- setting trends, as the drive man- their potentials. Given the constant- bility). agement system of the current ly increasing quantity of electronics Porsche 911 Turbo shows.

24 Porsche Engineering Magazine Special Issue 2006 From architecture to intelligence Electrics & Electronics

by the gears can be changed fully automatically as well as manually. With the “Tiptronic S” Porsche cus- tomers now also have the option to choose between manual operation and automatic mode. In automatic operation the shift points of the 5-speed converter are defined and controlled electronically, depending on the style of driving: A basic gearshift program supports eco- nomical driving and a sports pro- gram maximum driving perform- ance. Porsche Communication Management (PCM) in the Cayman S.

Porsche is also a pioneer when it The redeveloped, controlled all- controlled multi-disk that pro- comes to electronic driver informa- wheel drive enables the immense vides the ideal distribution of power tion systems: The first electronic engine power of the 911 Turbo to between the front and rear instrument cluster with an informa- be converted into propulsive power within fractions of a second. In tion and diagnosis system world- as the situation demands. The 1989, Porsche offered a new, elec- wide was introduced in the Porsche Porsche Traction Management tronically controlled shift system 928 S4 in 1988. The current (PTM) has an electromagnetically under the name “Tiptronic”, where- Porsche Communication Manage- ment (PCM) is the central control unit for the radio, CD player, sound settings, on-board computer, navi- gation, telephone and electronic logbook. Data transfer within the PCM takes place at the speed of light. A MOST data (Media Oriented Systems Transport) trans- ports the data at high speed between the individual components via optical cables without loss of signal. I

Porsche Traction Management (PTM) of the 911 Turbo with electronically controlled multiple- disk clutch.

Porsche Engineering Magazine Special Issue 2006 25 Industrial Engineering Free-thinking solutions

Expertise from automotive development for other branches of industry

The original of all tractors developed by Porsche: the “Volkstraktor” (Type 110).

Porsche has always been known for innovative and often unconventional solutions for non-automotive requirements.

The area of Industrial Engineering mercial vehicles and agricultural the “Volkstraktor” (People’s Tractor) has also a long tradition as a key machinery and, in former times, project ranged from the design of element of contract development military engineering. agricultural machinery to the plan- services at Porsche. Since the first ning of its own tractor factory days of the company’s existence, As for the Volkswagen, Porsche which was not realized due to the Porsche has served numerous engineers constructed small agri- war. In the post-war years the trac- branches of industry, which have cultural tractors since 1937 (Types tor types 312 and 313 developed benefited from the automotive 110, 111, 112 and 113), which on the basis of the Type 113 were know-how of this sports car manu- were noted for their low price, tech- to become an important building facturer. These customer projects nical sturdiness and exceptional block in the reconstruction of the focus mainly on the areas of com- range of application. The scope of Porsche KG, as it was called at the

26 Porsche Engineering Magazine Special Issue 2006 Free-thinking solutions Industrial Engineering

Ferdinand Porsche (second from right) and ACGO GmbH also makes use of Porsche know-how for its Fendt tractor. his son Ferry (right) assess a trial wind power system in 1940. time. The refined design was Claas, Porsche has developed tech- tems in the 1950s: On behalf of acquired in 1949 by agricultural nical solutions in de- DeWind AG from Lübeck, Porsche machinery manufacturer Allgaier in velopment as well as in the areas Engineering created the design for Göpping, and more than 25,000 of acoustics and vibration technolo- a two megawatt wind power sta- units were produced between 1949 gy for harvesting machinery. tion. and 1956. Constantly improved Tractor manufacturer Fendt has from 1956 to 1963 as the Porsche passed its styling projects to To mark the milestone of the devel- diesel tractor, more than 120,000 Weissach since the 1990s. opment of industrial vehicles, fork- Porsche tractors in various levels American manufacturer John Deere lift manufacturer Linde award- were built at the Porsche-Diesel- also places its trust in the many ed the order to design a new gener- Motorenbau GmbH in Friedrichs- years of Porsche Engineering expe- ation of ground conveyors to hafen. Development orders from rience in agricultural technology. Porsche in 1981. A new family of the area of agricultural technology forklift was created which still form a fixed part of the work At the same time of the orders marked the beginning of a long done by Porsche Engineering. For coming from the area of vehicle cooperation. To this day Porsche agricultural machinery manufacturer technology, the Porsche Enginee- Engineering develops trendsetting ring Office developed a series of designs for industrial vehicles on wind power systems for generating behalf of the Linde AG. However, electricity in the early 1940s. Three the convincing design is not a wind turbines were created in three means to an end, but remains func- power categories: 130 watt tional and combines the latest in (Type 135), 736 watt (Type 136) technology and innovative ergonom- and 4,500 watt (Type 137). In ics. I The lift truck designed by Porsche 2001 Porsche referred to the basic Engineering for Linde AG was awarded the “red dot: best of the best” in 2005. research done into wind power sys-

Porsche Engineering Magazine Special Issue 2006 27 Drivetrain Transmitting Power

Accelerated power of innovation

The C with Porsche double-clutch transmission was used successfully in racing in 1987.

The Drivetrain section at Porsche Engineering customers and the trade in equal offers its customers the broad knowledge of a measure. The Cayenne series is the highpoint of the competence in the complete vehicle developer with decades of all-wheel drive sector which Porsche competence. has built over decades. At the turn of the last century Ferdinand Porsche was the first automobile engineer The drivetrain technology is one of tions of individual components to to work on the four-wheel drive and the most decisive technologies of the complete development of a new even introduced the drive concept the modern automotive industry. drivetrain and its electronic control into series production. In the 1930s While a host of significant innova- systems. and 1940s Porsche technicians tions have enhanced the perform- worked on the off-road military ance of and possibilities for using The scope of application of vehicle vehicles such as the VW “Schwimm- the technologies, the engineering projects undertaken by Porsche is wagen” amphibious vehicle and the demands placed on vehicle and not limited only to roads, but also VW “Kommandeurwagen” command component developers have covers the development of capable vehicle, which were developed on increased constantly. The Drivetrain all-wheel systems for off-road driv- the basis of the Volkswagen Beetle. section makes this accumulated ing. In 2003 Porsche presented a The Porsche engineers made refer- knowledge available for customer multi-purpose vehicle suitable for ence to these designs at the end of projects. The spectrum of orders off-road use in the form of the 1953 in the development of the ranges from the technical modifica- Cayenne, whose technology amazed Porsche “Jagdwagen” or Hunting Car.

28 Porsche Engineering Magazine Special Issue 2006 Transmitting Power Drivetrain

was technically feasible in car mak- ing at the time.

Porsche has also been a pioneer in the field of transmission technology for decades. In 1952, Porsche pre- sented a fully-synchronized trans- mission with ring synchronization at the which was to set the trend for automotive construction. The synchronous transmission from Zuffenhausen not only helped Porsche sports cars achieve dynamic driving properties; The Porsche transmission with ring synchronization was to set the trend for automotive con- more than a million units were also struction. built under license for other car manufacturers until 1968. The This amphibious all-wheel drive vehi- fitted with a switchable all-wheel patented was also cle was created as part of a tender drive. Porsche tested the drive used in Formula 1, when Mercedes- for the German Army and went into technology of the Porsche 959 in Benz used synchronous rings of the small-scale civil production in 1954. the Porsche 911 Carrera 4x4 used “System Porsche” for the transmis- in rallies in 1983 and 1984. sion of the legendary W 196 racing Porsche is also a pioneer of all- Electronically controlled, the all- car. wheel technology in motor sports. wheel system which was fitted as The Type 360 Cisitalia Grand Prix standard in the 959 showed what Another technological highlight was racing car completed in 1948 was the Porsche double-clutch transmis- sion (PDC) developed in Weissach. This first sequential transmission with two countershafts and double- clutch was initially tested in a Porsche Type 956 in 1983. For the first time the PDC allowed gears to be changed without a loss of accel- eration, and is considered the tech- nical forerunner of future genera- tions of transmission, which can also be used in series production thanks to modern control techno- logy. I The drive of the Type 360 Cisitalia Grand Prix racing car with an output of 385 bhp (1948).

Porsche Engineering Magazine Special Issue 2006 29 Body & Safety From form to function

Unconventional ways for body concepts

The Auto Union P-Racing car (Type 22) on the Nürburgring in 1936.

Developing the body is an important part of modern car production. At Porsche, individual concepts are guarantees of success for developing its own and its customers’ cars.

The special interfacing competence 1930s. The shape of the VW Beetle attached to the A- for safety of Porsche Engineering lies in the came about from the fashion for reasons. merging of styling, integration, streamlining and from the require- packaging and functionality. As a ment in the specification to provide series car manufacturer, Porsche seats for four people. Unique also has years of experience in design elements were engineered integrating components and sub- for the individual body areas, which systems perfectly in the develop- formed an organic whole together. ment and production of the com- Even at that time, construction plete vehicle. work was so clean that the Volks- wagen had no welded seams that The targeted speed of the T 80 of more than 600 km/h necessitated special body Porsche already exhibited trend- had to be concealed with solder. geometry which was based on aircraft con- setting engineering thinking during The VW Beetle was also one of the struction. the ‘Volkswagen’ project in the first cars to have the door hinges

30 Porsche Engineering Magazine Special Issue 2006 From form to function Body & Safety

Porsche again exhibited technical farsightedness with the Auto Union P-racing car, which was developed alongside the Volkswagen, and showed how the technical concep- tion of a vehicle could also have a positive influence on the external form. The mid-engine layout of the racing car did not only ensure an ideal distribution of weight and excellent centre of gravity, but also became a technological model for First aerodynamic tests were carried out on the Porsche 356 using pasted woolen threads. generations of motor sports vehi- cles. The high-speed record-break- ing T 80 constructed by Porsche sparkled with a cd value of Carrera GT also has excellent safe- engineers on behalf of Daimler-Benz just 0.296. ty potentials. AG was built from 1937 until 1939. Powered by a 3,500 bhp aircraft Innovative concepts and combina- To achieve the highest possible engine, the T 80 should have bro- tions of materials have been a negative lift coefficients, the ken the speed record for land vehi- special element of Porsche`s body Carrera GT has a floor geometry cles, but this was prevented by the development from the very begin- usually found in racing cars. The outbreak of war. The seat position ning. The objective is the synthesis fully clad underbody made from car- of the pilot was located between of maximum light-weight construc- bon has a rear diffuser and flow two side rudders that were sup- tion for the body and components, ducts that provide an unusually high posed to provide directional stabili- and maximum demands on safety suction effect for road vehicles. I ty. Anhedral side wings generated and rigidity. The best example is the necessary down force. the GT. For the first time in a production vehicle Vehicle aerodynamics and wind you find a chassis and tunnel tests were already a fixed the super-sports car’s engine mount part of Porsche`s development made from carbon-fiber reinforced work in the 1930s. Ferry Porsche plastic (CFRP). The material carbon and Erwin Komenda used the test creates after complex processing results obtained before the war the ideal conditions for combining when they designed the shape of superb handling and driving dynam- Apart from the monocoque and engine mount of the Carrera GT, numerous other the Porsche 356 in 1948. There- ics with minimal weight. Apart from components were made from carbon-fiber fore it was no surprise that the early ideal performance the Porsche reinforced plastic (CFRP). coupé version of the Porsche 356

Porsche Engineering Magazine Special Issue 2006 31 Production Engineering From production planning to quality assurance

From designing to the start of production

Leipzig are the result of a produc- tion process that has undergone decades of constant evolution. The company first moved into the Zuffenhausen factory in 1938, but the war forced a relocation to the Austrian town of Gmünd in Carinthia in 1944, where a total of 53 Type 356 cars were assembled by hand up to 1950. Since July of that year the production of Porsche sports cars has taken place in Zuffen- Building the engine for the Porsche 356 in 1953. hausen. Due to the expansion of capacity needed for the construc- tion of the Porsche Cayenne, a new The services offered by Porsche Engineering production site was built in range from the initial design sketches to the in 2000, which meets the very lat- start of production. est requirements. Apart from the high-performance Carrera GT sports car produced until 2006, the four- The constantly increasing rate of over many years has given Porsche door Panamera sports coupé will innovation cycles and the accompa- unique competence in the manage- roll off the production line there nying diversity of products and vari- ment of production, quality and starting in 2009. I ants are linked with development logistics. Porsche Engineering and product launch times becoming offers this comprehensive know- shorter and shorter. Through its how to its customers. Production Engineering area, Porsche Engineering makes the This area of performance is also experience it has gathered on the based on a gamut of experience production lines in Zuffenhausen amassed over decades at Porsche. and Leipzig available to its cus- For the Porsche Engineering Office tomers as a management service. the order to build the Volkswagen As the most profitable car maker in contained not only the vehicle-relat- the world, Porsche AG is consid- ed development, but also covered ered the epitome in the planning of the planning of an independent production processes and tech- plant from 1936 on, which exists to niques for large and small-scale this day as the main VW plant in series production. A continuous Wolfsburg. The production methods process of improvement to tech- used in the current Porsche facto- A total of 1,270 Porsche Carrera GT high performance sports cars were produced at nologies and processes carried out ries in Stuttgart-Zuffenhausen and the Leipzig site up to May 2006.

32 Porsche Engineering Magazine Special Issue 2006 Milestones Special

Milestones in Customer Development from 1931 – 2006

1931 1933 1934 1937 1939

Under the model The Type 32 Daimler-Benz AG designation Type 64 compact car built on gives the Porsche and, respectively, The Porsche Working on behalf of behalf of NSU-Werke Engineering Office Type 60K10, Engineering Office Zündapp GmbH, the features an air- the assignment to Porsche develops a receives the official Porsche Engineering cooled flat-four fitted build the T 80 World racing coupé with an assignment from the Office develops the at the rear and uses Speed Record Car. aerodynamic alumini- “Reichsverband der Type 12 compact Porsche’s torsion Powered by a 3500- um body for the Deutschen Auto- car with many techni- bar suspension con- bhp aircraft engine, Berlin-Rome long- mobilindustrie” cal features paving cept. the T 80 is to break distance race. (“Reich Association the way for the sub- the world land speed of the German sequent Volkswagen The Auto Union P record. But the Based on the “KdF Automotive Industry”) Beetle. Type 22 racing car record attempt for Car”, Porsche builds powered by a 16- (RDA) to design and 1939 had to be can- further models for build the Volks- Developing torsion cylinder mid-engine celled due to the military use such as wagen. The design bar suspension, is built by Porsche War. the Type 82 VW and construction Porsche creates a en-gineers according “Kübelwagen” or the work for the Type 60 new sus-pension con- to the rules and reg- The Type 110 small all-wheel-drive Type model, as it is cept destined for ulations of the new farming tractor sets 87 “Kommandeur- called, is based on successful use over 750-kg Grand Prix the foundation for wagen” or “Com- Ferdi-nand Porsche’s many decades in racing formula. the subsequent mander’s Car”. “Study for the international automo- “People’s Tractor” Construction of a bile production. and the Porsche German Peo-ple’s diesel tractor. Car”.

Porsche Engineering Magazine Special Issue 2006 33 Special Milestones

1942 1947 1952 1954 1955

As part of a tender from the German The Type 360 Grand Army, Porsche devel- Prix racing car devel- ops the amphibian oped on behalf of all-wheel-drive Type Porsche KG receives Porsche KG receives Italian car maker 597 “Jagdwagen” or the assignment to a major development Cisitalia is far ahead “Hunting Car”. And build the Type 205 assignment from US of its time: Power although the “Jagd- “Maus” armoured car car maker Stude- Working on behalf of comes from a super- wagen” is acknowl- driven by a com- baker. During this Volkswagen AG, charged 1.5-litre edged to be techni- bined gasoline and two-year period of Porsche’s construc- twelve-cylinder and is cally superior, the electrical power sys- cooperation, tion engineers devel- transmitted to the assignment is award- tem and weighing a Porsche develops op Type 672, a com- wheels by manually ed for market and total of 189 tonnes Type 542, a modern pact concept car activated all-wheel- political reasons to following completion four-door saloon with rear-wheel drive. drive. DKW, the German of the design and regrettably never to This prototype is manufacturer of cars drafts. In all, howev- enter series produc- powered by an extra- and motorcycles. er, only two proto- tion due to a short- flat six-cylinder types of this age of funds on the underfloor engine. are ever built. part of Porsche’s US customer.

34 Porsche Engineering Magazine Special Issue 2006 Milestones Special

1959 1960 1961 1971 1973

Porsche presents In summer the the Longlife Car Development Division Conceived as the Research Project at complete with the potential successor Following the assign- the Motor Construction, Test- to the VW Beetle in ment in 1958 to Show, a concept car ing, and Design both and develop a battle designed for twenty Porsche presents a Departments starts design, tank, construction of years of reliable use. complete range of to move to Porsche’s Type 728 (Develop- the Type 814 aircraft engines at new Development ment Assignment 53) Leopard tank starts the German Centre in Weissach. is completed in in 1961, with a total Industrial Fair in In the years to spring 1960 on of 2,400 units sub- Hanover. Engine out- come, the Weissach behalf of Volks- sequently going to put ranges from the Development Centre wagen. the German Army. 65-bhp Type 678/1 completes not only Development of the all the way to Type numerous design Type 807 rescue 678/4 developing no and construction tank extends from less than 75 bhp concepts for Volks- 1961 to 1966. starter output. wagen, but also projects such as a compact four-cylin- der power unit for Spanish car maker Seat or a complete small car for state Russian car manufac- turer AvtoVAZ (Lada).

Porsche Engineering Magazine Special Issue 2006 35 Special Milestones

1975 1977 1979 1981 1982

In cooperation with The SAVE (Rapid Airbus Industries, Ambulant Pre-Clinic engineers in Weissach The Measuring Referred to within Initial Treatment) set out to design an Centre for the Company as project for the devel- ergonomic cockpit Environmental Type 995, the con- opment of an innova- layout for the Airbus Protection, the first cept of a sports car tive ambulance sys- passenger aircraft. self-sufficient of the future is devel- tem is made up of a On behalf of the exhaust emission oped in 1979 on rescue vehicle com- German Federal Using the flat-six test centre in the behalf of the German plete with a mobile Ministry of Research power unit carried world, is opened in Federal Ministry of rescue unit and is and Technology, the over from the late autumn 1982. Research and Tech- consistently enh- Weissach Develop- Porsche 911, engi- Fully computerised, nology. This four- anced in an ongoing ment Centre com- neers in Weissach the test stands and door concept car process and various pletes the O.R.B.I.T. create Porsche air- dynamometers in focuses in particular project phases until firefighting system. craft engine PFM Weissach simulate on fuel economy, 1984. The purpose of this 3200 conceived to real-life driving condi- safety, and noise research project is power small aircraft. tions and thus serve emissions. After development to support the fire to reproduce various assignment EA 425 brigade by means of From 1981 to 1984 test cycles. Test conducted on behalf trendsetting techni- Porsche develops an series under all kinds of Volkswagen for a cal equipment. entirely new range of of climatic and alti- successor to the VW trucks. This marks tude conditions can Porsche 914 is dis- the beginning of a be carried out in the carded, Porsche de- joint venture lasting climate pressure cides to launch this many years. chamber. front-engined sports car under the name Porsche 924.

36 Porsche Engineering Magazine Special Issue 2006 Milestones Special

1983 1984 1987 1988 1990

The Porsche double clutch transmission (PDK) developed in Weissach enables The Type 2708 rac- the driver to shift The Weissach ing car developed gears without the Development Centre for the US CART slightest interruption Porsche develops is further enhanced Series is an all-new of engine power and the Lada “Samara” and upgraded by a construction with an torque. on behalf of state modern crash test aluminium-plastic Russian car manufac- facility with perma- monocoque body. The TAG Turbo power turer AvtoVAZ. This nently installed con- The power unit is a In spring Porsche AG unit developed on robust compact car trol and supervision 750-bhp V8 racing starts assembly of behalf of British with front-wheel drive technologies. Apart engine running on the Mercedes-Benz Racing Team McLaren is conceived parti- from Porsche sports methanol. 500 E. Apart from a international makes cularly for the cars, models from wide range of devel- its debut in the demands made by other manufacturers opment activities, McLaren MP4 road conditions in are also tested here this assignment from Formula 1 racing the . on behalf of various Mercedes-Benz AG car. Output of this customers. includes the con- turbocharged 1.5- struction of the litre V6 is up to body-in-white as well 1000 . as the final assembly The TAG Turbo made process. by Porsche becomes the dominating power unit in Formula 1 from 1984 to 1986.

Porsche Engineering Magazine Special Issue 2006 37 Special Milestones

1991 1993 1994 2001 2002

On behalf of Adam Porsche Engineering Opel AG, Porsche Group GmbH (PEG), a A highlight in the Customer wholly-owned sub- In a joint venture joint venture with US Development starts sidiary of Porsche AG, The 3.5-litre twelve- Audi and Porsche motorcycle manuf- the overall develop- officially commences cylinder Grand Prix develop a high-per- acturer Harley ment of a compact its business activities power unit developed formance sports Davidson conducted van according to a on August 1st. by Porsche is sup- estate, the Audi since 1997 is the pre-determined con- plied exclusively to Avant RS2. Starting completion of the cept. the Footwork Arrows in October, the Avant Revolution power Racing Team in the RS2 is built in the unit developed by Porsche AG takes 1991 Formula 1 Zuffenhausen Plant Porsche to produc- part in an interna- season. parallel to the tion standard and tional presentation at Mercedes-Benz featured since 2002 the Peking World E 500. in the Harley Trade Centre, togeth- Davidson V-Rod. er with 19 other manufacturers. The C88 family car pre- sented on the occa- sion is a concept vehicle developed by Porsche Engineering Services especially for the Chinese mar- ket.

38 Porsche Engineering Magazine Special Issue 2006 Complete Vehicle · Styling · Body & Safety · Engine · Drivetrain · Chassis · Electrics & Electronics · Testing · Industrial Engineering · Production Engineering

Since 1931 we tinkered. And we’re not finished yet.

75 years of Porsche engineering services.

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