Porsche Engineering Magazine

Issue 1/2009

No interference A look back at the past New EMC test chamber in operation The new Porsche Museum

Perfection is in the detail Safely tucked in with Porsche Focus on Exclusive & Tequipment New hospital bed design Contents

Contents

Editorial 3

About Porsche Engineering 4

Safely tucked in with Porsche 5 Developing a hospital bed

Designing new machines 8 Social commitment in Markgröningen

A roof over your head 10 Developing the Targa glass sunroof

EMC testing 12 No interference

Review 14 Milestones in customer development

Development history 16 The new Porsche Museum

Focus on Exclusive & Tequipment 19 Quality comes from attention to detail

Panamera 23 The fourth dimension

Special feature 26 The No. 1

2 Editorial

Dear Readers,

We are ambitious. Our aim is always to be one step ahead. Our ambition drives us to be faster than others. Porsche is famous for speed and for technical depth. Because we focus on creating the products of the future.

These virtues are more important than de monstrate not only our technical skills ever in light of the major economic chal- but also our social commitment. lenges we are all facing. In all areas of technology we must take what is good Even during the development of state- and improve on it. of-the-art hospital beds our engineers have followed the principle that there Our ambition is what transforms every is always room for improvement and customer project into a challenge. Our have left their mark on the design. We engineers know that there is always room also give an insight into some of the for improvement. They translate this prin- products we have developed for Porsche ciple into every language and are under- Exclusive & Tequipment which make each stood throughout the world. Anyone who of our cars unique. is constantly looking ahead can also occasionally take the time to glance over Porsche and innovation have always their shoulder. In this issue we have gone hand in hand. We offer you the allowed ourselves the luxury of looking chance to find out about the inspira- back over our history. You can find out tional Porsche fourth dimension, the more about Porsche’s very first model and new Panamera. You can also take a get a taste of the newly opened Porsche look at our new EMC test chamber in Museum in Stuttgart. The museum has Bietigheim. Come with us on a brief on display some of the many and varied journey through the world of develop- Porsche customer development projects ment and find out first hand about our from the last 75 years. In this issue we fascinating work and the principles that have highlighted some examples. guide us.

Despite the challenges mentioned, we deeply value using our skills on behalf We hope you enjoy the latest issue of of less privileged people. You can read our magazine. about the development of a special production machine for a workshop for Dr. Peter Schäfer and Malte Radmann, disabled people which allowed us to Managing Directors of Porsche Engineering

3 Impressum

About Porsche Engineering

At Porsche Engineering, engineers are automotive developer for your project working on your behalf to come up with or would prefer a specialist system new and unusual ideas for vehicles and developer, we can offer both, because industrial products. We develop a wide Porsche Engineering works at the inter- variety of solutions for automotive face between these two areas. All the manufacturers and suppliers, ranging expertise of Porsche Engineering has from designing individual components been brought together in Weissach, but and complex modules to planning and is available all over the world, including implementing complete vehicle devel- on-site at your premises. Wherever opment projects, including managing we work, we bring a part of Porsche the start of volume production. What Engineering with us. If you would like to makes our services special is that they find out more about the different areas are based on the expertise of a major of our business, please visit our website car manufacturer. Whether you need an at www.porsche-engineering.com

Impressum • Porsche Engineering Magazine

Publisher Editor Porsche Engineering Group GmbH Nicole Möller

Address Design: Machart–Design, Stuttgart Porsche Engineering Group GmbH Repro: Piltz Reproduktionen, Stuttgart Porschestraße Printing: Leibfarth&Schwarz, Dettingen/Erms 71287 Weissach, Germany Translation: TransMission Übersetzungen, Stuttgart Tel. +49 711 9118 88 88 Fax +49 711 9118 89 99 All rights reserved. No part of this publication may be reproduced without the prior permission of the E-mail: [email protected] publisher. We cannot guarantee that unrequested Website: www.porsche-engineering.com photos, slides, videos or manuscripts will be returned.

4 Electrics & Electronics Völker

The Porsche under the Hospital Bed

Safely tucked in with Porsche. Porsche Engineering which specialises in the production of develops new drive and control units for hospital and innovative hospital and nursing beds. In order to ensure that its products nursing beds. meet the requirements of professio nal hospital care and comply with the latest technical standards, Völker turned to Even hospital beds need good requirements and short innovation Porsche Engineering for help. brakes cycles. The demands placed on these products are not only the result of legis- It’s true that the engineers at Porsche Manufacturers of medical products are lation and competition. Patients also Engineering are not accustomed to required to meet increasingly strict require the latest technology in the pro- dealing with hospital beds on a daily standards. The development process is ducts they use. One company that has basis, but they are experts in devel- characterised by high safety and quality to meet these high standards is Völker, oping electronic systems and electric

5 Electrics & Electronics Völker

motors. In the many departments at One type of motor for all the drive Single-fault safety guaranteed Porsche Engineering, a wide variety of functions products are developed for customers The new electronic system developed every day, so an innovative drive system What makes this development so spec- by the Porsche engineers guarantees for hospital beds was another exciting ial is that the new HV02 motor can be single-fault safety without the patient new project. used as the main drive unit for a wide functions needing to be blocked, for range of functions, such as the tele- example. A pulse width modulation sys- A Porsche in the hospital scopic lift. It can also function as a single tem ensures that the bed moves at a drive unit for the trapezoid lift and the uniform speed, even with varying loads, This development project resulted in propulsion system and as a dual drive which has allowed the safe operating engineering a system based on a LIN unit for adjusting the mattress frame, load to be increased to 250 kilograms. which is divided into four parts. The A 300 VA transformer is used for this motor is designed for easy installation, purpose. This is the equivalent of dou- as in the automotive industry. The con- ble the previous power supply. The sig- nector system meets the highest indus- nificant power reserve in the trans- try standards. No wire or soldered joints former also gives it a longer duty cycle are needed as the connectors are bas- (20 percent instead of the conventional ed on the Poka-Yoke principle, which 10 percent). At the same time, the heat helps to prevent faults. loss from the transformer has been reduced. The newly developed nurse control unit The developers from Porsche Engineer- ing naturally focused on good brakes, The newly developed battery system in the same way as they would do with a also offers a number of benefits. The sports car. Even with larger loads, such increased capacity of 7.2 Ah allows the as heavy patients, the brakes ensure adjustment functions to be used without that the mattress frame remains safely mains power supply for a longer period in its preset position by using a specific of time which increases patient safety. holding torque. The battery no longer functions only as an emergency backup. A dual drive unit is better The new hand control unit. Both devices are laser welded to ensure that they are robust and The dual drive unit in the centre of the water-tight bed moves the parts of the bed which support the patient's back and those (local interconnect network) bus, con- which support the thighs. The adjustment sisting of four basic components: an angles are permanently stored in the dual electric drive motor, a hand control unit drive system, which allows for positioning for patients, a nurse control unit and a without a homing mode and limit switch. power supply. The system meets the Another benefit of the new unit is that latest safety standards in the field of partial manual adjustment of the back medical technology and is designed for support is now possible without the bed use in a demanding hospital environ- having to move to the limit switch before A glimpse into the internals of the DA01. The easily ment. it can continue operating. removable batteries are clearly visible

6 Electrics & Electronics Völker

dundant tests. If the tests do not produce plausible results, the power and therefore the control functions are shut off. The developers have ensured the safety of the system by taking a func- tional approach to safety, similar to that employed in the automotive industry, and by applying a highly detailed FMEA (failure mode and effects analysis).

Service technicians in mind

It is only to be expected that the engineers at Porsche Engineering constantly come back to automotive concepts. For example, they have developed a The LIN bus system, which has been specially designed to meet the requirements of the Völker beds, diagnostics tool similar to that used by controls all the motors and drive components service technicians in a car workshop. This tests all the components connect- Bed controls to meet every need matically recognised and integrated ed to the bus and makes troubleshoot- by the system. Customers can also add ing much easier and quicker. The soft- The hardware and software of the additional control units to the beds at a ware can be updated without problems Völker LIN bus system was created on later date, simply by plugging them in. simply by exchanging the hand control the basis of the Porsche Engineering The number of cores in the cables in unit and the nurse control unit. development model for mechatronic the wiring loom has been reduced from components. It was successfully test- 14 to 3 or 4, which significantly lowers Objectives achieved ed by TÜV SÜD Product Service GmbH the risk of the system failing. The stan- for compliance with international stan- dardised connectors allow components All the objectives of the development dards. The specification far exceeds to be plugged into any of the sockets project were achieved. Porsche En- the requirements of the DIN EN on the bed. gineering deliberately based its pro- 60601-2-38 and FDIS 60601-2-52 ject on the high product development standards. Designed for safety standards in the automotive industry. This has given the bed manufacturer A new feature developed by Porsche The safety concept developed by Völker a higher quality product and a Engineering is the plug-and-play exten- Porsche Engineering ensures that all decisive advantage over its competi- sion which is fully compliant with the the bus components, including the tors. An ongoing risk assessment was LIN standard. This allows components motor management unit, the power carried out by TÜV SÜD Product Ser- to be added to and removed from the supply and the control units, have self- vice through-out the course of the pro- LIN bus while the bed is in use. As a monitoring functions which are inde- ject. The main focus was on safety and result, the bed can be equipped with a pendent of one another. Critical safety availability, because the highest prior- variable number of hand control units parameters, such as the power supply ity is to ensure that patients are not and nurse control units which are auto- or the position, are subjected to re- put at risk.

7 Social Commitment Insights

Four “Porsches” for Markgröningen

Porsche Engineering develops four machines for the The group considered very carefully disabled workshop in Markgröningen to help with the which project they should choose. Final- ly they decided to support a charitable production of jerry can lids. organisation and to use their skills for the benefit of the employees in the workshop at Markgröningen. Michael Holdreich simply can’t stop can lids. Michael Holdreich and his col- smiling. And why is he so happy? It’s leagues produce around 1.5 million of The call from the team came just at the quite simple. “Because he now has his these each year. right time for Karl-Heinz Dettling, works very own Porsche,” explains Frank manager at the workshop. He had been Sayer, project engineer from Porsche A total of ten engineers developed looking for a suitable machine to help Engineering. The “Porsche” in this case the four machines for the disabled his employees with the production of is standing on a work bench and is blue workshop in Markgröningen as part jerry can lids for a long time. At that and box-shaped. It is one of the four of the trainee development programme point each individual lid had to be pro- machines developed by the engineers at Porsche Engineering. During the duced manually using a lever press at Porsche Engineering for the disabled 18-month programme, trainees work operated with one hand. This was very workshop in Markgröningen. The ma- on a project which allows them to put tiring work. “It was not only monotonous chine helps in the production of jerry into practice what they have learned. for the people here but it also meant that

8 Social Commitment Insights

specially designed for the needs of a specific user group. This meant that the work processes were adapted to suit the users and not vice versa. The team achieved all its objectives and the original project description “Development of a device to make assembly work easier and increase productivity” has become a reality. The implementation of the machines was divided into four areas. While one group worked on the controls and sensors, another purchased the necessary materials. A third group designed the parts holders and base plate and the fourth group was responsible Contract production of jerry can lids for the press unit and the frame. they were putting a strain on one side Porsche but four, which all of them en- The best thing of all is that, because the of their bodies,” said Dettling. The new joy using. lids can now be manufactured more machine has also reduced the number quickly, the workshop’s productivity has of rejects and the time needed for quali- The project team demonstrated that it increased. As a result, it can take on ad- ty control, making more time available was able to meet complex challenges ditional orders and offer its employees for producing the lids. In three stages and, in particular, to develop a machine more variety in their work. the machine brings the clip, the seal and the lid together (see the picture on the left hand page). One major benefit Engineering drawing of the parts holder of the machine is that the employees themselves decide when to start the mechanical press process. “This is particularly important, because it ensures that the employees are not subjected to mental stress,” explains Sayer.

The requirements specification for the pro ject was comprehensive, but this did not present a problem for the team at Porsche Engineering. “The engineers have succeeded in producing a superb machine,” says Dettling. The employees in the workshop are able to work more efficien tly and they are also taking pleasure in their work, which is clear from their faces. They now not only have one

9 Chassis Targa Roof

The 911 Targa: Topless in Seven Seconds

As well as the panoramic views offered by the glass roof in the Targa, it also conceals a series of ingenious technical solutions and gives the interior of the car a light and airy feel.

It is the attention to detail which makes The sliding roof comes with a new, more cable could have caused a problem when the 911 Targa a typical Porsche. The 1.54 opaque blind as standard. Fully extended, the roof is closed, but a simple solution square metre glass roof is a particularly the blind covers the entire area of the has been found. Like a seatbelt, the cable striking feature, with impressive levels sliding roof. It can be electrically operat- is rolled up using a spring which keeps it of technical sophistication. The roof ed independently of the roof. The blind tensioned. This prevents kinks forming consists of two sections: the sliding protects the occupants of the car from in the cable that could cause it to break. roof at the front and the glass rear excessive UV light and heat. The drive As a result, driver and passengers can screen. The roof can open fully and unit for the blind is mounted on the slid- enjoy their journey even at temperatures slide under the rear screen in only seven ing roof. Therefore the power cable for above 30 °C (86 °F), with the help of the seconds, leaving an opening 0.45 square the drive unit must be long enough to automatic climate control system which metres in size. provide power when the roof is open. The comes as standard.

10 Chassis Targa Roof

Equipped for extremes

According to the Porsche engineers, the drive system for the roof is as complex as the mechanism of a watch. It is powerful, rapid and almost frictionless. The precision engineers have ensured that the sliding roof made of laminated glass can open or close in seven sec - onds even in extreme situations. At high speeds in particular –the 911 Targa 4S has a top speed of 297 km/h (185 mph) – the roof is exposed to powerful wind forces and turbulence. However, all the seals in the moving part of the roof are designed in such a way that they are pretensioned by the wind forces and therefore do a more The Targa roof has a hinged rear screen effective job. The design ensures that there are no gaps in the seals and no Its special design guarantees maxi- the sunlight to penetrate into the car, whistling noises. A sophisticated coat- mum stability and allows about 300 but only 17 percent of its energy in the ing on the faces of the seals helps to individual components for the drive, form of heat. As a result, the interior of prevent the friction in the sunroof seal and operating systems to operate the car remains pleasantly bright. The guide rail from reaching excessive pro- smoothly within a temperature window electrically operated blind cuts out even portions. The coating is applied in a of around 85 °C (185 °F). more sunlight. The new fabric from layer only a few micrometres thick and which the blind is made is more opaque has a much longer service life than Protection against heat and cold and increases the amount of shade conventional coatings made of grease, from 50 to 96 percent. This means that for example. The engineers have not The engineers have shown particular the blind filters out around 96 percent only set high standards for the seal skill in the design of the glass panels. of the sunlight, corresponding to a re- faces, but also for the roof module itself. The coating allows around one third of duction in brightness from 1400 to 600 lux. In other words, this is the equivalent of normal indoor lighting. The glass Technical data: the Targa roof roof filters out a high proportion of the UV rays with the help of a special film Weight: between the two layers of glass. This 52 kg Dimensions (length x width): makes the film unobtrusive and ensures 104 cm x 180 cm that the glass roof does not have the very Materials: dark appearance of some sunglasses. Frame — steel/aluminium composite structure; Sliding roof — multi-layer As a result, driving the Targa with the laminated glass with UV-light-absorbent roof closed is a bright and pleasant ex- film between the layers; Rear screen — toughened safety glass. perience even in countries where there are high levels of UV light.

11 Electric & Electronics New EMC test chamber in operation

No Interference

A glimpse behind the scenes of the new chamber for search for the needle in the haystack. measuring electromagnetic compatibility at the Porsche Step-by-step he tests every electric motor, however small, which may operate Engineering site in Bietigheim-Bissingen. the windscreen wipers, the electric win- dows or the door mirrors, for example, for electromagnetic compatibility with Nowadays, people expect to listen to the products. The number and complexity radio and mobile phone frequencies. radio, make phone calls, surf the net and of these components has increased “There are many causes of poor recep- use Bluetooth and navigation systems in rapidly in recent years, particularly in tion,” explains the head of the EMC their cars, which means that cars contain the automotive industry. As a result, the centre in Bietigheim. “For example, in- increasingly sensitive systems. Ensuring need to measure electromagnetic com- adequate shielding of the motor or an that all the equipment functions smooth- patibility (EMC) in order to avoid or pre- unsuitable cable layout.” The highly skil- ly is the job of the specialists at Porsche vent electronic interference of all kinds led technicians and engineers in the EMC Engineering. The new test chamber in has also grown. team in Bietigheim are hot on the trail of Bietigheim will help them to achieve their the causes of interference. Their investi- objectives. Working in the new EMC test chamber gations take place in an anechoic chamber which is lined with tiles made of Electronic components play an essenti- When Ralf Fanz gets to grips with a new ferrite (iron oxide) and carbon-loaded al role in the vast majority of high-tech prototype, it’s rather like the proverbial foam pyramids to provide protection

12 Electric & Electronics New EMC test chamber in operation

from interference and ensure that all the result, a great deal of expert knowledge tion. It can take more than a year to measurements are reproducible. A se- is needed to identify all the sources of complete all the tests and resolve all cond EMC test chamber has recently interference in a car. the problems. been brought into operation in order to investigate the causes of interference The sequence of events in an It is worth mentioning that the experts quickly during the process of developing EMC test from Porsche Engineering not only test electronic systems. The latest Porsche sports cars, but also take on third-party prototypes are tested in the chamber, At Porsche Engineering the traditional projects. For example, electrically adjust- which has a floor area of 43 square me- vehicle test consists of several phases. able hospitable beds are also tested in tres and is 3.6 metres high. First of all, measurements are taken of the anechoic chamber, because their the vehicle as a whole. After this, all the electronic systems could interfere with EMC — a quality feature components except those which are critical medical devices in the hospital. In being investigated are disabled and the addition, the control unit of the bed must EMC is an essential quality feature for components under investigation are ana- not affect resuscitation equipment, such Porsche. Safety is a very important fac- lysed in more detail. As soon as a source as defibrillators. tor for all the electronic components in of interference is identified, every possi- cars. As a result, the EMC standards ble effort is made to eliminate it. This However, the specialists in Bietigheim which the Porsche cars must meet are can involve direct intervention in the con- also analyse road sensors, fire service much more demanding than those re- trol unit or shielding the feed wires. The radio systems and the electronic compo- quired by legislation, just like the require- process is not as simple as it may seem, nents of water sports equipment. “The ment for perfect reception of all the because every change can give rise to requests from customers have changed radio services offered in the cars. It is new problems. “This is why experience is significantly over the last few months. not only the seats, rain sensors, central so important in this type of work,” ex- The complexity of the projects is growing locking, navigation systems, airbags and plains Ralf Fanz. and customers value the extensive expe- coolant and oil level displays, but also rience and comprehensive expertise of the climate control system, distance sen- If all the individual components come up Porsche Engineering in its role as an sor, antitheft systems, tyre pressure con- to scratch in the tests, they are operated end-to-end development partner,” says trol monitoring system and other electro- again as part of the car as a whole, and Ralf Fanz. “We not only work on the elec- nic functions that make sports cars into new measurements are taken. During tronics systems for sensors which oper- a complex challenge for the EMC spec- this process, new sources of interference ate in the millivolt range, but also on ialist. Modern cars have between 40 may arise, which are gradually eliminated systems for hybrid and electric vehicles and 100 control units and sensors. As a until the car is ready for volume produc- which use more than 300 volts.”

The importance of EMC

Ensuring the electromagnetic compatibility of components consists primarily of two tasks. On the one hand, the effect on other devices or cars of interference emitted by electronic components must be limited. On the other hand, EMC involves protecting the component from electromagnetic influences. Different principles for different areas of application have been laid down by law. The futuristic walls of the new anechoic chamber

13 History Milestones in customer development

Milestones in Customer Development

“The important thing is Only the people who ask the right duction. This applies to vehicles, indi- not to stop questioning.” questions will hit upon the inspiring vidual components and tests. Our engi- ideas. At Porsche Engineering, these neers constantly demonstrate their Albert Einstein ideas must fulfil one criterion in partic- curiosity and their creative ideas, their ular. They must be feasible, which gen- pioneering spirit and their extensive erally means suitable for volume pro- experience.

1954 1959 1973 1975

“Jagdwagen” Typ 597 PFM 3200 aircraft engine Long-term research project SAVE

This vehicle is a true all-rounder; it can From 1959 onwards Porsche had a pro- In 1972 the Club of Rome published The SAVE vehicle is designed to pro- be driven on- and off-road and it is also gramme for developing small aircraft a report called “The Limits to Growth”. vide emergency treatment after acci- amphibious. It was developed in 1954 engines. In 1981 the development pro- Porsche’s response was a long-term dents. The modular design allows a for the German army. The all-wheel-drive cess made a quantum leap forward with research project known as the FLA. The conventional small van, for example, off-road vehicle had the opportunity to the PFM 3200 aircraft engine. The engine aim was to cover 300,000 kilometres to be converted into an ambulance. demonstrate its technical superiority. was based on the familiar and multi- in 20 years in one car. Durable and reus- The SAVE system was created in During a presentation, the Typ 597 had talented flat-six engine from the 911 able materials were used in order to 1975 and set standards in ambulance to pull its competitors out of the mud which had been extensively modified and achieve the main objective of saving design throughout the world. where they had become stuck. fitted with a propeller. resources.

1981 1984 1987 1994

Linde forklift truck TAG – McLaren Boat engine C88 Chinese concept car

Porsche began developing an entire mo- This 1.5 litre engine produces more than An engine, based on the 8-cylinder 928 Porsche presented the C88 concept del range of innovative forklift trucks for 1000 bhp. The high-performance engine engine, was developed in 1987 for use car, which was specially developed for Linde AG at the beginning of the 1980s. was developed for the British racing in offshore racing boats. A four-valve the Chinese market, at an international This was not so much business as plea- team McLaren which dominated version was used and it was fitted with family car conference in Beijing in sure, because it allowed Porsche to Formula 1 at the beginning of the KKK turbochargers with cooled turbo November 1994. There is a particular demonstrate that industrial trucks do 1980s and won three world champion- housings. The charge air and the exhaust reason behind the name C88 given to not have to be ugly. ships in a row. system were cooled using sea water. this model for the Far East. In Chinese the number 88 means “good luck”.

14 History Milestones in customer development

In fact, they’ve been doing this for more ledge base of Porsche Engineering over recent decades for its customers. than 75 years. We are ambitious and forms the foundation for solving tech- Other customer development projects our aim is always to be one step ahead. nical problems in many areas and are on display in the "Mediathek" at the projects. On these pages you will new Porsche Museum in Zuffenhausen. Development is a continuing process, find examples of the products which You can discover more about the as experience shows. The entire know- Porsche Engineering has developed museum on pages 16 and 17.

1977 1979 1980 1981

ORBIT Typ 995 Typ 960 Airbus cockpit

The ORBIT is a fire service vehicle. In Weissach Porsche carried out a re- A research study in 1980 with the name In the early 1980s Porsche developed a ORBIT stands for optimum rescue and search study with the internal code 995 Typ 960 aimed to reduce fuel consump- new cockpit in cooperation with aircraft fire fighting capabilities with integrated on behalf of the German Federal Ministry tion without weakening safety-related manufacturer Airbus. To improve work- assistance. Depending on require- of Research and Technology. The study components. To this end, the body was ing conditions in the cockpit, the engi- ments, different modules can be ad- was based on the 928. The focus was on made from HSLA steels. The use of high- neers from Weissach put themselves in ded to the basic design. This research noise emissions and fuel consumption, strength, low-alloy steels represented a the position of the pilots. The develop- study from 1977 has a similar modular along with a number of active and pas- major innovation in car design in 1980. ment of the cockpit layout created a new design to the SAVE ambulance and sive safety measures. trend in which monitors replaced the also played a pioneering role. then standard analogue instruments.

1996 2001 2004 2007

Harley Davidson – V-Rod, VR1000 race engine DeWind – wind turbine Alber – wheelchair Fendt – tractor

In 1984 Porsche developed the Evo- In the early 1940s, Porsche designed The development of an off-road electric Porsche has a long tradition of design- lution engine and participated in the a range of wind power plants for generat- wheelchair in 2004 represented unknown ing agricultural machinery, dating back design of the Revolution engine. ing electricity. This involved important territory for Porsche. The name of the to its “Volkstraktor”, a best seller in the The V-Rod was the first water-cooled research in the field of renewable energy. spring-suspension model, which was 1930s. Current developments, such as Harley engine. In 2002 the engineers Designers today are still making use of developed on behalf of Ulrich Alber GmbH, this Fendt tractor, are an impressive in Weissach developed the race en- the experience gained on this project. In was “Adventure”. The wheelchair had combination of technical expertise and gine, ready for volume production. 2001 Porsche produced this design for hydraulic damping and full independent the styling which is characteristic of This was the start of a new Harley a wind turbine for the Lübeck-based suspension. Porsche. Davidson model range. DeWind AG.

15 History The new Porsche Museum

New Museum in Stuttgart-Zuffenhausen

The exhibits in the new Porsche museum are just as eye-catching as the building itself. Visitors find themselves in a new and completely white world covering an area of 5600 square metres.

Travelling in Time through the the legendary wheel hub motor of the events as Porsche’s “Museum on Wheels”. History of Porsche Lohner-Porsche, the world’s first hybrid In 2009, for example, the 550 A Spyder automobile built as far back as in 1900, will be making an appearance in the One of the greatest and most spectacu- all the way to the latest generation of Italian Mille Miglia and the 356 Carrera lar building projects in the history of the Porsche 911. Abarth GTL will be entering the Classic Dr. Ing. h.c. F. Porsche AG was completed Adelaide in Australia. So instead of a con - in December 2008: the new Porsche From the exhibition straight to the ventional, static exhibition, the visitor is Museum in Stuttgart-Zuffenhausen. Lo- road: the “Museum on Wheels” able to enjoy a constantly changing suc- cated directly in the very heart of this cession of cars with rarities rearranged unique sports car company so rich in Porsche cars do not grow old. Instead, time and again. tradition, the Museum serves to present they become classics still suited in every the fascinating thrill and diversity of the respect for road use. Indeed, this is one Welcoming the visitor as a true Porsche brand to visitors from all over of the secrets behind the success of the guest: generosity is seductive the world. More than 80 cars are on dis- brand, which is also why the exhibits play in the 5,600 square metre (60,250 proudly presented in the Porsche Mu- The Porsche Museum welcomes the visi- square feet) Exhibition Area styled and seum are always on the move, nearly all tor with a generous gesture, the mono- designed futuristically by the Viennese of the vehicles exhibited being entered lith opening up between the lower level architects Delugan Meissl, ranging from regularly in historical races and drive and the street level to the generous height

16 History The new Porsche Museum

of 10 metres or almost 33 feet to en- hance the broad open space of the area in front of the Museum. Having passed through the main entrance, the visitor will come to the Lobby leading on to the bistro and coffee bar as well as the Mu- seum shop, the cloakroom and cash reg - isters. The rising design of the roof on the basic building structure provides ample space opposite the entrance for a second floor where the reading hall of the Archives is clearly in sight.

Moving up an escalator, the visitor enters the Exhibition Area in the upper part of The famous Porsche “Jagdwagen” (hunting car) is on display in the Porsche Engineering area the building covering an area of approxi- mately 5,600 square metres or 53,800 square feet. Now he can decide whether to start his tour of the Museum in chronological order with the history of the Company prior to 1948 or whether he would like to move on directly to the main exhibition area a few steps higher, following the likewise chronological pres - entation of the Company’s history after 1948.

Visitors can experience the fascination of Porsche on different levels

How is a Porsche created? a Porsche is created, developed and built for the customer. The question as to “how a Porsche is created?” is also answered right in the The focus is on design, development middle of this journey in time through and production, films and exhibits infor- the history of the Company: Reaching ming the visitor of development proces- the central point on the Exhibition Lev - ses taking place in parallel and offering el, the visitor is offered an insight into a good impression of how, through co - the Weissach Research and Develop- operation and networking, high-quality ment Centre as well as the Car Produc- products may be developed to full pro- tion Plant in Zuffenhausen. In the production standard within a relatively short More than 80 eye-catching exhibits are on show cess, cutaway models demonstrate how time.

17 History The new Porsche Museum

The Porsche No. 1 is one of many highlights of the new museum. You can find out more about the car in the museum itself or from page 26 onwards

Unique: the “transparent” Museum The creative think-tank: engineering services. Exceptional exhibits Workshop and the Porsche Archives Porsche Engineering such as the rare Porsche Hunting Car built in 1956, the C88 concept car de- Porsche lives out its history – and cus- During his – or her – journey through the veloped for the Chinese market in 1994, tomers live out Porsche’s history too. history of Porsche, the visitor will also and the McLaren MP4 TAG Formula 1 To ensure the highest level of care and encounter Porsche Engineering. Ever racing car powered by a TAG Turbo en- maintenance for the brand’s historical since Ferdinand Porsche established his gine made by Porsche emphasise the cars, Porsche has established a special Construction Office in 1931, Porsche has sheer diversity of Porsche’s develop- Museum Workshop where private cus - offered external clients a wide range of ment activities for other manufacturers. tomers are also able to have their classic cars restored. The visitor, in turn, has the opportunity to watch Porsche’s mas - Dates and facts ter mechanics and specialists working Overall cost: Approx. Euro 100 million on all kinds of classic Porsches. For be- Dimensions of Museum Building: 140 metres/459 feet long, 70 metres/230 feet wide fore the visitor even enters the exhibi- Overall surface of Museum Building: 25,800 square metres (277,600 square feet) Weight of Museum Building: Approx 35,000 tonnes tion, he will pass by the glass partition Concrete: Approx 21,000 cubic metres to the Museum Workshop, enjoying a Steel: Approx 6,000 tonnes truly unique experience of transparency Excavation (earth): Approx 66,000 cubic metres Facade area of Exhibition Building: Approx 10,000 square metres (108,000 square feet) offered the world over in this way only made up of approx 30,000 rhomboid sections by the new Porsche Museum. Exhibition area: 5,600 square metres/60,250 square feet Exhibits: Approx 80 Museum cars and 200 small exhibits Overall collection of Museum cars: More than 400 exhibits The historical Porsche Archives with all Conference area: Approx 600 square metres/6,450 square feet, flexible arrangement thanks to moving partitions its treasures has also moved to the new Roof terrace: Approx 800 square metres/8,600 square feet Museum and is partly in sight through Other Features: Christophorus Restaurant, Museum Workshop, glass walls from the lobby. After register - Porsche Archive, Museums Shop, Coffee Bar, Museum Restaurant “Boxenstopp” ing in advance, specialists and enthusi- Porsche Museum, asts are able to visit the archives for Porscheplatz, 70435 Stuttgart, Germany, www.porsche.de/museum their research on the history of Porsche.

18 Porsche Exclusive & Tequipment Personalisation

Engineering Art

Porsche Exclusive & Tequipment are synonymous right from the factory, when a customer with the highest level of personalisation possible in orders a new Porsche. For cars which are already on the road, the Porsche a Porsche. Tequipment programme offers a variety of retrofit personalisation options. A wide range of optional extras are available in The creativity and individuality of our thing is possible for different mo d els almost all product categories for the customers are realised by the special- from sophisticated and stylish interiors sports cars and the Cayenne. ists at Porsche Exclusive & Tequipment using hand-sewn, high-quality leather through their advanced technical skills, through to Aerokits and SportDesign We would like to present some of these carefully selected materials and close packages. These have, of course, been products here and explain the complex attention to detail. The result is often a tested in Porsche’s own wind tunnel. development process which underlies completely unique vehicle. Almost any- Porsche Exclusive represents individuality them.

19 Porsche Exclusive & Tequipment Personalisation

The Cayman Aerokit underwent extensive testing in the wind tunnel in Weissach

Perfection is in the detail One of these examples is the Cayman Aerokit. It is the perfect complement Where perfection is required, the Porsche for the car’s elongated coupé shape. It development engineers are not far be- makes the Cayman look even more hind. Details are more than just indi- sleek and dynamic. It also improves the vidual components. They form part of a car’s aerodynamic efficiency, while re- harmonious whole. Each element must taining its existing drag coefficient. The The rear spoiler of the Cayman improves its not only be visually appealing but also result of extensive wind tunnel testing is stability and agility technically excellent. For this reason all a perfectly balanced car with aerody- the Exclusive & Tequipment products namically coordinated wheel loads on catching impression which brings to for specific models are developed, test- the front and rear axle. An improved mind the Carrera GT. The sports tail ed and coordinated in relation to the nose area with spoiler lips in the body pipes highlight the athletic appearance complete car by the same Porsche engin- colour and a new fixed rear spoiler in- of the Porsche Cayenne. The precision- eers and designers who create Porsche crease the Cayman’s stability and agility cast components are produced using cars. All of this happens primarily in and, of course, make it even more en- a combination of existing manufactur- the Porsche development centre in joyable to drive. ing processes and materials. They are Weissach, from the design right through not only pleasing to the eye of the car to the final approval. All the products Just a part. Part of a dream. owner, they are also heat resistant and undergo time-consuming tests for func- exceptionally corrosion resistant, which tionality and durability during the devel- Another example of the detail involved ensures that the engineers can be opment process because they must in development work is represented by proud of the products they have de- adhere to strict Porsche quality guide- the two double-ended tail pipes developed. The exhaust system is the per- lines and standards. We will take a look signed to look like four exhausts in the fect example of detailed functionality. in more detail at these activities using rear apron of the Cayenne. The design During the design of the sports tail specific products as examples. is original and makes a powerful, eye- pipes a precision-cast aluminium com-

20 Porsche Exclusive & Tequipment Personalisation

Exclusive finish for components, for example using carbon fibre (left); Cayenne sports tail pipes (right) ponent was used for the first time, to- bonded together to form a wax stick or cess. Contact surfaces, clips and drilled gether with several other parts made of casting cluster. A ceramic shell must be holes for the inner cone, together with stainless steel. The tail pipes were ready applied to the wax casting cluster in the the support and mounting for the twin for volume production in just ten months. next stage of the precision casting pro- stainless steel pipes, result in a labyrin- cess. This is achieved by dipping the thine interior behind the solid outer cov- New technologies were used to join the casting cluster several times into a cera- er. The shape leads to large undercuts components of the pipes together. Rapid mic bath. Following the fully automated and different wall thicknesses in the prototyping allowed sample parts to be process of creating the ceramic shell, precision-cast component. The design produced in a very short time which which takes several days, the wax is melt - of the assembly and the high level of ac- could be fitted to cars and thoroughly ed, the shell is fired and the precision curacy of the precision casting process tested on the road. Rapid prototyping is parts are cast out of aluminium alloy mean than no machining is needed. The a process in which a component is built using a low-pressure casting process. In delicate aluminium casting gives the up in layers from amorphous or free- the subsequent assembly phase, the sports tail pipe a unique and more dy- form materials using physical and/or coated, precision-cast cover weighing namic appearance. chemical effects. The process can signi- only 450 grams is combined with the ficantly shorten development times and stainless steel components to form a Cayenne S sports exhaust reduce the associated costs. part which is ready to be fitted to the car. Despite the fact that the cover ap- The Porsche sound is powerful, throaty During the production of the tail pipes, pears much larger than the standard and sporty. And the best thing about a tool made of more than 70 individual tail pipe, the total weight is no greater it is that there’s even more where that parts is used for injection moulding de- than the original. The cast component came from. All you need to do is fit a licate and highly sensitive wax compo- has a highly complex shape, because of sports exhaust system. A modified main nents, which are then manually remov ed its functionality, and this shape becomes silencer produces an even more throaty from the mould with great care and very obvious during the assembly pro- and beefy V8-style sound. Two tail pipes

21 Porsche Exclusive & Tequipment Personalisation

sin is automatically injected into the layers of carbon fibre in an enclosed metal mould and no longer needs to be applied manually. The process also has major technical advantages. Alongside faster manufacturing times, the level of automation and the reliability of the process can also be increased.

As a result, there are no longer any vari- Carbon fibre door-sill guard from Porsche with optional lighting ations in the weight or quality of the product. In addition, the quality of the sur- run right and left into the striking double- sideration the load, the speed of the car, face is significantly improved, which gi- ended tail pipe covers made from the engine speed and the gear which is ves a better appearance. For this rea- chromed stainless steel. The design of selected. The sound changes depend ing son, the process is also used to manu- the tail pipes is similar to that of the on how the car is driven. If the driver has facture doors for Porsche Motorsport. standard double tail pipes of the Cayenne a calm driving style, the throaty Porsche Turbo. However, a connecting bar gives sound is created. Sporty driv ing pro - Several stages are involved in the RTM these pipes a unique appearance which duces a much more aggressive sound. process. Firstly, the dry carbon fibres in is exclusive to the Cayenne S with sports textile form which are used for reinforce- exhaust system. The tail pipes are neatly Automation replaces manual tasks ment are placed in an open, pressure- built into the rear apron of the Cayenne tight, two-sided mould that can be Turbo, which is included in the package Porsche sill covers make a distinctly hea ted. The textile material is pressed with the sports exhaust. sporty impression. Both the illuminated together when the two halves of the and non-illuminated versions made from mould close. Resin is then injected into The standard Sport button is used to carbon fibre are manufactured using a the mould under pressure. Once the adjust the car’s settings to the sports resin transfer moulding (RTM) process. mould is completely full, the resin is exhaust. Switching to sports mode The secret of the process is that hot re- cured at the specified temperature. means that a more sporty engine and transmission management system is used automatically. The dampers are RTM process changed to the sports setting by the Porsche Active Suspension Manage- ment (PASM)/Porsche Dynamic Chassis Control (PDCC) systems and the chassis is lowered. If the driver wants a more comfortable damper setting in cars with PASM/PDCC while retaining the other Fitting the preform Resin injection Curing the Removing the with resin overrun preform preform aspects of sports mode and the sports exhaust, the PASM/PDCC can be separ- ately adjusted along with the chassis height. The sound of the sports exhaust Resin transfer moulding is the process used to produce the Porsche sills. is intelli gently managed, taking into con-

22 Complete Vehicle The new Panamera

The Fourth Dimension: the New Panamera

The design, profile and silhouette of the Panamera clearly indicate that it is a new member of the Porsche family. Designed as a four-door sports tourer, the Panamera is multi-talented and has an impressive interior design.

This car combines sporty driving dy - The innovative interior design of the Germany on 12 September 2009, the nam ics, a spacious, flexible interior and Panamera is impressive even at first top Panamera models will be available the superb comfort of a Gran Turismo. glance. You can find out more about it with a V8 engine and luxury fittings. Joining the 911, Boxster and Cayman here. sports cars and the sporty Cayenne A new feeling of space and a new SUV, the Panamera is Porsche’s fourth The second glance is under the bonnet driving experience model range. where the top-of-the-range model has an engine that produces 500 bhp. At With a centre console which runs all Welcome to the new Panamera! the market launch, which takes place in the way from the dashboard to the

23 Complete Vehicle The new Panamera

The centre console which runs from the front to the back of the Panamera enhances the interior design rear seats, Porsche’s four-door Gran Keeping you cool plenty of headroom and legroom even Turismo offers a new feeling of space for tall passengers. In the Panamera Tur- and a new driving experience in all As well as offering driving pleasure, the bo the electric seat adjustment is com - four seats. The interior is ergonomical- new Panamera comes with four-zone bined with a comfort memory package ly designed for the driver and gives automatic climate control as an optional that also allows the seat cushion to be each passenger his or her own per- extra, with individual temperature, fan extended and the lumbar supports to be sonal space in tailor-made individual speed and air distribution settings for adjusted and includes electric adjust- seats. The low seating position and the each seat. In the event of an accident, ment of the steering column. Other op- sporty, low-slung steering wheel offer the driver and passengers in the new tions, such as adaptive sports seats and the direct contact with the road which Panamera are protected by driver and adjustable comfort seats in the rear, are is so characteristic of Porsche. Along- front passenger airbags, curtain airbags also available on request. side these traditional values, the Pan- and, in the front seats, side and knee air- amera also offers owners numerous bags. Side airbags are available as an op- Beautiful sound — both inside options for customising the interior. A tional extra for the rear seats. The com- and out smooth or a natural leather finish is fort seats provided as standard in the available in a total of 13 colour and front of the Panamera S and 4S have a The new Panamera is the first Porsche to material combinations, including four sporty design and eight different electri- offer an optional top-quality high-end au- two-tone colourways and seven option- cal adjustments to ensure that the driver dio system, the surround sound system al interior decors using exclusive ma- and front passenger travel in complete from the Berlin audio specialist Burme- terials such as carbon fibre and natural comfort. The two individual back seats ster, one of the most prestigious high- olive wood. have a folding central arm rest and offer end audio companies in the world. This

24 Complete Vehicle The new Panamera

Initially the Panamera will be available and CO2 emissions are 260 g/km, in ac- only with a V8 engine and with rear- cordance with the Euro 5 standard. wheel and all-wheel drive. The entry level Panamera S boasts a 4.8 litre V8 which The top-of-the-range Panamera Turbo produces 400 bhp (294 kW). The seven- has a 4.8 litre V8 biturbo engine pro- gear Porsche Doppelkupplung (Porsche ducing 500 bhp (368 kW). This model double-clutch gearbox or PDK) is avail- also has the seven-gear PDK delivering able as an option. The Panamera S can go power to all four wheels. The all-wheel from 0 to 100 km/h (62 mph) in 5.4 sec- drive Panamera Turbo can accelerate onds and has a top speed of 283 km/h from 0 to 100 km/h (62 mph) in only The Panamera comes with a 1300 watt surround (176 mph). Combined fuel consumption 4.2 seconds. Its top speed is 303 km/h sound system from audio specialist Burmester is 10.8 l/100 km and CO2 emissions are (188 mph). Combined fuel consumption

253 g/km, in accordance with the Euro is 12.2 l/100 km and CO2 emissions are is the first time that large and powerful 5 emissions and consumption standard. 286 g/km. loudspeakers of this kind have been used in a standard production car and in- Even sportier All the Panamera models have direct corporated into the design of a car right fuel injection, low-friction powertrains from the concept phase. The loudspeak- The sporty Panamera 4S has a 4.8 litre and lightweight bodies. In addition, the ers, which have a surface area of more V8 engine with a power output of 400 Panamera variants with the automatic than 2400 square centimetres, produce bhp (294 kW). The seven-gear PDK de- PDK (Porsche Doppelkupplung) offer a sound very similar to that of a live con- livers the power to all four wheels. For the the new auto start-stop function. This cert. A total of 16 loudspeakers are Panamera 4S, 0 to 100 km/h (62 mph) automatically turns the engine off when supplied by 16 amplifier channels with a takes 5.0 seconds and the car has a top the car comes to a stop with the brakes total output of more than 1000 watts. speed of 282 km/h (175 mph). Com- on, for example at traffic lights or in a This ensures a unique sound which is bined fuel consumption is 11.1 l/100 km traffic jam. complemented by an active subwoofer with a 300 watt class D amplifier.

Ample space for long journeys

The luggage compartment demonstrates the practicality of the Panamera in every- day use. When the rear lid is opened, four suitcases can easily be placed behind the rear seats. The height of the luggage space allows them to be stowed in an upright position. The volume of the Pan- amera S and 4S luggage compartment is 445 litres. In the case of the Panamera Turbo this figure is 432 litres. With the rear seat backs folded down, the space available increases to a generous 1250 litres. The buttons for the most important systems are on the left and right of the gear lever

25 Special feature The No. 1

The Typ 356: The Porsche No. 1

“In the beginning I looked around and could not find quite the car I dreamed of. So I decided to build it myself.” Ferry Porsche

The Porsche design and engineering number 356. Ferry Porsche, son of Fer- with the chassis number 356-001 on company, which was founded in 1931, dinand Porsche and deputy manager, 8 June 1948. However, the family com- tried to make a new start after the had the vision of “building a sports car pany had to fight for its place on the ex- Second World War, but times were hard that I like myself”. The Porsche engineers clusive sports car market. for a firm that specialised in time- were fascinated by the idea of the sports consuming and costly engine and ve- car and had produced a road-going Only three weeks after receiving official hicle design. chassis by February 1948. approval, the Porsche 356 “No. 1” underwent its first test when Herbert Kaes, However, in the spring of 1947 Ferry Not long after that the new car was fit- Ferdinand Porsche’s nephew, won his Porsche began thinking about building ted with a stylish roadster body made class in the Innsbruck city race on 1 July a sports car using Volkswagen parts. In- of aluminium. The authorities in the 1948. Volume production of the coupé itially the car was known as the “VW Austrian province of Carinthia officially and cabriolet versions of the Typ 356/2 Sport” and then it was given the design approved the mid-engined sports car began in the second half of 1948 and

26 Special feature The No. 1

52 cars had been built by hand in Gmünd by 1950. Like the prototype, the Porsche Technical data Typ 356/2 had an aluminium body, but the engine was moved to the back of Kerb weight 585 kg the car in order to make luggage space Permissible load 200 kg available behind the front seats. After Engine Four-cylinder, two-valve, naturally aspirated, overhead valve, air-cooled mid engine Porsche returned to Stuttgart in 1950, Stroke/bore 64mm/75mm volume production of the Porsche 356 Capacity 1131 cc began in a factory building rented from Power 35 bhp at 4000 rpm the Reutter bodywork company. Fuel system Downdraught carburettor Transmission Rear-wheel drive, four-speed gear box Chassis Steel tube chassis with aluminium body, By the tenth anniversary of the first independent suspension, mechanical drum brakes 356, more than 25,000 Porsche sports Dimensions and weight Wheelbase 2150 mm, track front 1290 mm, cars had left the plant in Zuffenhausen. track rear 1250 mm, weight 585 kg Performance Top speed 135 km/h (84 mph) When production finally stopped in Silencer type Oval resonator silencer with no baffles, 1965, the total number of cars produced side inlets and a fish-tail exhaust was 78,000. It was the successor to the Transmission type Engine, single-plate dry clutch, four-speed manual gearbox with one 356, the Porsche 911, designed by Ferry reverse gear, rear axle with differential Number and type of brakes Hand brake: mechanical internal expanding brakes on all four wheels Porsche’s son Ferdinand Alexander, Foot brake: mechanical internal expanding brakes on all four wheels which helped the company to become Wheelbase 2150 mm one of the world’s leading producers of Turning circle 10.2 m sports cars.

27 Complete Vehicle · Styling · Body & Safety · Engine · Drivetrain · Chassis · Electrics & Electronics · Testing · Industrial Engineering · Production Engineering

Your cars are developed by the same engineers as ours. Good to know, isn´t it?

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