Porsche Test Systems to Speed Up Development Processes

Porsche engineers use advanced testing procedures to develop the drive systems for electric vehicles. These procedures consist of real-life tests and tests in a virtual environment. In this way, engineers can reduce the number of test vehicles normally required and significantly shorten the development time.

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Engineers at Porsche use test methods that are specifically adapted to the requirements of high-voltage technology. These include conventional test systems, but also systems for virtual testing of PI controllers. With the help of artificial intelligence, engineers will also be able to reduce development times and costs.

To increase efficiency in the development of new components and systems for electric drive systems, Porsche engineers are using test methods specifically tailored to high-voltage technologies. For example, high-voltage batteries are tested on vehicles and component test benches in Bietigheim-Bissingen and Nardò, while hardware in loop simulation environments are used for software testing of pulse inverters (PI).

The PI plays a key role in electric vehicles because it converts the DC voltage from the battery into a multiphase AC voltage, which is necessary for the rotation of the motor. When it comes to energy recycling, on the other hand, PI works in the opposite direction, converting the motor’s AC voltage into DC voltage, which is used to charge the battery.

 “Precise PI control for the various performance and comfort requirements in different driving situations requires highly complex control algorithms and safety functions that have to be tested before the drive is put into operation,” explains Rafael Banzhaf, Technical Project Leader at Porsche Engineering. In the future, the engineers also plan to make use of artificial intelligence methods. “Our approach transfers expert knowledge into the digital world, helping to save development time and costs. Initial validations have been very successful. Therefore, I am convinced that we will also use AI in the regular testing process in the medium term,” explains Banzhaf.

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