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Travelling from the Arctic Circle to South Africa, and from the Alps to Dubai can now be simulated in just a few hours at the Weissach Development Center. At the new climate center operational for two years, Porsche engineers can replicate almost any weather and climate conditions worldwide.
Exposing prototypes to various conditions
One of these engineers is Horst-Uwe Kroß, who leads V&V Thermodynamics at Porsche AG. Kroß explains, “Our new climatic wind tunnel in the climate center allows us to recreate temperatures ranging from -30 to +50°C, as well as weather conditions like monsoons and drizzles. We can simulate wind speeds up to 250 km/h, solar radiation up to 1200 watts per square meter, and humidity between 5 and 95 percent.”
The primary objective is to subject prototypes in the climatic wind tunnel to conditions resembling those on roads in places like the Arab Emirates or Norway. This enables precise measurement of even the smallest changes as every aspect of the simulation with the vehicle can be replicated in detail. “While natural factors change position, temperature, and sunlight levels, we can maintain the same conditions for the vehicle in the climatic wind tunnel, allowing us to observe even the minuscule adjustments,” Kroß elaborates.
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![Macan S, Weissach, 2024, Porsche AG](https://automart.blog/wp-content/uploads/2024/06/Windtunnel-2.jpg)
What is tested in the climatic wind tunnel?
In the climatic wind tunnel, Kroß and his team evaluate the cooling systems of vehicles, battery performance in different climates, and the durability of components in varying wind conditions. Tests include maintaining a comfortable interior temperature of 22°C while simulating 40°C external temperatures and ensuring rapid de-icing of windows along with quick attainment of a warm interior after entering a cold vehicle in winter.
“Our goal is to create sports cars that offer high comfort levels,” states Kroß. To achieve this, several hundred points specified by developers are tested on prototypes. The climatic wind tunnel not only assesses environmental impacts but also replicates specific driving scenarios, such as navigating an Alpine pass with a trailer or driving in city traffic. The driving situation can be precisely simulated by adjusting dynamometer resistance and utilizing navigation data. However, cornering simulations are still a work in progress.
![Panamera Turbo E-Hybrid, Weissach, 2024, Porsche AG](https://automart.blog/wp-content/uploads/2024/06/Windtunnel-1.jpg)
From the test center to the streets
Post-testing in the climatic wind tunnel, the vehicles are further evaluated in real-road conditions. Kroß emphasizes, “Although our modern test bench is crucial, road testing remains essential as the subjective Porsche driving experience is influenced by the unique character of each vehicle, a trait only human test drivers can identify.” Prototypes undergo real-world testing in varying climates to compare results with those obtained from the climatic wind tunnel.
As technology advances and legal requirements for testing change, Kroß and his team face evolving demands. The increasing charging capabilities of cars necessitate enhanced test facilities for simulation. Adapting test benches to comply with changing legal standards remains an ongoing process.
“The building and systems within it must form a harmonious orchestra to consistently reproduce conditions down to a tenth of a degree,” Kroß remarks. “With so many components, human limitations are evident, but artificial intelligence will aid in orchestrating the precise synchronization of all elements.”