80754_porsche_01_03_GB:80754_porsche_01_03_GB 15.04.

2008 11:56 Uhr Seite 1

Edition 1/2008

Porsche Engineering Magazine

The 911 GT2 The Hardware Lab

Performance redefined The highest standard for customers

The engine of the Porsche 917 Testing, measuring, analyzing

A complete work of art with 1,100 bhp Optimization of vehicle drivetrains
80754_porsche_01_03_GB:80754_porsche_01_03_GB 15.04.2008 11:56 Uhr Seite 2

Editorial

Dear Readers:

Coming up with good ideas is one thing. But what is just

as important is finding new ways to implement them.
That’s what we do well. With innovative approaches and a
passion for our work, Porsche Engineering achieves peak
performance every day.

As times change, not only do the expec- optimized to customer specifications

tations of customer development change, using proven measurement and analysis
but the demands on the vehicles in- methods. Whether you are steering your
crease as well. You know that these de- Porsche through the urban jungle of
mands are coupled with performance. Tokyo or cruising the frozen expanses
But you might not know the high-per- of Alaska – no problem for your engine
formance technology behind them. Less and transmission. Also, advanced com-
fuel consumption, lighter-weight materi- puter technologies enable us to shorten
als, fast implementation – the demands engine development times significantly.
are ever-growing. We will present the development of the
intake port as an example.
In this issue, you can read all about our
work on improving performance. Qualified networks of technicians and
engineers for the right ideas form the
Enter the fascinating world of the GT2, basis for the development work of
the 911 series production vehicle with Porsche Engineering. Take a peek behind
the most powerful engine of its time. the scenes of a specialty department:
530 bhp – a mix of aerodynamic design, our Hardware Lab.
innovative technology, and incredible
power. Let your mind travel in a Porsche Did you ever hear, by the way, about the
Cayenne S Transsyberia. And remem- “zero” hour of the 911? Wait and see.
ber last issue's cover photo? The leg-
endary engine of the Porsche 917. In Follow us on a journey through our de-
1973, its whopping 1,100 bhp provided velopment work and experience our
enough thrust to leave the competition idea of performance close-up.
in the dust.
We wish you a pleasant read.
Our computers have to be just as power-
ful. Today, vehicle drivetrains can be The Editorial Staff

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Contents

Contents

News 4
About Porsche Engineering

The new 911 GT2 5

With new developments, now at 530 bhp

The engine of the Porsche 917 8

A complete work of art with 1,100 bhp

Intake port development 10

Shorter development times thanks to
advanced computer technology

Optimization of vehicle drivetrains 13

Advanced measurement and analysis methods
for engine and transmission

Cayenne S Transsyberia 16
Special model for the most extreme
outdoor situations

The Hardware Lab 20

Tailored solutions for demanding customers

911 22
How the sports car got its name

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News

About Porsche Engineering

At Porsche Engineering, engineers work Or would you prefer a specialized system

for you meticulously on new, unusual developer? We offer our customers both –
ideas for vehicles and industrial products. because Porsche Engineering works
Upon request from automotive manufac- where these two areas meet.
turers and suppliers, we develop a variety
of solutions – ranging from the design of The joint knowledge of Porsche Engi-
individual components, through the lay- neering converges in Weissach – and
out of complex modules, to the planning yet it is globally available. Of course, also
and implementation of complete vehicle directly at your site. Regardless of where
developments including management of we work, we always bring a piece of
the run-up to production. What makes it Porsche Engineering with us. If you
special is that all this is done with the would like to learn more about us,
expertise of a series manufacturer. please request our image brochure by
email:
Does your company need an experienced
automotive developer for your project? [email protected]

Porsche honors graduates of Czech Technical

University, Prague.

Stuttgart meet future legal requirements. Other

prizewinners were Denis Waraus (25)
Dr. Ing. h.c. F. Porsche AG, Stuttgart, and and Lukas Sojka (25). All three winners
Czech Technical University in Prague receive a cash prize and an invitation to
(CTU) have presented the “Porsche Engi- visit the Development Center. In addi-
neering Award” for the third time. At the tion, the winner of the first place is be-
Development Center in Weissach, Wolf- ing offered a doctorate position at
gang Dürheimer, Development Director Porsche Engineering Services s.r.o. in
of Porsche, presented awards to three Prague.
graduates of CTU for their outstanding
final theses. The first prize went to Porsche and CTU have been working to-
Thomas Dynybyl (24), who investigated gether in the field of technical calcula-
the subjects of cylinder cut-off systems tion and simulation since 1996. The
and downsizing in particular in his work Porsche Engineering Award has been
“Reversible Engines”. In explaining its presented each year since 2006 for the
choice, the jury, which was composed of three best final theses of the students
representatives of Porsche and of CTU, of the Czech Technical University in
referred to the special importance of in- Prague. The prize is intended to further
novative engine concepts to the auto- cement the relationship between CTU
mobile industry in order to be able to and Porsche AG.

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Complete vehicle 911 GT2

Performance redefined – the new 911 GT2

With a power boost of 50 bhp compared formance that is second to none. With a
with the engine of the 911 Turbo, the new power-to-weight ratio of 3.69 kilograms
911 GT2 is the most powerful 911 pro- (8 lb) per kilowatt, the rear-drive GT2
duction vehicle of its time. Impressive pre- rockets from 0 to 100 km/h (63 mph)
cision work quickens the heartbeat of any in 3.7 seconds.
engineer. Striving for efficient perfor-
mance has always been the goal of the The increase in power compared with the
development work of Porsche. But how current Porsche 911 Turbo is achieved
can an almost perfect sports car be even mainly by a revised turbocharger with
further optimized? flow-optimized turbine and a larger com-
pressor, as well as a complete redesign
Resistance is futile. Highlights that of the expansion intake system. The newly
make history. designed titanium rear silencer with re-
duced flow resistance also adds to this.
The sophisticated aerodynamics in combi-
nation with the extremely sporty suspen- Turn the page for our detailed descrip-
sion and an engine output of 390 kW tion of the special features of the expan-
(530 bhp) give the 911 GT2 driving per- sion intake system.

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Complete vehicle 911 GT2

The expansion intake system

The expansion intake system of the Existing intake manifolds, such as the rated engines, this effect only occurs in
new 911 GT2 is an enhancement of the resonance intake manifold, use the air the higher rpm range. This effect is
existing turbo engines. The unique and vibrations in the intake system to fill the neutralized at maximum power in the
special feature is its operating principle, cylinders with as much fuel-air mixture highest rpm range. The expansion in-
which has revolutionized existing pro- as possible. The compression effect take system of the new 911 GT2 turns
cesses. Like a traditional intake mani- (compression of air) achieved during the resonance charge effect around
fold for 6-cylinder Boxer engines, the the air vibrations is used for this pur- completely at higher engine speeds: the
expansion intake system consists of a pose. The disadvantage of a resonance principle of expansion (expansion of air)
distributor pipe, two accumulators and intake manifold, especially in turbo en- is used instead of compression.
six individual intake ports. The decisive gines, is that the air is heated up when it
and revolutionary approach is reflected is compressed. This means that the fuel- During expansion, the air is cooled
in the new geometric dimensions of the air mixture in the combustion chamber rather than heated as in compression.
distributor pipe and the individual intake cannot be ignited with the best possible This effect results in a lower fuel-air
ports. Compared to a conventional in- efficiency. mixture temperature in the combustion
take manifold, the distributor pipe of the chamber, which means it can be ignited
expansion intake system is longer and For this reason, the current 911 Turbo in a more efficient manner. This im-
has a smaller diameter, while the individ- uses a resonance intake manifold that is proves engine efficiency and gives a
ual intake manifolds are shorter. designed so that, unlike naturally aspi- higher engine output with low fuel con-

For the first time, the Porsche expansion intake system has been installed in the GT2

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Complete vehicle 911 GT2

sumption at high loads and engine This effect may seem to be a disadvantage, the fuel-air mixture in the cylinders at a
speeds. The name of the expansion in- but the raised temperature level means practically equal air flow rate. As described
take system is derived from the physical that more heat is discharged in the charge- above, these functional interactions, with
effect of expansion. The principle of the air coolers, which in turn means that the air the help of more effective ignition, improve
expansion intake system can only be ap- temperature downstream of the charge-air engine efficiency and give a higher engine
plied in turbo engines. The cylinders are coolers is only slightly higher than with con- output with low fuel consumption at high
filled with slightly less air during expan- ventional charging. loads and engine speeds.
sion than during compression. This ef-
fect is compensated in the new 911 GT2 This increase in thermal energy is accom- The environment has also been taken into
by a slightly increased boost pressure. modated by using the expansion intake account. At maximum power output, fuel
The increased boost pressure increases system which, through the expansion of consumption using this intake system is
the temperature of the air downstream the air in the subsequent intake system, up to 15% lower than for turbocharging
of the compressor. causes noticeably lower temperatures of with a conventional intake manifold.

Technical data

n 530 bhp
n From zero to 100 km/h (63 mph)
in 3.7 seconds
n Top speed 204 mph
n One-gallon (3.6-liter) six-
cylinder turbocharged engine

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Engine Engine of the 917

1,100 bhp – the engine of the legendary Porsche 917

As the most powerful racecar in the world and with the “Greatest Sports Car in History”
award under its belt, the reputation of the Porsche 917 is legendary. This prestige is
largely thanks to the most powerful air-cooled engine of all time.

In the spring of 1968, the FIA (Fédération championship title with a vehicle in the of Le Mans. But this dominance almost
Internationale de l’Automobile) imposed 1.3-gallon production sports car catego- proved to be the brand’s undoing. For
a new regulation for the World Champi- ry, as well as scoring the victory in the 1972, FIA changed the rules again and
onship of Makes, which starting in 1969 prestigious 24 Hours of Le Mans race. In 1.3-gallon sports cars – and thus the 917
allowed both 0.8-gallon (3-liter) proto- record time, the engineers developed an – were no longer allowed to compete in
type race cars and 1.3-gallon (5-liter) air-cooled, 12-cylinder naturally aspirated the Championship of Makes races. But
“production sports cars” (with the re- engine, which impressively reached the set Porsche did not want to send the out-
quirement to build at least 25 identical goals. In 1969, 1970, and 1971, Porsche standing racecar to a museum just yet.
vehicles) to participate in the long-dis- won the World Championship of Makes; The decision was made to compete in the
tance race. Porsche figured they had in 1970 and 1971, the 917 vehicles tri- CanAm series, which knew neither dis-
good chances of finally winning the world umphed with double wins in the 24 Hours placement nor weight limits. For Porsche
to hold its own against the established
CanAm competition, whose racecars were
equipped with large 1.8- to 2.1-gallon
(seven- to eight-liter) V8 engines, the
twelve-cylinder engine of the 917 would
have to be turbocharged.

Pioneering work in development

Never before had turbocharged engines

been used in road races. The dynamic
characteristics were so poor that the turbo
engines were not competitive, despite in-
creased power output. But the engineers
were able to develop a new technology for
controlling the boost pressure, thereby al-
most completely eliminating the dreaded
“turbo lag”. A valve in the exhaust pipe,
which is controlled by the boost pressure,
opens when the desired boost pressure is
reached and, bypassing the turbine of the
turbocharger, guides the exhaust gas that
is not needed to the outside. This new con-
trol technology allowed significantly im-
proved tuning of turbo engines, partly be-
Bright prospects: the air-cooled, turbocharged Porsche 917/30 won hands down in 1973 cause now smaller turbo units could be

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Engine Engine of the 917

used. In addition, it resulted in a reduction degree V design with two overhead cam- through axial feed on both ends of the
of thermal engine loads. shafts per cylinder bank. The center crankshaft. Thus the 12-cylinder engine
drive is the design highlight of this en- owes its proverbial reliability and
Finally, the new technology paved the gine. In this design, the power take-off ruggedness mostly to its center drive
way for the triumph of turbocharging. is through a set of gears in the center design.
Now it was no longer just motor sports – rather than at the end of the crank-
production car engines were also suc- shaft; an intermediate shaft then trans- A complete work of art in engine
cessfully turbocharged. mits the power to the transmission. The development
drive gear in the center of the crank-
The most powerful automobile shaft – where there is no torsional Almost 40 years after its first race, the
engine of all time vibration – also drives the camshafts Porsche 917 is now a legend. The
and all secondary power take-offs. This development experience of Porsche
With 1,000 bhp under the hood of the offsets the torsional vibrations, makes and the special construction provided
1.3-gallon turbocharged engine, Porsche the engine more robust, thus consider- impressive proof that it was smart not
participated in its first CanAm season in ably increasing its life. In addition, it en- to retire the 917 after such a short time
1972, with the main intent of gaining ex- sures the proper lubricating oil supply in competing in the World Champion-
perience. But the Porsche 917 Turbo for the critical connecting rod bearings ship of Makes.
immediately won six of nine races, thus
securing the CanAm championship title.

The following season, 1973, Porsche

showed up with the most powerful auto-
mobile engine of all time. The 1.4-gallon
(5.4-liter) version of the twelve-cylinder
now delivered 1,100 bhp at 7,800 rpm,
and a maximum engine torque of 1,100
Nm at 6,400 rpm. This guaranteed
extravagant acceleration values (from
zero to 100 km/h – 63 mph – in a mere
2.4 seconds). Porsche then went on to
win the 1973 CanAm championship, with
eight victories in eight races. After this
victorious run, though, the rules were
changed again to the disadvantage of the
917, so that Porsche had to retire from
CanAm racing. This ended factory-spon-
sored racing of the 917 for good.

Outstanding performance is nothing

without an engine that endures

The heart of the Porsche 917 is an air-

cooled twelve-cylinder engine in 180- Powerhouse: the twelve-cylinder engine achieves a stable 1,100 bhp at 7,800 rpm

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Engine Intake port development

It’s all in the right mix

Porsche Engineering masters the challenge of optimizing intake ports with flying colors.
This describes a method where a number of improvements are implemented during the
early stages of development.

The consistent use of state-of-the-art Porsche, the development of the intake weighed against the targeted tumble or
technology and methods can significant- ports has become an even more de- swirl flow indication. In spark-ignition en-
ly shorten development times for new manding task. gines, especially in those with direct fuel
engines. The intake port geometry in injection, the incoming air is swirled
the cylinder head decisively affects the The right dosage is everything around the lateral axis of the cylinder to
flow quality of the intake air in the cylin- improve mixture formation. During the
der (see diagram, p. 10). Since the de- Depending on the combustion process, subsequent compression and fuel injec-
velopment of new combustion process- intake port development pursues differ- tion, this targeted air swirl achieves fast
es, such as direct injection systems, ent sub-goals. Here, the large air flow and direct homogenization of the fuel-
called Direct Fuel Injection (DFI) at rate that is often desired must be air mixture. This optimized fuel burning

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Engine Intake port development

process significantly reduces nitrogen

oxide, particulate, and CO2 emissions
while improving fuel economy. At the
same time, the flow rate can be im-
proved by minimizing the flow resis-
tance in the intake port. This in turn has
positive effects on the engine perfor-
mance.

More powerful engines, but

eco-friendly, please!

By optimizing the intake ports, Porsche

Engineering not only achieves better en-
gine output; with a targeted charge mo-
tion in the direct injection processes,
CO2 emissions are lowered at the same Design of an intake port using a CAD model that
time. The flow rate (called the alpha k was created with CATIA V5

value) is a general formulation which

takes the losses occurring in the intake the definition of a certain velocity of flow advantage in the designing of variants.
port flow into consideration. These are and the flow rate. A defined number of parameters allows
caused by friction and the inertia of air faster and higher-quality design of in-
masses. High engine power requires a For intake port design, Porsche Engi- take port variants, for example with a
high flow rate. Changing the cross-sec- neering uses the CAD program CATIA different cross-section curve. The use of
tion of the intake port affects the veloci- V5, for which our own design method a CAD program makes the modeling
ty of the flow, while the port geometry has been developed (see graphic, p. 11). process many times more efficient.
determines the direction of flow. The In the CAD models, the designers rely on
faster the air enters the cylinder, the a highly parameterized geometry, which Parallel to the creation of the port mod-
more vigorous the swirl. they control centrally through design els in CAD, critical points, such as the
spreadsheets in Microsoft Excel. These water cooling jacket or the valve spring
True, the development of intake ports is spreadsheets not only import parame- mounting, are examined for narrowing.
not new. What is new, however, is the ters into a CAD model, but also export In the past, this analysis was also done
simulation options Porsche Engineering measured data from cross-section curves by hand. Today, the experts at Porsche
has available thanks to computer-aided and represent them graphically. In pre- Engineering use the CATIA V5 DMU
calculations. The geometric influence vious versions of CATIA, each cross- (Digital Mock-Up) Navigator for auto-
parameters of intake ports are numer- section had to be measured and entered mated narrowing studies, to examine all
ous, since any change in geometry af- “by hand” into a graph. As a whole, the critical areas more accurately, quickly,
fects the flow. parameters and measured data tell the and reliably for compliance with the re-
design engineer whether the specified quired wall thicknesses and their opti-
Intake port development today velocity of flow was reached. mization potential. The narrowing points
can be shown in color in the complex
Intake port development starts with the The faster control and evaluation of dif- cylinder head assembly, thus making
specification of different goals, such as ferent models in CATIA V5 is a definite them explicit.

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Engine Intake port development

Once a large number of intake port vari- ports necessary) and objective evalua-
ants has been generated in the design tion within one day (see diagram, p. 12).
phase, the next step is to determine the
best variant for the combustion process. Unsuitable variants can be eliminated
Even after the design phase Porsche beforehand. The preferred variants,
Engineering relies on advanced, com- where the alpha-k value found in the
puter-aided analysis methods for deter- CFD simulation proves promising, will
mining the flow properties of different then be validated on the test stand us-
intake port variants. In the past, each ing stereolithography. With this step,
part was built as an STL (stereolithogra- Porsche Engineering can also save de-
phy) part; that is, an accurate plastic velopment time and costs.
(epoxy resin) prototype of an intake
port variant that was subsequently test- Porsche Engineering sets a standard
ed on a flow test stand to determine with this new method for developing in-
the alpha-k value and the charge mo- take ports. This achievement by the en-
tion it produces. Building these proto- gineers not only saves resources, devel-
types is very time-intensive. Today, a opment time and costs, but also actually
pre-selection is made from all variants, enhances quality and more clearly inter-
and only the variant with the greatest meshes the processes. The develop-
potential is tested on the flow test ment engineers at Porsche Engineering
stand. The engineers at Porsche Engi- see future areas of application for cus-
neering use a CFD (Computer Fluid Dy- tomers in the layout and optimization of
namics) program that is fully integrated exhaust manifolds, brake disc cooling
in CATIA V5, allowing more efficient cal- and intake systems, as well as the flow
culations (no reformatting or data ex- characteristics of catalytic converters.

CFD simulation to evaluate air swirl, using the example of a port configuration for a diesel engine with direct fuel injection

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Drivetrain Measuring methods

Making sure the engine and transmission are ready for action

Through various measuring and testing methods, Porsche programs are too stringent, even slight
damage will not be permitted, resulting
Engineering makes sure that efficient layout and testing of in reinforcement of components, which
drivetrains is possible in the early stages of development. may lead to excess component weight
and additional costs for measures to
extend the life of the vehicle. Too little
More than ever before, the develop- component reliability, thereby increas- testing bears the risk of weak spots go-
ment process in the automotive sector ing their failure risk. ing unnoticed, resulting in component
is characterized by increasingly shorter damage when the vehicle is used by the
development cycles for a higher num- The purpose of testing the components customer. The consequences can be
ber of vehicle variants. To reach the am- either on the test stand or in the vehicle unpleasant.
bitious goals of the automotive industry as part of the development process is
regarding CO2 reduction, coupled with to show the failure risk of the vehicle in Besides the ultimate goal of testing
rising demands on vehicle comfort and customer use. A basic requirement of what is important, this must also in-
dynamics, the drivetrain needs to con- representative testing is that the test creasingly be done at minimal cost and
tinuously shed weight, despite increas- specifications accurately describe what time expenditure. We have to test the
es in engine power. Of course, the relat- the components are to withstand later right things (reasonable component
ed rise in weight-specific performance on, taking into account the permissible loads) in as little time as possible (high
of the vehicles must not compromise failure rate in customer use. If the test time acceleration) and at minimum cost.

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Drivetrain Measuring methods

lightweight commercial vehicles), trans- proof function, and memory capability.

Major goals in component mission testing comprises statistical The system is started with a central
testing: variables, such as the routes driven, the switch that supplies all booster and
actual vehicle load, and the very differ- measuring blocks through a central
n Reasonable component load ent driving styles to which the vehicle power supply. False measurements due
n High time acceleration might be exposed in customer use. The to system components that were
n At minimal cost term “customer” includes the tradition- switched on “accidentally” must be
al private person as a car buyer as well avoided. The same applies after con-
as customer groups and commercial clusion of the measurement: if individ-
To define the test specifications of a users who operate vehicles under spe- ual components are mistakenly not
drivetrain component, its future world- cial conditions. switched off, the vehicle battery is dis-
wide area of application must thus be charged before the next round of
determined. In addition to the basic re- Vehicle measurement at Porsche measurements. The signal scope of the
quirements of the technical specifica- Engineering measurement series is usually up to
tion, such as engine variants and vehi- 150 signals, which are measured during
cle segments (SUV, sedan, sports car, The objective of the vehicle measure- the time range between 2,000 Hertz
ments performed by Porsche Engineer- (torques) and one Hertz (temperatures).
ing is to measure the characteristic op-
erating loads on the drivetrain that are Rugged and cost-saving new
to be expected in day-to-day operation developments
with sufficient statistical certainty over
driving distances of up to 15,000 kilo- Special challenges for measuring oper-
meters (9,321 miles) in a given time ating loads are posed by driving maneu-
range. The measuring conditions have vers with extreme torque peaks, such
been specified to consider all major in- as highly dynamic friction value jumps,
fluential parameters, such as route idiot starts, and traffic light starts. Since
composition, driving style, and vehicle torque measurements are based on the
load. In subsequent data preparation, elastic deformation of drive compo-
load spectrums for precisely defined nents, using conventional side shafts
customer usage potentials are then with wire strain gauges applied (so-
derived from the measurements. The called measuring shafts) would not
measuring technology is designed to achieve the intended goal. After the first
survive customary “day-to-day” opera- abusive maneuver, such shafts are
tion as well as extreme loads from usually so deformed that they exceed
abusive maneuvers, such as so-called the measuring range of the shaft. In an
“idiot starts”, without damage. effort to circumvent this problem, Porsche
Engineering, together with a system
To record measured data from a travel partner, have developed innovative
distance of more than 15,000 kilome- measuring flanges (see diagramm, p.13)
ters over three weeks of vehicle opera- that – while comparable with conventional
tion within the set time range, the measuring shafts regarding precision and
Multi-level measuring system configuration in the measuring system must be character- costs – can withstand torque peaks of up
luggage compartment of a sports car ized by a reliable system start, failure- to 8,000 Nm, undamaged.

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Drivetrain Measuring methods

Quantifying load spectrums

Damage equivalent torque on the rear axle (all gear levels)
The measured data, which are around
three terabytes per vehicle and repre- Traction Gear levels 1 - 6
sent around 240 hours of driving in the Drive torque of the axle transmission
time range, are used to quantify the Damage equivalency curve
loads on the drivetrain, the so-called 1 2
load spectrum. Its content is defined by 3
4
mixed operation in cities, on interurban 5
6
roads, and freeways, dependent on driv-
ing style and vehicle load.

In addition to the torque load, the load

spectrums also describe functional in-
teractions or actions in the drivetrain Overrun Crown wheel contortions (log)
that are of special interest for compo-
nent layout and testing. For example, The diagram shows the load spectrum of a rear axle transmission with sub-spectrums from six driving
how often does a hydraulic valve for gears in traction and overrun.

valve-lift adjustment switch over a dis-

tance of 100,000 kilometers (62,140 conditioning compressor, and alterna- rameters (including output, torque, and
miles)? How often does the oxygen tor) in real operation? How often do cer- temperatures) are analyzed. These
sensor measure certain temperature tain gearshifts occur on a given road analyses are performed separately for
ranges in onroad operation? What is the section? What are the resulting loads on different customer types as far as they
power take-off of the secondary units of the gearwheel of the gear in question, are relevant to the vehicle layout, name-
the engine (power-steering pump, air- and how significant is the influence of ly for a defined combination of road
driving style on all these parameters? type, driving style, and vehicle load. In
order to derive test programs, one
Engine dwell time diagram On the left is an example of the diagram must either determine damage-equiva-
of a mid-sized car in mixed on-road op- lent test time/test torque data or sub-
eration comprising city, interurban, and ject the data in the time range to vari-
freeway driving. The right-hand area is ous time acceleration methods. After
defined by the full-load characteristic that, they can be represented on the
curve. The maximum engine output test stand in a time-accelerated simula-
Time [s]
range is located in the front of the dia- tion test.
gram.
This method shows that the subject of
Detailed analysis of testing load spectrum definition for the drive-
0 data sets train can be mastered systematically
with the right special measuring tech-
Engine Engine
speed [rpm]
After measuring, the data sets are nology. The benefits that these data
torque [Nm]
processed in raw data preparation. Dur- provide to development in defining the
ing the subsequent detailed analysis, technical specification undoubtedly jus-
Engine dwell time diagram for a mid-sized vehicle load spectrums for all major load pa- tify the high expense.

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Complete vehicle Cayenne S Transsyberia

Off-road dream: the Cayenne S Transsyberia

On the basis of the Cayenne S, Porsche has built a special forced, extra-large underbody paneling,
as well as reinforced wishbones on
model for the most extreme outdoor situations. The the front axle. Another highlight is the
driver's safety is assured. Even on the most rugged terrain. new Porsche Dynamic Chassis Control
(PDCC), whose two active stabilizers al-
most completely offset lateral inclina-
With its intelligent all-wheel drive, its lored specifically to the requirements of tion when negotiating curves. Even off-
powerful and efficient V8 engine with long-distance rally racing has been de- road the PDCC allows the maximum
direct fuel injection and height-adjustable veloped in the Weissach Development possible wheel articulation, thereby
air suspension including Porsche Active Center. Compared with its urban cousin, increasing the traction of the electroni-
Suspension Management (PASM), the the “Cayenne S Transsyberia” features cally controlled all-wheel drive. The
Porsche Cayenne S is well equipped for special off-road tires with rougher tread Cayenne S Transsyberia is Porsche in
any terrain. And to top its sportiness: a bars, a safety cage, a shorter final-drive its purest form, tailored to the needs of
car based on the Cayenne S and tai- ratio, a rear-differential lock, and rein- sporty and highly ambitious customers.

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Complete vehicle Cayenne S Transsyberia

Rally properties with a proven

track record

The engine of the Porsche Cayenne S

Transsyberia was taken almost without
modification from the on-road version
of the Cayenne S. The 1.3-gallon (4.8-
liter) V8 naturally aspirated engine with
direct fuel injection achieves 385 bhp
(283 kW) at 6,200 revs per minute. The
maximum torque of 500 Nm is attained
at speeds as low as 3,500 rpm. Vario-
Cam Plus valve management ensures a
smooth and consistent surge of power
throughout the entire speed range. De-
pending on the engine speed, the elec-
tronic engine management system
switches the intake valve stroke from
0.1 to 0.4 inches (3.6 to 10 millime-
ters). The length of the intake manifold
can also be varied, thus achieving a
high torque curve at low rpm. A re- Off-road – yes, please! 62% of the engine torque to the rear
duced-weight sports exhaust system on wheels and 38% to the front wheels.
the Cayenne S Transsyberia produces a One fundamental factor in the outstand- The distribution ratio can be varied in
particularly striking tone. Tiptronic-S ing driving dynamics of the Cayenne S line with the current driving situation
transmission, with shortened final drive Transsyberia is its power transmission using an electrically actuated and con-
ratio and transmission control opti- to all four wheels. In basic mode, the trolled multiple-disc clutch. But even
mized for off-road use, provides in- Porsche Traction Management (PTM) 100% of the engine power can be
creased acceleration power. permanent all-wheel drive transmits transmitted either to the front or the
rear as needed. The map-controlled
center-differential lock and the rear-
axle limited-slip differential do more
than simply respond to insufficient
traction at the rear or front axles. Sen-
sors also measure the vehicle speed,
the lateral acceleration, the steering
angle, and the accelerator pedal’s posi-
tion. Thus the PTM is always able to
calculate the required degree of locking
for both axles and properly split the
drive torque between them. A rear-dif-
ferential lock has been installed in or-
Offroad performance: for the things you have to do – and the things you just can’t leave alone der to enhance off-road performance.

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Complete vehicle Cayenne S Transsyberia

Maximum safety in a crash

When it comes to body rigidity and pas-

sive safety, the Porsche Cayenne holds a
top position among off-road vehicles.
More than 60% of the body-in-white is
made of high-strength steel. A three-tier
deformation zone absorbs forces during
a collision and distributes them to the
rigid lower longitudinal members, door
sills, and tunnel area. The reinforcements
in the A- and B-pillars are manufactured
from high-strength steel to protect
against roll-over. To protect both driver
and passenger in competitive situations
even better against the consequences of
a collision or roll-over, the Cayenne S
Transsyberia has an additional safety
cage, which is bolted to the passenger
cell and compliant with FIA design regu-
lations.

The bare necessities

To offset the extra weight of the safety

cage and rally equipment and to further
lower the vehicle’s center of gravity, the
rear seats, standard interior body pan-
els and soundproofing material have all
Solid safety cage in the interior been removed from the car. The central
locking system has been replaced with
On difficult terrain in particular, the ble air filter snorkel, to ensure that the a manual locking mechanism for the
Porsche Dynamic Chassis Control (PDCC) “bow waves” created when driving front doors with orange loops. The rear
in conjunction with the air suspension through water cannot enter the intake window and the rear side windows are
and the Porsche Active Suspension duct. Likewise, the wheels and suspen- made from lightweight polycarbonate.
Management (PASM) increase traction. sion of this ultimate sporting performer As in all Cayenne models, the front side
When driving in water, the maximum were designed for extreme endurance. windows have a hydrophobic coating.
fording depth at High Level II of the air The double-arm front axle comes with Water is repelled and runs off, which
suspension is approximately 30 inches reinforced wishbones and a track width make the glass less prone to soiling
(75 centimeters). In addition, the body that is 1.3 inches (34 millimeters) wider. than conventional windows. Both the
and doors are sealed against water up The standard high-speed tires have driver and front passenger enjoy the
to side window height. The air intake has been replaced with rough-tread off- benefits of lightweight sports seats with
been moved to roof height using a flexi- road tires. Alcantara covers.

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Complete vehicle Cayenne S Transsyberia

The ultimate sporting performer enormous stresses of a rally. The typical Equipped for any situation
with technical highlights foot-operated brake on the Cayenne S
has been replaced with a handbrake, City driving is not exactly a favorite of
The Cayenne is equipped with a naviga- which can be used to oversteer the car the Transsyberia. It is built for extreme
tion system as standard; it allows off-road in tight curves. Four auxiliary high-beam outdoor situations. To successfully
trip planning and can be operated by the lights are mounted on the roof. master particularly difficult and de-
passenger. The glove compartment has
been replaced with a Tripmaster comput-
er, helping the copilot find routes between
the various navigation points. Most of the
control units are installed in the interior
and all electrics cables have been rerout-
ed. The on-board electrics can be quickly
switched on and off with a central switch
on the lower right of the driver’s seat,
making it possible to reset the electronics
while driving.

Reinforced, extra-large underfloor panel-

ing made of aluminum and an additional
cover made of stainless steel for the ex-
haust tailpipes protect the Cayenne S
Transsyberia from damage caused by the The large tailgate conceals complete rally equipment

manding terrain, as well as to salvage

other vehicles, the Cayenne S Transsy-
beria comes with a winch that is easy
to fit if necessary and is stored in the
luggage compartment.

The luggage compartment also comes

with two 5.3-gallon (20-liter) reserve
cans, a hydraulic off-road car jack, two
fire extinguishers, two sand panels,
two full-sized spare wheels, and two
transport boxes for tools. Also on
board are two two-man tents, two
sleeping mats, four tightening straps,
a 29-foot (nine-meter) rescue belt with
a chain joint, a folding spade, a folding
saw, an axe, and a working headlamp,
along with four towing lugs, and a
The Cayenne S Transsyberia always cuts a good figure HAZET tool set.

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Insights The Hardware Lab

Tailored solutions for demanding customers

Typical Porsche: the Hardware Lab of Porsche Engineering develops products that meet
the highest standards and customer requirements. Efficiency and intensive customer
support go hand in hand.

Electronics as the key technology play active safety through intelligent integra- of the Porsche developers. Often it takes
an increasingly important role in the in- tion of assistance systems. them only a few days to create an initial
formation and communication age. Ease sample (A-sample) of complex control
of operation, multi-functionality, high re- Diligent development process units that can be used in integrated sys-
liability, and real-time responses are the tems and that provide fast, real-time
major requirements of contemporary In all hardware developments of Porsche feedback regarding the future feasibility
hardware. This trend applies increasing- Engineering, quality is at the top of the of the customer’s requirements. The ap-
ly to the automotive industry, as more list. For this reason, all development plications on the control units are first
complex and faster hardware finds its processes are aligned with the Porsche modeled, simulated, and then tested ex-
way into modern cars. standards. Increasingly complex products tensively in executable code on the target
combined with shorter time-to-market hardware (Rapid Prototyping). This way,
The Hardware Lab basically follows and more demanding quality expectations specification and development errors can
three trends: the linkage of multimedia make it necessary to determine customer be discovered in a very early phase of a
and sound systems; the use of state-of- requirements early on and to create a project. If needed, we will support our
the-art electronics to reduce consump- realistic test environment for the future customers throughout further develop-
tion; and finally, increasing passive and product. This is one of the specialty areas ment with B-, C-, and D-samples, up to

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Insights The Hardware Lab

three months after the start of produc-

tion. Veteran experts support the cus-
tomer on the way to a successful prod-
uct and help with all development steps,
all the way up to approval testing and
consultation regarding electromagnetic
compatibility (EMC).

Development examples – product

portfolio

High-performance audio amplifiers and

music player interfaces for vehicles are
examples of recent innovative develop-
ments by the Hardware Lab. These proj-
ects often involve easy-to-operate inter-
faces between consumer electronics and
the audio system of a vehicle. Other proj-
ects are in the areas of electric drives,
electric drives for sports equipment, and ucts, makes the Hardware Lab an attrac-
innovative solutions in combination with tive partner. After all, the engineers in the
hybrid drives. Their extensive knowledge Hardware Lab have many years of expe-
of battery technologies, which increasingly rience with the integration of vehicle assis-
contributes to the success of future prod- tance systems into complete vehicles.

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Special 911

911 – a synonym for performance

Historical deciphering of the Porsche success code The obvious solution was to double the
one: 911. This decision was made rela-
revealed surprising findings – about the “zero” hour tively fast. Without delay, the graphic de-
of the 911. signers at Porsche tackled the graphic
implementation of the change. And their
brushstrokes demonstrated taste and
When the new Porsche was presented at claiming that it – and it alone – had the confident style. Over time and across
the International Motor Show (IAA) in exclusive right to use type designations model changes, the upright, angular 911
Frankfurt am Main in September 1963, it with a zero in the middle. logo morphed into the rounded, slightly
bore the identification plate “Type 901”. italic lettering, the typical “Carrera logo”,
The development department had done The new sports car from Porsche met as it is called internally.
diligent preparatory work to exclude pos- with a positive response all over the
sible objections to the type designation, world. Yet, after intensive internal legal
so they had every reason to feel safe. At investigation, renaming it was unavoid-
the Motor Show, the new sports car re- able. Still, the elegance of the vehicle This logo has long since become an op-
ceived a great response and the success was to be maintained for a new launch. tical distinguishing feature of this model.
of the “Type 901” seemed predestined. After the Porsche had caused such a It is also legally protected – as a regis-
furor in such a short time with its 901 tered trademark. The fact that the
Imagine the development engineers’ sur- number addition, just as the type 356 Porsche type 901 became the type 911
prise when an objection from a French had in its time, they were adamant about only a year after its initial launch certainly
automaker arrived at the end of 1964, keeping the nine and the one. has not harmed its career.

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

Power is work divided by time.

Plus passion.

For information about Porsche Customer Development visit the website or contact:

Phone +49 711 911-88888, Fax +49 711 911-88999

Internet: www.porsche-engineering.com, e-mail: [email protected]

Porsche Engineering
driving identities
80754_porsche_20_24_GB:80754_porsche_20_24_GB 15.04.2008 12:04 Uhr Seite 6

Porsche Engineering Magazine

Publisher’s data

Publisher
Porsche Engineering
Group GmbH

Address
Porsche Engineering Group GmbH
Porschestrasse
D-71287 Weissach

Tel. +49 711 911 8 88 88

Fax +49 711 911 8 89 99

Email:
[email protected]
Internet:
www.porsche-engineering.de

Editor-in-Chief
Nicole Möller

Porsche Engineering
driving identities