E&HTI Gets a Rare Glimpse into Porsche’s State-of-the-Art Wind Tunnel at Weissach Development Centre
Francesca Cogotti, an aerodynamics engineer at Porsche, shared her insights about the significance of aerodynamics in modern vehicles, especially in the age of electromobility. Cogotti believes that advancements in aerodynamics are partly “the revenge of the aerodynamicist,” emphasizing the increased importance of efficient design in electric vehicles.
Porsche’s wind tunnel in Weissach, Germany, is a hub of cutting-edge research and development. Commissioned in 2010 and operational since 2015, this facility has been a non-stop operation, with two shifts working seamlessly from early morning to late night.
The Role of Aerodynamics in Electromobility
“Nowadays aerodynamics is more important than ever,” Cogotti explains. The primary focus is on improving battery efficiency to extend the range of electric vehicles. However, Porsche also prioritizes performance, balancing efficiency gains with the dynamic driving experience.
During a recent visit, the Porsche team demonstrated the wind tunnel with three different Taycan models: the Taycan Turbo S, Taycan Turbo GT, and the Turbo GT with the Weissach Package. These tests helped measure and optimize various aspects such as wheel and tire configurations, ride heights, and spoiler positions to ensure certification compliance.
Maximizing Efficiency and Performance
The Taycan Turbo S showed particular improvements, gaining over 40km on the WLTP test cycle with an aerodynamic drag coefficient of 0.22 in Range mode and 0.26 in Sport+ mode, down from 0.29 in the original model. Christopher Sachs, a complete vehicle line development engineer, highlighted that downforce was crucial for the Turbo GT and Weissach Package models to enhance track performance.
Key improvements included modifications to the front lights, air intakes, rear design, active rear spoiler, and new 21-inch aerodynamic wheels with Pirelli P-Zero tires. Software improvements also played a significant role, allowing the active grille shutters to remain closed during high-speed driving, further reducing drag.
Collaboration between Aerodynamics and Design Teams
Cogotti noted that the aerodynamics team’s collaboration with designers has strengthened since the adoption of electric mobility. This partnership has led to more efficient vehicle designs, balancing performance and practicality.
However, achieving optimal aerodynamics often requires compromises. For instance, the demand for easier maintenance led to less extensive under-body panels, necessitating engineers to find alternative ways to improve efficiency and performance.
Enhancing Downforce with the Weissach Package
For the Taycan Turbo GT and Weissach Package models, the focus was on downforce and aerodynamic balance. Key design changes included a fixed rear wing, revised front splitter, and changes to underbody aerodynamics.
These modifications significantly increased downforce, reducing front axle lift. At 305km/h, the Weissach Package model generates up to 80kg of downforce on the front axle and 140kg on the rear. In contrast, the Turbo GT model experiences up to 30kg of lift on the front and 30kg of downforce on the rear at the same speed.
Inside Porsche’s Göttingen Design Wind Tunnel
Max Ganis, Head of Aerodynamics and Aeroacoustics at Porsche, described the facility as one of the most advanced and expensive in the industry. It is designed in a Göttingen style with a closed loop and a 7 megawatt motor-powered fan featuring carbon fiber blades.
This fan can generate wind speeds of up to 300km/h, allowing Porsche to test vehicles at the highest possible velocities. The wind tunnel contains two different belt systems: a five-belt system for precise testing of road cars and a single belt system for understanding motorsport characteristics.
The five-belt system simulates road conditions, including each wheel’s movement and the ground surface beneath the car. Switching between belt systems can take up to three hours, but it enables more efficient vehicle certification testing.
The Wind Tunnel’s Acoustic Capabilities
The wind tunnel is also a fully certified acoustic wind tunnel, equipped with a large microform array that facilitates 3D beam-forming analysis of potential noise sources on the car.
Temperature control within the wind tunnel is crucial for maintaining consistent measurement results. The facility’s temperature is kept at a constant 25 degrees Celsius, requiring significant energy but necessary for precise testing.
Despite its high energy consumption, Porsche is taking steps to make the facility more sustainable. Solar panels on the roof and an open cooling tower help reduce overall energy demands.
Conclusion: The Importance of Advanced Testing Facilities
Porsche’s wind tunnel in Weissach is a testament to the company’s commitment to innovation and excellence in vehicle engineering. By continuously testing and optimizing vehicle designs in this state-of-the-art facility, Porsche can ensure its models offer the best balance of efficiency and performance.
As the automotive industry continues to evolve, facilities like these will plays a vital role in shaping the future of transportation. The collaboration between engineers and designers at Porsche highlights the importance of pushing boundaries while maintaining practical considerations.
What do you think about Porsche’s wind tunnel and its impact on vehicle development? Share your thoughts in the comments and join our conversation. Don’t forget to like, share, and subscribe to stay updated with the latest in automotive news and technology.
