Inter-Axle Torque Coordination and Upshift Optimization of Porsche Taycan’s AWD Propulsion System via Multi-Domain Simulation

This paper presents the development of a multi-domain simulation for the Porsche Taycan’s all-wheel-drive (AWD) electric propulsion system to investigate the impact of the rear drive unit’s two-speed transmission on performance and drive quality during maximum acceleration. This study was undertaken independent of the vehicle and propulsion system OEM. A lumped-parameter model of the front and rear electric drive units (EDU) and the high-voltage battery was developed and calibrated against the published data for key benchmarks, including 0–100 kph acceleration times and peak longitudinal acceleration. The mechanical shifting mechanism was reverse-engineered to simulate high-performance shift trajectories. To manage the transition, a clutch control scheme integrates a reduced-order clutch-to-clutch model featuring a feedforward (FF) torque estimator and a closed-loop feedback (FB) controller to achieve target input shaft speeds and shift durations. The study concludes with a comprehensive analysis of the propulsion system’s behavior at a battery state of charge of 96% and 25% and three electric motor speeds at which the upshift is commanded. The simulation results demonstrate that executing an early upshift at 10,700 rpm with 96% of SOC yields a 0.100-s inertia phase shift time, restricts the clutch thermal dissipation to 21 kJ, and achieves an 8-s velocity of 203.4 kph, outperforming the upshift at 15,300 rpm (0.210 s, 34 kJ, and 202.8 kph). Furthermore, the transient regenerative braking on the rear axle during the inertia phase reduces the peak current draw from 675 A to 87 A, recovering the DC bus voltage to enable cross-axle torque boosting on the front axle.