The grand tour

“The whole is greater than the sum of its parts” – the universal scholar Aristotle knew this more than 2,000 years ago. This timeless insight applies especially to the complete vehicle testing of the Audi e-tron GT. Expectations were high and yet they were exceeded: the result was a breathtaking car, an Audi through and through, borne out of meticulous work, intensive efforts refining small details and a great deal of passion.

No wow without know-how: a strong and lean PSW team carried out numerous tests under Audi leadership – from field tests, international tests and loading on ship tests right up to successful acceptance runs. The basis for this was an extensive catalogue of target values with hundreds of test points.

Frank Sauer's job was to find answers: has the whole vehicle been built correctly in accordance with Audi's specifications? Does the software meet all the requirements as a system? Has everything really been put through its paces? As an experienced mechanical engineer with a background in vehicle design and development, he knows what’s important – and how to master the complexity of such a project. “In the field tests, we tested up to seven vehicles in shifts, practically around the clock, covering a total of more than 180,000 kilometres. Air conditioning, infotainment, head-up display, navigation, multifunctional steering wheel – everything simply has to work to proven Audi quality.

To do this, I define the run times for the individual system tests at the start of the project – this requires the right touch, a kind of empathy for the overall system.” And how does he describe his own experiences? “A steep development curve!” laughs Frank Sauer, “especially at the beginning. We had to acquire a lot of know-how in a very short time. So was it pioneering work? “It certainly was! Being part of this project was a great experience for each of us.”

The mechatronics and mechanical engineer has been working at PSW since 2012. Ms. Strasser, what were your tasks on the Audi e-tron GT? “They were diverse: in addition to the international testing, I was also involved in weight management and other aspects.” Why is international testing so important? “The vehicle must be optimally prepared for all markets. Two particularly important markets are China and the USA. There are different displays, different apps and online services, different components, different charging processes, different main units. Does the remote opening of garage doors work?

What things change when subjected to extreme climates or altitudes? Does a milkshake fit in the cup holder? We have to precisely test and record all of this and much more. We also have to keep the time zones in mind: China in the morning, USA in the evening, there are umpteen balls in the air at the same time.” Did things get tricky sometimes? Vanessa Strasser laughs: “Absolutely! There were some pitfalls, but we all dealt with them together with the Audi departments – and this leads to a lot of know-how.” Could you sum up what the project meant to you in one sentence, Ms. Strasser? “Growth! For the team, for PSW and also for me personally.”

When it comes to loading, the devil is in the details. Industrial engineer Alexander Binder has a story or two about this: “How does the e-tron GT get shipped to Audi's target markets all over the world? What’s possible by ship, train or car transporter? We quickly became a committed team, the spirit was perfect, right from the start!” The challenges went hand in hand: for example, as a performance vehicle, the Audi e-tron GT has limited ground clearance, which is why the approach angle of a ramp must not exceed 12 degrees to ensure optimal loading.

“Our project team quickly and efficiently gained knowledge here and on other issues. For example, regarding the huge ship in Emden, Germany which transports up to 7,000 vehicles overseas in one go, we had to see how we could optimally lash down the Audi e-tron GT. Here we were also supported by Audi, especially by the specialists from manufacturing. Your conclusion, Mr. Binder? “A great experience, an agile project, a lot of personal responsibility, a great team – this gives you an appetite for more!”

Gerald Lang is an electronics specialist with decades of expertise in vehicle wiring systems. It’s no wonder that he knows his way around when it comes to resolving complex issues and achieving high performance. What drives him? “I want to create processes that allow everything to run smoothly, to create freedom. That was difficult, especially during the pandemic, after all, such a project lives from intensive communication and the exchange of ideas. But everyone in the team immediately accepted the challenge and pulled together admirably.” His area of work includes the evaluation and acceptance runs:

“There is a cascade of runs to receive structured assessments of how the vehicle drives. This starts with the first technology demonstrators and increases to around 50 acceptance runs in the pre-series phase. The most important thing: seeing, hearing, feeling – and evaluating! Does everything feel like an Audi? Does everything work like an Audi? Does everything sound like an Audi? It's great when you follow the vehicle through its development and then see it approved.” With his eyes lighting up, Gerald Lang adds: “And when you look at the newspaper in the morning you see FC Bayern Munich players enthusiastically collecting their first Audi e-tron GT – that really is something ...”

In December 2018, industrial engineer Stefan Wolpert moved from Audi to PSW. It was already clear at the time that the Audi e-tron GT would be a truly electrifying task. “All told, it was exactly what I wanted to do: planning, controlling, developing and designing. We set up the project together with Audi, and the first task was to write a strategy. What do we need? And who do we need? What do we know and what don’t we know? So many questions, there was no time to have any doubts or feel nervous. And it quickly became clear that the growing team would work wonderfully together.

“Such a project has its own dynamic anyway, doesn't it? Mr. Wolpert laughs and nods: “The task was complex: the composition of the components, acoustics, dynamics, character, infotainment and much more. But we said to ourselves: let’s go for it!” And what happens now? “We want to secure what we have learned in the long term for us and continue to expand our powerful network – the next challenging tasks have already arrived!”