Wednesday, 01 December 2021 18:01

Porsche Whistleblower: ‘60% of All Delivered Taycan Have Battery Issues That Caused Replacements, Damages and Fires’

Written by Alex Voigt, Teslarati
The Porsche Taycan’s charging port. The Porsche Taycan’s charging port. Porsche Newsroom/Twitter


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“Six out of 10 Porsche Taycan” ever delivered have a problem with battery management that affects and damages battery cells, requires replacement of cells and batteries, and is causing vehicle fires, according to a source working at Porsche’s headquarters in Zuffenhausen, Germany.

Porsche is reportedly hiding the problem from customers and authorities and quietly replacing damaged battery cell modules without informing customers to cover up the problem.


Tesla offered to help Porsche with battery management through Audi contacts years ago, but Porsche management at the time rejected any external help, saying it could handle everything internally, the source noted.


“The problem affects six of 10 delivered vehicles,” the source, who could be described as a whistleblower, said.


A Risky Business


The Porsche whistleblower explained the Taycan’s 800V high-voltage onboard charger used today does not control the charging process well enough and can overcharge some battery cells, causing them to overheat. For safety reasons, overheated battery cells are disabled and isolated from the battery pack, reducing battery capacity and thus the vehicle’s range.


The problem occurs when the batteries are charged at a low AC speed of up to 7.5 KW, a common use case for all charging, such as at home or on low-speed chargers, the source said. 


The 800V architecture of the Taycan, a vehicle the German automaker is proud of, has many advantages, but the strong current requires a very well-controlled charging process to avoid charging some cells faster than others. The battery cells in a BEV are always charged in parallel to shorten the charging time, but this carries the risk that some cells will be charged faster than others.


If one of the many cells in a BEV is charged faster than the rest, overcharging and overheating can occur, which can lead to vehicle fires, if, for instance, an additional air leak happens. 


About 1% of the 60% of vehicles affected, or about 360 Taycans out of 36,000 vehicles delivered, had a preventable vehicle, cable or smoldering fire attributable to the problem, the whistleblower said. These are figures from Porsche’s internal statistics, which the company...

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