AUTO COMPONENTS INDIA November 2018

www.autocomponentsindia.com Vol 5 Issue 9

` 100

November 2018

COMPONENTS

INDIA

VOICE OF THE AUTOMOTIVE SUPPLIERS

Hyundai Santro takes new avatar

POWERTRAIN TECHNOLOGIES

ACCELERATE INNOVATION

Mobile Climate Control targets bus market, opens new plant in Bengaluru

E DITORIAL

CONTENTS

Volume 5 | Issue 9

NOVEMBER 2018

COVER STORY z

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Sundaram-Clayton inaugurates new foundry in Chennai ISUZU launches new mu-X

06 | NEWS Datsun launches new Go and Go+

New powertrain technologies shift gears swiftly to be market-ready ZF plans to bring Clutch-by-Wire system to India Bosch braces up for BS-VI norms Continental develops 48V eScooter motor Lucas TVS is ready to meet the new powetrain wave SEG Automotive offers solutions to reduce vehicle emissions Search on for possible future of sustainable mobility solutions BorgWarner to make variable cam timing in Chennai plant Zygor Energy spark plug to cut emissions from existing and new vehicles GMTC-I develops future-ready automotive products Witzenmann India expands capacity for domestic market, exports Bonfiglioli sets up new facility in Chennai NGK Spark Plugs to enter mass markets with new products Shell’s new Advance AX7 engine oil to improve fuel efficiency Amara Raja, Johnson Controls tie-up to bring new battery technologies Classic Legends unveils engine for new JAWA Motorcycle

52 | OEM Hyundai Santro takes new avatar

14| CORPORATE

Manatec bags innovation award SFL’s 17 Indian plants wins Deming Prize Mahindra, Ford to share Powertrain Rane NSK Steering gets 2018 Deming Prize HiKOKI unfolds business plans for India

Mobile Climate Control targets Indian bus market, opens new plant in Bengaluru

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58 | ALLIED INDUSTRIES BFW Smart Plant in Hosur shifts manufacturing paradigms

E DITORIAL INEVITABLE DISRUPTION

T AUTO COMPONENTS INDIA Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E),Mumbai - 400 013 Tel +91 22 43525252, Email us at s.bhargav@nextgenpublishing.net Executive Editor Bhargav TS Editorial Advisory Board H. S. Billimoria, Aspi Bhathena Web Editor Ashish Bhatia Correspondent Sricharan R (Chennai) Gunjan D. Bidani (New Delhi) Head - Design & Production Ravi Parmar Asst Art Director Ajit Manjrekar Production Supervisor Dinesh Bhajnik Publisher Marzban Jasoomani General Manager – North & East Ellora Dasgupta General Manager – South Girish Shet Deputy General Manager – North & East Chanchal Arora (Delhi) Regional Marketing Manager Salma Jabbar (Chennai) Marketing Manager Minocher Parakh (Mumbai) Manager Circulation - North and East Kapil Kaushik (Delhi) Subscription Supervisor Sachin Kelkar Tel +91 22 43525220 Apple Newsstand & Magzter Queries: help@magzter.com Territory Sales Incharge (Circulation) Srinivas Gangula (Hyderabad) Cell +91 09000555756 Territory Sales Incharge (Circulation) Vidyasagar Gupta (Kolkata) Mob: 09804085683 REGIONAL MARKETING OFFICES Next Gen Publishing Pvt. Ltd. Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E), Mumbai - 400 013 Tel +91 22 43525252 26 B, Ground Floor, Okhla Industrial Estate, Okhla Phase III, New Delhi - 110020, India Tel +91 11 42346600/78, Fax +91 11 42346679 Unit No:509, 5th Floor, ‘B’ wing, Mittal Towers, MG Road, Bengaluru - 560001, India Tel +91 080 66110116/17, Fax +91 80 41472574

oday’s economies are dramatically changing, triggered by development in emerging markets, the accelerated rise of new technologies, sustainability policies, and changing consumer preferences about ownership. Digitisation, increasing automation, and new business models have revolutionised industries, including automotive. These forces are giving rise to 4 disruptive technologydriven trends: diverse mobility, connectivity, electrification and autonomous driving.

Most industry players and experts agree that these trends will reinforce and accelerate one another, and the automotive industry is ripe for disruption. Given the widespread understanding that game-changing disruption is already on the horizon, there is still no integrated perspective on the shape of the industry after a decade or so. Everyone is talking about the emergence of alternative powertrain concepts like hybrid and electric vehicles for zero emissions. However, to reduce CO2 emission in a sustainable manner, it is critical to optimise further the internal combustion (IC) engine and make it more fuel efficient. But without any hesitation I will say IC engines won’t die and it will continue to dominate the roads at least for the next 15 years with a lot of efforts to bring down emissions.

In city traffic in particular, fuel savings of up to 25% could be achieved with an automatic start-stop mechanism. Automatic engine cut-off can reduce fuel consumption by 4%.

In further hybridisation (strong or parallel), an electric motor with sufficient capacity to power the vehicle independently is installed alongside a conventional combustion engine. There has also been a gradual upshift in the demand for automatic transmission.

Automatic gear boxes with wider gear spacing and hydraulically or electronically supported gear-change can reduce fuel consumption by around 10%.

A perfect powertrain solution will address fuel economy, total cost of ownership and comfort. Transformation of the mobility scenario in India is only possible with the concerted action of all stakeholders. Only with a clear and unambiguous policy, the industry can move towards cleaner mobility. The current issue is power-packed with reports on different powertrain technologies and corporate initiatives to reduce emissions and increase fuel efficiency.

Bhargav TS Executive Editor s.bhargav@nextgenpublishing.net

Cenetoph Elite, No.5, Cenetoph 1st street, Teynampet, Chennai - 600018, India Tel +91 044 421-08-421/044 421-75-421 Devendra Mehta - Mob No.- 09714913234 Ahmedabad 201 Gera Serenity, North Main road, Koregaon Park, Pune - 411001.

Tel + 91 20 26830465

Views and opinions expressed in the magazine are not necessarily those of Next Gen Publishing Pvt. Ltd. Next Gen Publishing Pvt. Ltd. does not take responsibility for returning unsolicited manuscripts, photographs or other material. All material published in Auto Components India is copyright and no part of the magazine may be reproduced in part or full without the express prior written permission of the publisher Printed by Marzban Jasoomani Next Gen Publishing Pvt. Ltd., Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E),Mumbai - 400 013. Published by Marzban Jasoomani on behalf of Next Gen Publishing Pvt. Ltd., Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E), Mumbai - 400 013. Printed at Spring Graphics, 215 & 238, Shah & Nahar Industrial Estate, Sun Mill Compund, Lower Parel (West), Mumbai 400013, India.

Published at Next Gen Publishing Pvt. Ltd., Mafatlal Chambers B, Ground Floor, N. M. Joshi Marg, Lower Parel (E),Mumbai - 400 013

All readers are recommended to make their own independent enquiries before sending money, incurring expenses or entering into commitments in relation to any advertisement appearing in the publication. Auto Components India does not vouch for any claims made by advertisers for their products and services. The editor, publisher, printer and employees of the publication shall not be held liable for any consequence in the events of such claims not being honoured by the advertisers. All disputes are subject to the exclusive jurisdiction of competent courts and forums in Mumbai only.

Editor Bhargav TS

N EWS Datsun launches new GO and GO+

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atsun India has launched the highly-anticipated new Datsun GO and Datsun GO+ for the stylish influential, young, progressive and dynamic Indian customers. At an introductory price of Rs 3.29 lakh for the GO and Rs 3.83 Lakh, for the GO+, these offerings boast an attractive proposition of new design with an array of advanced features for evolving customers. Deliveries to new owners has commenced from all Nissan and Datsun dealerships across the country.

Thomas Kuehl, President, Nissan India said, “The new Datsun GO and Datsun GO+ are conceptualised for the new-age Indian consumer, the millennials who are mature, smart goers, family- oriented with a progressive and evolved mindset.

Powered by Japanese engineering, Datsun GO and GO+ are equipped with fabulous new features and upgrades for a more comfortable, safe and stylish

interior, the Datsun cars are further enhanced with first in the segment features to empower the owner with advanced safety, the best-in-class space and connected mobility.

driving experience.”

The cars, offered as the perfect package for a new era, embodies class-leading Japanese technologies to deliver fun and agile driving, fuel-efficiency, spaciousness and safety. The all-new Datsun GO and GO+ come equipped with Ride Control Advanced Suspension system and raceinspired 1.2L HR12 DE petrol engine delivering a mileage of 19.83Kmpl.

Combining sporty exteriors and spacious

The ‘Dynamic, solid and stylish’ exteriors with enhanced appeal complemented with great body stance gives the Datsun GO and GO+ a premium appeal. The cars have been well-crafted with ‘Sporty, Premium, and refined interiors’ that provide comfortable driving experience.

The features include an all-new interior design with new instrument cluster, antifatigue front seats, premium instrument panel, 7-inch touchscreen infotainment system equipped with voice recognition and Android Auto/ Apple Car Play.

Available in 5 grades, the new Datsun GO and GO+ have been launched in 2 new additional colours “Amber Orange” and “Sun Stone Brown”, respectively. ACI

Manatec bags innovation award

M

anatec Electronics has been conferred with the ‘Innovation Award’ under the Trucks Products & Services category in 2018 Automechanika, Frankfurt, Germany for their innovation of HCV wheel aligner ‘Jumbo 3D Super’. Jumbo 3D is the world’s first 3D wheel aligner for multi axle trucks, trailers and buses.

Jumbo 3D uses latest innovative digital-imaging technology by deploying high resolution digital cameras 2 per side and operate with intelligent software.

The product is capable of measuring the

for lifting the heavy axles one by one manually by the mechanics. The benefit is very high productivity and manual energy saving.

The product is suitable for multi axle trucks, buses and trailers. There is no electronics fitted to the wheels and therefore very less maintenance cost.

wheel alignment parameters including wheel “Runout” of 5 axles simultaneously in 2 minutes, against 40 minutes in the present system and eliminates the need

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Thrust angle adjustment in a single axle vehicle is a tedious job using conventional trial and error method. Manatec have developed single axle adjuster tool which helps in effortlessly adjusting the thrust angle precisely and saves considerable time and energy. ACI

N EWS SFL’s 17 Indian plants win Deming Prize

S

undram Fasteners Limited (SFL), part of $7.2 bn TVS group, has won the prestigious Deming Prize for all its 17 plants in India.

The TQM initiative at SFL was driven by its Managing Director, Arathi Krishna. The Deming Prize is a highly acclaimed quality award presented by the Union of Japanese Scientists and Engineers (JUSE) to companies that have achieved breakthrough results by the application of TQM. SFL experienced distinctive performance benchmarks being created by TQM and decided to implement TQM in a systemised and unified manner across its plants.

Arathi Krishna, the first woman MD ever to receive the award said, “It is especially gratifying that SFL has managed to simultaneously win the Deming Prize for all its 17 different plants which cover a range of technologies from casting to forging and products and customer segments from Aerospace to commercial vehicles to cars and wind-mills in a short span of 6 years.”

She further added, “Winning this award is a confirmation of the practices that we have been implementing at all our plants. It is a testimony to our persistent drive towards quality and catapults us to be

among the best companies globally.”

She also commended the total employee involvement in the TQM journey and said, “the cooperation of the people and their singular focus to succeed has helped SFL make quick and successful strides in reaching our goal.”

SFL has already won international acclaim in quality by being a pioneer in TPM, having won the TPM Excellence Award from JIPM, Japan in 1998 the first in the engineering industry to get this recognition.

The Deming Prize will be formally presented to SFL on November 14, 2018 in Tokyo. ACI

Mahindra, Ford to share powertrain

M

ahindra Group and Ford have signed 2 definitive agreements on powertrain sharing and connected car solutions. The strategic alliance between the 2 companies was first announced in September 2017 and followed up with 5 Memoranda of Understanding (MoU) in March 2018.

Mahindra Group will develop and supply a low-displacement petrol engine to Ford India for use in its present and future vehicles, starting in 2020. The BS-VI compliant powertrain will help Ford extend and strengthen its existing offering of petrol engines, that currently includes the all-new 3-cylinder TiVCT family.

Building on their intent to co-develop a suite of connected car solutions, Mahindra and Ford also announced joint development of a telematics control unit. Once developed, the connected vehicle solution will be deployed across Mahindra and Ford vehicles.

teams have made since we announced our strategic alliance with Mahindra Group a year ago. Today we go further in delivering even greater value. With our collaboration in powertrain and connected car solutions, we will deliver an affordable portfolio and enable our Indian consumers to get behind the wheel, feeling more confident and connected,” Jim Farley, Ford Executive Vice President and President of Global Markets, said.

Dr Pawan Goenka, Managing Director, Mahindra and Mahindra said, “The agreements further builds on commitments made so far, leading to a fruition of exciting new opportunities.

We are confident to meet customer expectations by working together on a number of joint development areas.

Going forward we will continue to identify the synergies that exist between the two companies.”

“We are pleased with the progress our

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Both the companies continue to make progress on the remaining elements of the MoU signed earlier this year. These include applying their respective strengths on product development for India and emerging markets, and co-development of compact SUVs and electric vehicles. The strategic alliance between the 2 companies focuses on leveraging the benefits of Ford’s global reach and expertise and Mahindra’s scale in India and its successful operating model, a joint statement said. ACI

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NEWS

Rane NSK bags 2018 Deming Prize

R

ane NSK Steering Systems Pvt. Ltd, a Rane Group company, has been awarded the 2018 Deming Prize.

The Deming Prize, a highly prestigious quality award, is presented annually by the Union of Japanese Scientists and Engineers (JUSE) to companies that have achieved distinctive performance benchmarks through the application of Total Quality Management (TQM). The Deming Prize will be formally presented to Rane NSK Steering Systems on November 14 in Tokyo.

The team at Rane NSK Steering Systems has always been a partner of choice to their customers. The organization has built comprehensive quality systems to produce world class products.

This award recognizes their process robustness and emphasis on continuous improvement.

Commenting on this achievement, L. Ganesh, Chairman of Rane Group said, “It is a proud moment for Rane NSK Steering Systems to be awarded the 2018 Deming

Prize. Rane Group is privileged to be honoured with 3 Deming Grand Prizes and 5 Deming Prizes for various business units.

The TQM journey which started in the year 2000 has come full circle with all our major manufacturing businesses having secured Deming Prize. This award will further motivate the team to shift gears from operational excellence to business excellence with emphasis on result areas.” ACI

HiKOKI unfolds business plans for India

H

itachi Koki, manufacturer of power tools and life-science equipment, has announced its aggressive business plans for India. Now rebranded as “HiKOKI”, the company’s Indian arm has been operating since 1996 and is the largest and fastest growing subsidiary in Asia (after Japan). HiKOKI India has registered steady growth over last 20 years with a CAGR of 16%. It is aiming to scale up its dealer count from 600 to 1000 by 2020.

Hitachi Koki is widely known in all segments for its technologically advanced, reliable and low-maintenance tools. During 2017-18, HiKOKI India sold 3,60,000 tools and aims to sell 400,000 tools during FY2018-19. Simultaneous to its rebranding efforts, the company is also launching new technology MultiVolt tools. Identifying a visible shift from corded to cordless tools among end users, HiKOKI is planning to introduce affordable, user-friendly cordless and DIY tools in the India market.

Dattatraya Joshi, Executive Director and Secretary, Hitachi Koki India said, “The power tools market is estimated at Rs 4000 crore and is growing rapidly at 7%, and is projected to grow at a steady pace for the next 10 years. Backed

and fabrication sectors. The company manufactures more than 50% of domestic requirement by volume. It also exports tools to Bangladesh, Sri Lanka and Nepal; and exports select components to other Hitachi Koki subsidiaries’ in Malaysia and Japan.

by powerful government initiatives to boost the manufacturing sector, India gives us a unique opportunity for growth, innovation and contribution when compared with other developed countries. There is a growing demand for quality and world-class tools which can enable India to compete globally.

Keeping this demand in mind, we are strengthening our business and customising our offerings for the Indian market. We foresee growth opportunities shifting to Tier-II and III cities. Hence, we are looking to strengthen our base in this area and increase our market share.

Overall, we are aiming to make India our growth engine for the coming years and our dynamic new partnership with KKR is further enabling us to accelerate this growth and pursue our goals more aggressively.”

HiKOKI India boasts of leading customers in automobile, construction

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The corporate rebranding of Hitachi Koki to new brand HiKOKI is a major step for Hitachi Koki and its international growth strategy to ensure sustainable growth and expand business in the nearly 150 countries in its global network. KKR acquired Hitachi Koki in March 2017.

While the company’s management remains the same, it has acquired better financial strength and autonomy which offers more scope to take decisions faster and develop products as per the market requirement.

HiKOKI India in its first step of embracing its new identity will be conducting a Mobile Vehicle Campaign where 2 mobile vehicles will travel throughout the country over the next 6 months to provide a complete experience zone for its consumers. This campaign will provide a great opportunity for HiKOKI to present its top-notch ensemble of new tools to its consumers and experience first-hand. ACI

NEWS

Sundaram-Clayton inaugurates new foundry in Chennai

S

undaram-Clayton Ltd. (SCL), a member of the TVS Group, has inaugurated its new foundry at Oragadam, near Chennai. The new facility was inaugurated

by Young Key Koo, Managing Director and CEO of Hyundai Motor India. The Oragadam plant has been set up with an investment of over Rs 150 crore. This major capacity expansion aims to meet the rapidly growing demand for its products from the automotive industry and will primarily serve Hyundai Motor India Limited. With a capacity of 8000 tonne, the plant will produce machined castings ranging from 1.9 kg to 7.2 kg.

SCL produces more than 50,000 tonnes of castings annually for the passenger car, commercial vehicle and two-wheeler segments, supplying to key customers like Hyundai Motor India, Cummins,

said. “This facility reinforces our drive to serve our customers by cutting down supply times because of the proximity to their factories and gives us a competitive edge.

This is a critical advantage given the lean inventory management of our customers who want the supply chain to be agile.”

Volvo, Daimler, PACCAR, BMW, Honda, Ford, HANON, WABCO, ZF and TVS Motor Company. SCL is known for its industry leading quality practices and its best practices in manufacturing, driven by Total Quality Management (TQM), Total Productive Maintenance (TPM) and lean manufacturing.

“At SCL we are committed to work as closely with the customer as possible,’’ Dr Lakshmi Venu, the Joint Managing Director of SCL,

SCL is confident that the Indian automotive market will continue to see robust growth.

With fuel-efficiency improvements being important to the Indian market, aluminium components will play a key role in supporting OEMs to meet their consumers’ expectations. This capacity expansion is a part of SCL’s strategy to partner in the lightweighting of their customers’ vehicles, both with R&D capability and a responsive supply chain. SCL has facilities in Padi, Oragadam and Mahindra World City near Chennai, and one plant in Hosur. ACI

ISUZU launches new mu-X

I

suzu Motors India, a subsidiary of Isuzu Motors Limited, Japan, has launched the new ISUZU mu-X, 7-seater, full-size, premium SUV in Chennai at the newly-opened lifestyle showroom of KUN ISUZU. The new mu-X is built at ISUZU’s state-of-the-art manufacturing plant at SriCity in Andhra Pradesh.

The new mu-X projects a more aggressive stance with its ‘Eagleinspired’ styling and refreshed design at the front and rear of the SUV. The refreshed model of the mu-X now comes with sportier ‘Lava Black’ premium interior upholstery and fine quilted leather seats, making it more desirable in the 7-seater, full-size, premium SUV segment in India. The SUV is now packed with more features on the exterior and interiors with

we began our operations in 2012.

Our products have been very well accepted by the Indian market for its world-class quality, durability and reliability. ISUZU is in the midst of creating a new lifestyle in India with these globally proven vehicles. India-made range of D-MAX and mu-X SUV vehicles will strengthen and add fillip to our export operations and will play an important role, contributing to the future growth of ISUZU.” enhanced safety features including 6-Airbags and Hill Descent Control (HDC), addressing the needs of the modern Indian families.

Masanori Katayama, President, Isuzu Motors Limited said, “India is one of the key growth markets for ISUZU and we have made significant progress since

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The ISUZU mu-X has been gathering a lot of momentum in the Indian SUV market and is gradually becoming a preferred choice for many Indian families, thanks to its sheer space and comfort it offers. The new mu-X is a perfect answer to those who will appreciate the capability and value it offers. ACI

C ORPORATE Mobile Climate Control targets Indian bus market, opens new plant in Bengaluru Story by: Sricharan R

M

obile Climate Control (MCC), that develops, manufactures and sells complete climate control systems for commercial vehicles, has set up a new facility in Narasapura Industrial Area, near Bengaluru.

MCC is active in the market for climate control systems for buses, off-road, utility and defence vehicles. It is focused on customised solutions in small to medium-sized series. Its solutions include heating, ventilation, air conditioning, and controls, as well as a wide range of associated components.

“Our new Indian plant is of the same standard as the rest of our facilities across the globe. It is a state-of-the-art plant. We will deliver cost-efficient products of superior quality from the beginning. We are going to have an efficient operation and it is the way to be competitive in any market.

The Bengaluru plant will also be our export hub,” Clas Gunneberg, President and CEO, MCC, said.

PHOTOGRAPHY Bhargav TS

An industry leader in North America and Europe the company is now focusing on the growing Indian market. The newly-built 20,000 sq. ft. facility will make

most innovative and proven product line for the Indian and the global markets. MCC, as an HVAC vehicle systems manufacturing company, offers a variety of systems that include heating, cooling, ventilation, air conditioning and refrigeration for conventional and electrical city/transit, coach/tourist, school, shuttle/minibuses, vocational trucks, construction and much more.

The company also plans to set up a testing facility in the plant by 2020. The investment for the testing centre will depend mainly on the capacity. It is also planning to use India as a base for exports to other markets.

“We have plans to export to the European market from here and we expect it to happen soon.

At the new facility, we will be sourcing the entire unit, but to start with, it will not be fully assembled here. A few things will be in CKDs. We see the tendency of the Indian manufacturers starting to export buses to other countries. We would like to supply our products to them. We also see an opportunity to export directly from India to other countries,” he said.

About the export plan, Eberhard Wolters, President Europe, MCC, said, “We will be exporting our products depending on the customer expectations. The new facility gives us options like making complete units or parts like the condenser, coil or blower as part of the package. As the manual labour is less expensive in India than it is in many parts of Europe, we aim to import units that are as complete as possible.

That is our strategy.”

Gunneberg said, “We are planning to make AC system that it is slightly lower in capacity than what is needed in parts of India. Most of the products that will be sold in India are of 40-45 kWh. We will probably be exporting 30 kWh units. We have a production facility in Poland

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C ORPORATE a couple of years, but currently we are looking at the Indian market,” Wolters said.

Eberhard Wolters, President Europe, MCC, Clas Gunneberg, President and CEO, MCC, and Sunilkumar, President, MCC India

The MCC India facility in Bengaluru is built to the same standards as the company’s other plants

that manufacturers heating coils and blowers. We will concentrate more on AC units here. At first we will have 35-45 kWh and in the long run, we have plans to build other types of ACs.” MCC has an AC manufacturing company in China which caters to the off-road segment. It is looking at the bus segment now. The plant is different and competitive and makes quality products. MCC expect the Indian plant also to go rapidly and begin to export to other Asian, European and the US markets.

“India is bigger and we think that we have to do a lot to cope up with it. China will be an option op ption in

The AC firm has plans for the upcoming new trends in the Indian market. Gunneberg said, “We will be innovative and our products will be different from competitors. The major thing to start with is the fleet tracking opportunity. Then the ‘Siberian’ is what we have for the electric buses. We also intend to come up with new products to compete with the current ones. For lightweighting, we are finding other materials like fibreglass.

This will take out a lot of weight from the unit. As of now, we are not ready and we are trying to find a solution to keep the cost low and reduce the weight. The electronics in the system is made in-house and around 30% of our engineers work on the electronics of the system.”

For light-weighting, the company uses copper coils which are lighter and carry less coolant.

About lightweighting, Wolters said, “All these also depend on the customer requirements. It can be aluminium or copper.

We make what the customer asks for. As many have tried and failed on the aluminium in the ACs, we do not want to educate the market. The market is already mature and there may be a room for improvement and growth. Yet, it all depends on the bus manufacturers. We give them what they specifically want.”

Going forward the Swedish firm hopes that India will contribute a major share to its global market. For the start, the new facility will manufacture 80% for the domestic and the rest for exports. As they also have plans for the European market, the percentage level might change. If the market is good even up to 95% may be for India.

“This is because we believe that there is much room for growth here. But, it is not just about the growth in the turnover. There is also engineering power in India that will help us a lot both here and the European market. For example, when the US engineers go home finishing the design, the next day they will have the product ready from the Indian engineers. We want to make use of this, to design and other things, not just for the Indian market, but also for the European and the US markets.

It is going to be a team work,” Wolters said.

About their plans to work in the Indian market, Gunneberg said, “We have the custom engineering and we always listen to the customers. If they need changes we do it, no matter what the volume is. As soon as the volume increases here we will invest in the local production of heating coils, condensers etc. This will make us different from our competitors.” ACI

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C OVER STORY New powertrain technologies shift gears swiftly to be market-ready ACI Bureau

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n the advent of upcoming new emission regulations, the engine manufacturers, vehicle makers and component suppliers are looking at the opportunities the changing powertrain landscape is throwing up for them. To tap the fast evolving market, the component industry has to further improve its capabilities by acquiring technologies to make these parts through joint ventures or technical partnerships.

Ashok Leyland introduces ‘Innoline’ - World’s first BS4 engine driven by an inline fuel pump

With the new options like electrification of motors, turbocharged gasoline engines could gain steam as smaller diesels like the 1000cc engine, could get eclipsed as the new BS-VI emission regime would make it much harder

to tweak the smaller crop of engines.

More affordable powertrain solutions like electric and hybrids will also offer more viable options. To boost engine power, turbo proliferation and industry adoption will continue to grow at a fast pace in India reaching Rs 2,600-2,800 crore by FY20, according to the ratings agency ICRA. In 2020, when BS-VI engines will become expensive with the cost of their after treatment, the acquisition cost of a diesel vehicle will also rise commensurately. This high aftertreatment cost for a diesel engine will drive the shift in percentage terms towards gasoline engines. The diesel percentage will consequently decline due to the price sensitive nature of the market.

The OE manufacturers are working in close co-operation with the component suppliers on localisation and innovations right from the design stage. For instance, some of the top carmakers have 95-97% localisation in their top models that helps rein in costs. With technology continuously changing, innovations have to keep pace with them.

For India, engines with high and low-end torque for manoeuvring traffic snarls in cities are relevant.

However, higher engine power would be necessary for driving down highways on week-ends, similar to those preferred in Europe and the US. Industry experts agree that there will be complexities in upgrading the diesel engine to BS-VI. Striking the right balance between technology and cost will be a major challenge.

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Introduction of turbocharged gasoline direct injection technology would become mainstream in the compact SUV segment, while diesels would continue to dominate in the mid and high-end SUVs due to their fuel efficiency. Three and fourcylinder engines would be popular in petrol and diesels for passenger cars and SUVs, while the two-cylinder engine would drive commercial applications.

Looking at the current trend of SUV demand, more powerful engines will be looked at. While three and four-cylinder cylinder engines will be popular for smaller cars, the hybrid technology would leverage the motor to draw on additional power requirements. The diesel-dominated commercial vehicle and taxi segments will continue to be such in the near future also. However selfdriven smaller cars in urban markets may move to the more fuel efficient gasoline motors.

Despite the upcoming policy on electric vehicles, hybrids will find relevance with powertrains varying from mild to strong, based on the vehicle manufacturers and their applications.

While downsising and fuel efficiency will continue to be the key focus, the utilisation of start-stop technology will also rise. Officials predict that, in passenger cars, the shift to gasoline has already started and it will stay in the 75:25 gasoline:diesel ratio in the future.

With the increasing focus on the environment, OEMs have been

COVER STORY bringing in hybrid solutions and with the development of charging infrastructure and electric powertrain, electrically-driven vehicles will also grow. In addition, the change in emission norms will give a push to a cost-effective electric boosting technology solution like e-chargers and e-turbos. These will scale up efficiency and performance of the internal combustion engine in a mild hybrid vehicle.

In 2030, the share of electrified vehicles could range from 10 to 30% of new-vehicle sales. Adoption rates will be highest in developed, dense cities with strict emission regulations and consumer incentives (tax breaks, special parking and driving privileges, discounted electricity pricing, et cetera). Sales penetration will be slower in small towns and rural areas with lower levels of charging infrastructure and higher dependency on driving range.

Through continuous improvements in battery technology and cost, those local differences will become less pronounced, and electrified vehicles are expected to gain more and more market share from conventional vehicles. With battery costs potentially decreasing to $150 from $200 per kilowatt hour over the next decade, electrified vehicles will achieve cost competitiveness with conventional vehicles, creating the most significant catalyst for market penetration. At the same time, it is important to note that electrified vehicles include a large portion of hybrid electrics, which means that even beyond 2030, the internalcombustion engine will remain very relevant.

The Cover Story of the current issue is taking a close look at the new products and systems that support the development of new powertrains to be complaint with the new emission norms and

mobility solutions like hybrids and electric vehicles.

Bosch, a world-leading multinational engineering and electronics company, is gearing up with products to support the upcoming BS-VI norms in India. “We are working on a lot of BS-VI products and we want to support the OEMs for the timely launch in 2020. We have a big team of system engineers and categorisation engineers who are working on the BS-VI solution.

On technology-agnostic solutions, we are working closely with various OEMs, and legislative agencies and are trying to participate in legislation and technology participation for the future,” Sandeep N, Executive Vice President, Mobility Solutions, Bosch, said.

The Bengaluru-based General Motors Technical Centre India (GMTC-I), an engineering and research centre of General Motors(GM), is working on new products for the upcoming trends in the world market and helping GM to bring in the best future-ready products. “We are focused on the vision of GM that is zero crashes, zero emissions and zero congestion.

Zero emission is the ultimate goal

and to achieve this we need to take several steps. From an internal combustion engine perspective, we will continue to work on the engines and will make it more efficient for quite a long time. At the same time, we will also work on electrification,” Brian McMurray, Vice President, GMTC-I Engineering and Operations, said.

Hybrid system in a passenger car

As the different types of the hybrid electric vehicles (HEV) are becoming real competitors of the classical ICE-driven cars, hybrid spin-off applications, such as the integrated starter-generator (ISG) is emerging with benefits to hybrid electric vehicles. It was in this background that Continental developed its first 48V mild-hybrid system. It has been developed for cost-efficient mass hybridisation.

The Chennai-based Lucas TVS is coming up with a new traction motor for electric vehicles. “The traction motor is our first step towards the new things that are happening in India. The motors will be of 1 kWh, 3 kWh and 5 kWh and will be able to power, e- rickshaw and e-autos,” Aravind Balaji, Joint Managing Director, Lucas TVS, said. ACI 19 19

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AUTO COMPONENTS INDIA NOVEMBER 2018

C OVER STORY ZF plans to bring Clutch-by-Wire system to India coming years. However, the current forecasts also show that the overall sales curve for MT will continue to point upward for a long time in the emerging markets like India. At the same time the increasingly tough emission regulation is also driving the component makers and OEMs to innovate systems to increase the overall fuel efficiency.

Strory by: Bhargav TS

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lobal automotive component and technology major ZF Friedrichshafen AG introduced an ‘electrified’ clutch that makes manual powertrains even more efficient. ZF launched the Clutch-by-Wire (CBW) system

Jorg Buhl, Manager, Car Powertrain Technology, Design Actuation Systems, ZF Friedrichshafen AG

for the global market. It is an electromechanical actuator system that, for the first time, controls the clutch independently of the driver’s left foot and without a mechanical connection to the pedal. This enables car designers to implement fuel-saving features.

Due to the upcoming new emission regulations in India, all the OEMs are working on reduction of CO2 emissions and to increase fuel efficiency of a manual transmission (MT) system. In order to support the need, ZF India plans to bring CBW to the Indian market.

Though manual transmissions are losing market share in favour of automatic transmission, the absolute number of MTs is expected to increase in the

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Speaking to Auto Components India, Jorg Buhl, Manager, Car Powertrain Technology, Design Actuation Systems, ZF Friedrichshafen AG said, “The main idea to develop this system is to actuate the clutch electronically by an integrated electric motor.

With this system, the fuel consumption and therefore CO2 emissions drop by up to 10%.”

The soaring function alone, which requires an automatic transmission or an automated form of clutch control – could generate as much as 10% less fuel consumption. The CBW enables car designers for the first time to combine soaring with manual transmission.

Explaining how the CO2 and fuel consumption is reduced, Buhl said, “If the vehicle has achieved a certain speed on the highway, the driver can put his feet on the accelerator pedal, the system will detect the situation and will open the powertrain automatically by itself. So the combustion engine will run, for example at idle speed and with the open powertrain, you have reduced the friction inside and can roll for a long distance and this will reduce the

COVER STORY fuel consumption and the CO2 emissions. If the driver presses the accelerator pedal, the clutch will be closed again and can continue the driving. This is the latest development that we are doing at the moment for the manual transmission systems. Furthermore you can improve the comfort of the MT system with the CBW system.

With this, we have the possibility to implement new functions for safety, comfort and surely at the end to make a manual transmission system possible for reduction of fuel consumption.”

CBW controls the clutch independently of the driver’s left foot and without a mechanical connection to the pedal. This adds functions to manual systems that were previously reserved for automatic or automated transmissions: above all fuelminimising coasting. Apart from this the drivers should also work with the sailing function to reduce CO2 further. ZF’s fuelsaving sailing function separates the engine from the rest of the driveline in suitable situations and automatically engages the clutch. ZF has now also made this possible for automated manual transmission (AMT).

z Sailing functionality The clutch-by-wire clutch actuator is a further development of the tried and tested ZF AMT clutch actuators. So the company has developed its AMT clutch actuator to the new level, especially for the CBW application. Therefore the system had sailing functionality in an AMT application also. Buhl added, “We have done the test in Germany with the AMT-fitted car, which was equipped with sailing functionality. In the total 1400 km drive, we tested the vehicle with the sailing functionality for 700 km and the remaining without sailing

functionality. We figured out the benefits of around 5 to 7% during sailing function. All in all, this probably makes us the only partner that supplies a sailing concept for every car segment and virtually all commonly used transmission types.”

ZF Active Kinematics Control

z MT without clutch pedal The sailing function makes the most of situations in which the car also has sufficient momentum to freewheel forward. Clutch actuation systems from ZF then temporarily disengage the combustion engine so that it doesn’t suppress this kinetic energy. These can be electronically controlled and activated by wire, providing the basic prerequisite for the sailing function.

The disengaged engine can then idle while consuming a minimal amount of fuel. Ideally, however, it stops completely for a short period of time, because this is the only way in which zero emissions can really be achieved. “It is ultimately the vehicle manufacturers who decide how this concept is integrated into a car. We have also developed the sailing function, turning it into a sailing manager that can react even better to each driving situation,” Buhl said.

The CBW technology can also be designed for 2 pedal solution, which means, the clutch pedal can be eliminated and can be worked with the MT system. Here the clutch pedal is eliminated and needed some sensor system to detect the wish of the driver to change the gear and also needed some sensors inside the gear to detect the position of the gear.

With this combination of sensor system, on shift side and gearbox side the clutch pedal can be eliminated and will have much more comfortable system than the traditional manual system. This will be a big step forward for the comfort of the manual transmission system, says Buhl.

Automated Manual Transmission from ZF for CVs

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AUTO COMPONENTS INDIA NOVEMBER 2018

C OVER STORY z New technologies at FISITA 2018 In the recently-concluded FISITA 2018, ZF showcased its range of advanced technologies for the Indian market designed for passenger cars and commercial vehicles. The product range for passenger cars includes technologies such as its ProAI supercomputer, electric drive, seat belts, airbags, clutch cover XTend, clutch by wire and advanced driver assist systems (ADAS). In the commercial vehicle segment, the company is highlighted its clutches, dampers and automated manual transmissions.

Additionally, ZF also showcased its advanced chassis technology solution mSTARS (modular Semi-Trailing Arm Rear Suspension).

The mSTARS axle concept offers multifaceted applications in the most diverse vehicle segments such as the compact and mid-size car, the luxury vehicle and the sports car. For performance and comfort reasons, in the mSTARS core configuration all

control arms are connected to the subframe. In an entry version of the suspension, the longitudinal link can alternatively be attached to the vehicle

body. The application in hybrid, fuel cell and battery-powered vehicles is also possible in combination with standard powertrain modules or the active rearaxle steering system known as Active Kinematics Control (AKC).

Dr Holger Klein, Member of the Board of Management, ZF Friedrichshafen

ZF’s CBW is under development and the company is in discussion with several OEMs right now. At present CBW technology is for passenger car application up to maximum 350 Nm. “Today, we have worldwide market from around 37 million manual transmission cars with weight lower than 6 tonne and that’s our market we think about for CBW. If you look at the market in 2024, we see the market will be more or less on the same level. So the market for MT is still given in the future and we just offer the solution to make this MT systems fit for the future to reduce the CO2 norms. When it comes to the Indian market, we know how to develop a smart actuation system

Suresh KV, President of ZF India, said, “The demo vehicle equipped with mSTARS is a good example of how our global engineering teams work together to develop technologies which meet local market needs. This system can help our customers to meet the new requirements for lightweighting specified in the upcoming BS-VI norms from April 2020. We plan to launch our AMTs and dampers for commercial vehicles by 2020.”

with a long life time and wide range of functionalities. If we bring in all this knowledge to the new clutchby-wire technology, it could be possible to develop such a system in an attractive price range. Many customers in India are showing interest in this product, so we have to wait and see what will be the next step,” Buhl said.

ZF is also mulling entry into AMTs in CVs. The AMT has received a lot of traction in passenger vehicles and going forward could offer a lot of potential for growth in CVs as well. AMT solutions will surely fit in the Indian market and ZF is betting big on it in the coming years. With

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AG, said, “India is an important growth market for ZF and we are significantly expanding our presence here – in terms of localisation technologies for our domestic customers but also developing our engineering activities here to support our global business. We are expecting above market growth over the next few years. We have furthermore recently established India as an individual region within our own internal structure, allowing us to place greater focus and attention on this market.”

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both the PV and CV market moving up the technology graph, ZF’s focus going forward will be on its in-house technologies, moving to market-oriented technologies and customer-oriented designs.

ZF has developed a strong manufacturing footprint across both the automotive and nonautomotive businesses in India since it established operations in the region around 60 years ago.

With 2 wholly-owned subsidiaries, 5 joint venture operations and a new technical center dedicated to software engineering, ZF is well positioned to support its customers’ growth aspirations. ACI

C OVER STORY Bosch braces up for BS-VI norms Strory by: Sricharan R

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osch, a world-leading multinational engineering and electronics company based in Germany, supplies technology and services in the areas of mobility solutions, industrial technology, consumer goods, and energy and building technology. In Bengaluru Bosch has the largest development centre outside Germany, for end to end engineering and technology solutions. Bosch India is gearing up with products to support the upcoming BS-VI norms in the country.

PHOTOGRAPHY Bhargav TS

Bosch StartStop intelligent generator control

“We are working on a lot of BS-VI products and we want to support the OEMs for the timely launch in 2020. We have a big team of system engineers and categorisation engineers who are working on the BS-VI solution. On technology-agnostic solutions,

we are working closely with various OEMs, and legislative agencies and are trying to participate in legislation and technology development for the future,” Sandeep N, Executive Vice President, Mobility Solutions, Bosch, told Auto Components India.

The Bosch Group is present in more than 150 countries. In India it operates through 12 companies that carry out functions in both automotive and nonautomotive businesses through several manufacturing sites. The activities of Bosch in India are further empowered with R&D centres, and nationwide service and support networks.

z Technological support India plans to achieve BS-VI implementation from April 2020 and adopt electromobility solutions built for Indian conditions. Bosch offers the right technology to support both initiatives. The company believes that the ICE (Internal Combustion Engine) will continue to be the mainstream solution for freight and commercial vehicles. However, a key role here will be played by Bosch India’s electrification initiatives, to address the transformation in urban mobility. Keeping in mind the country’s climate change targets, Bosch views the co-existence of fossil fuel engines and electrification with hybridisation as an interim solution.

Hybrid technology will be a vital contributor towards the electrification goal in India due

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to the nation’s unique stopstart driving patterns and road congestion. In the light of that, fleet operators and smaller vehicles are poised to adopt electrification as soon as feasible options are available in the market. Bosch experts believe that the use of synthetic fuels as a scheduled supplement to electrification will play a vital role to reduce CO2 emission.

To make low emission traffic a reality, the company is making heavy investments – both in making electromobility a market success and in enhancing the combustion engine. Both technologies benefit the demand of the Indian market. Bosch has now achieved a breakthrough in diesel technology: with their new diesel technology, Bosch engineers have succeeded in getting NOx emissions massively down.

Another field of growth in India’s thriving automotive industry is the rising demand for connected mobility. Bosch continues to drive forward its transformation into a provider of mobility services. The company recently established a Connected Mobility Solutions division to develop and sell digital mobility services.

In India, the new business division will work to develop a global telematics platform that will be enabled and operated by local engineering talent.

The key offerings will include vehicle sharing, ridesharing, and connectivity-based services for car drivers.

With the new regulations coming in, Bosch is working

COVER STORY on the changes needed to be made in the components also.

For the two-wheelers, there is a transition from the carburettor to engine management systems and the firm is working in that space.

It is working on the safety feature also. For the passenger cars and commercial vehicles, the focus is on the exhaust gas treatment systems.

For the BS-VI, most of the component will be manufactured in India. Speaking about the components pricing, Sandeep said, “The main thing is that there is an ability to develop smarter system configurations. With smarter systems, we will have the chance to have cost-effective components. This is the way for the industry to go.”

Bosch provides a variety of products for fuel injections, low-pressure fuel supply, air management, transmission, e-mobility. For powertrain, it has products in cooling systems. Speaking about the powertrains, Sandeep said, “We are basically looking at the automotive technology in 3 domains: electrified, connected and automated. Although we term it as electrified, we are looking to provide solutions for emissions-free. Zero emission is the ultimate target.”

z Innovations Bosch R&D stands up to its corporate principle of ‘Invented for life’. The department holds around 60,000 associates who support Bosch worldwide. The centre is also the biggest software development centre outside Germany. The company also has an electromobility centre in Bengaluru, spearheading the local innovation in the area of

e-mobility. The development capacity in India is now extensively working for BS-VI. Talking about the new developments in the software side, Sandeep said, “From a software point of view, there are quite a few activities happening.

We are developing our own software platforms and going forward, this space will be a busy space. The first step is to establish connectivity. We have our connectivity control unit called the i-trans, which is a locally-developed solution. This helps us in setting up the first level of connectivity between car and cloud.”

Adding more about innovations, Sandeep said, “We have been traditionally a components manufacturer and a system integrator. We are now trying to go up the value chain and we are also trying to go both sides of the value chain. Connectivity is going to be a domain where you will see a lot of innovation coming up. Asset utilisation and shared mobility are the areas where you will see more innovations.”

z Localisation Sharing his views on the new technology for commercial vehicles, Sandeep said, the biggest challenge for the truck segment would be BS VI, telematics and connectivity.

He feels that there is a lot of potential in trucks, especially in the light duty and the last mile segments for improvement of asset utilisation. This is where he expects the technology of the future to come in.

“As the market in India is extremely dynamic in terms of legislation, the company has to improve not just in propulsion and emission, but also in safety

and connectivity. We expect that most optimum technology definitions to be from here. We have a very extensive production work, and we are producing a lot in China and in the Asia-Pacific region. We would definitely localise in India. Our depth of manufacture in India is proven and it is just a question of how the market is,” he said.

The company will be expanding its capacity to cater to the increasing volumes. “There will be investments in terms of electromobility and software development capability in India in the powertrain side.

Investment is indeed covering the entire spectrum of mobility solutions,” he said.

Bosch’s BLDC ECFM motor and coolant valve

Sharing his view on the electric vehicles, he said, Bosch is very clear on the e-mobility segment and it will come. “We believe that the e-mobility will emerge out of the specific used case. The two-wheelers and three-wheelers are in the form of pilot segments in achieving commercial viability which will be followed by commercial and taxi applications.

We believe in this roadmap and we are getting equipped to provide solutions. It will come, and how long will it take? We have to wait and see,” Sandeep said. ACI 25 25

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AUTO COMPONENTS INDIA NOVEMBER 2018

C OVER STORY Continental develops 48V eScooter motor Story & Photos: Bhargav TS

T

Continental’s 48V eScooter motor

he challenge of fuel economy standards is promoting optimised and sometimes novel vehicle powertrain architectures, that combine the traditional internal combustion engine (ICE) with various forms of electric drives. The different types of the hybrid electric vehicles (HEV) are real competitors of the classical ICE-driven cars. Today hybridised powertrains are commercially available. In such type of vehicles, hybrid spin-off applications, such as the integrated starter-generator (ISG) is emerging with benefits to hybrid electric vehicles, but with little or no cost/performance penalties. On this background, in 2016, Continental developed its first 48V mild-hybrid system and

supplied to its French and German passenger car OEMs. The 48V Eco Drive system by Continental has been developed for cost-efficient mass hybridisation. Functions such as advanced stop-start, coasting and electric boost, save 13-20% of fuel. In a mild-hybrid application the 48 Volt electric motor replaces the 12 Volt alternator and is directly connected to the engine via a belt. Continental is ramping up its production for a 48V application as it has bagged new orders from a US and Chinese automakers.

After tasting the sucess in the 48V mild-hybrid system, Continental has developed its 48V eScooter motor for full electric powertrain solution.

z 48V eScooter motor Talking to Auto Components India, Franck Bigot, Business Development & Strategy, Continental Automotive GmbH said, “In the coming months we will have a extension of production with a Chinese and the US OEM. In this case we have stop-start function, boosting, re-generation and in the transient phase we can also have more torque. With the same concept, we have now developed for two-wheeler application. Here we have removed the combustion engine, fuel tank and exhaust and installed this electric machine and a battery module, which is 2.6 kW and can have a range of 75 km.

With this, we received a 125cc equivalent combustion engine power, as it has 9.6 kW nominal and 12 kW big motor.”

Continental claims its mild-hybrid technology reduces average fuel

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consumption and emissions in real driving situations up to 21% in gasoline engines and up to 9% in diesels, as well as cutting nitrogenoxide emissions. The supplier anticipates that as early as 2025, about 14% of all new vehicles worldwide will feature this mildhybrid system.

“We have proposed this idea because we understood the two-wheeler market and who is demanding such kind of solutions. In the short or middle term, everything which is below 125 or 150 cc will be electrified.

Our opinion at Continental is, above 125cc will take time to be electrified. It is mainly because of the range is higher and at this point of time the battery capacity and density of energy is not sufficient.”

Currently, the most common mild hybrid topology is the P0 architecture, in which the electric machine is integrated in the Front End Accessory Drive (FEAD). In this case, the electric machine is replacing the alternator in terms of role and packaging. The beltintegrated starter generator (BiSG or e-machine) can an asynchronous or synchronous electric machine, which has 2 main functions: to provide torque to the powertrain in motor mode and produce electricity in generator mode.

z Throttle body M3C Talking about the other powertrain products that Continental is planning to bring to the Indian market, Bigot said, “We have our EFI with bluetooth module that consumes low energy. Any

COVER STORY workshop can deal with that. Our throttle body (M3C) Engine Control Unit is for one-and two-cylinders, 4 stroke engines up to 1,000cc in medium-to-high end motorcycles and scooters. It is a cost effective and robust solution to enhance engine and vehicle functions, to meet exhaust emission regulations and engine performance targets for medium size engines, as well as improving start-ability and overall performance over a wide range of environmental conditions.”

The throttle body is integrated with fuel injector, temperature and pressure sensor, as well as stepper motor, which leads to reduced components, simplified mounting, reduced assembly operation, cost optimisation, CAN interface for diagnostics, reprogramming, calibration and development and compatible with automotive standard calibration tool. The company is betting big with its electronic throttle control.

Here the throttle body includes a housing defining a throttle bore with a throttle plate in the bore and mounted on a shaft. An electric motor has a pinion gear. A gear assembly includes an intermediate gear and a sector gear and transfers rotational drive from the electric motor to the throttle plate. This throttle control actuator enables torque or load control for gasoline combustion engines and has lightweight construction.

performance over a wide range of environmental conditions.

The simple yet flexible package is suitable for all four-stroke, single-cylinder, small displacement engines ranging from 50cc to 180cc. M4L ECU for two-wheelers is smaller in size by almost 60% of its previous generation. It is also lower in costs. The number of connectors involved in the unit has also been reduced in the latest generation, and it now comes integrated with throttle position sensor. This can be implemented without making any major changes to the engine. It was first developed by our team based in France.”

With the air module engine control unit, Continental has developed control engineering that is modular in design with minimal weight and the smallest measurements and is found in many engine designs for a variety of manufacturers. This system, in a variety of configurations, also meets the requirements of the global market. For example, motorcycles with up to 250cc cylinder capacity already meet the requirements of emission standard that is expected by

2020 with the ‘M4L’ version. All Continental components for modern engine management can be individually configured due to their modular design. The components can be integrated into engines from different performance ranges, which help to react quickly and flexibly to the provisions of global markets and specific requirements of customers worldwide. ACI

Franck Bigot, Business Development & Strategy, Continental Automotive GmbH

Electronic throttle control

z Air Module Engine Control Unit Continental is also ready with its M4L air module engine control unit. It is specifically built for two-wheelers, is a cost-effective solution that meets exhaust emission regulations (BS IV and VI with OBD 1), and engine performance targets. Bigot said, “The fourth-generation M4L improves startability and overall 27 27 WWW.AUTOCOMPONENTSINDIA.COM

AUTO COMPONENTS INDIA NOVEMBER 2018

C OVER STORY Lucas TVS is ready to meet the new powetrain wave Story by: Bhargav TS & Sricharan R

T

Lucas TVS manufactures wide range of starter motors starting from 2W to CVs

he Chennai-based Lucas TVS Ltd, India’s leading automotive electrical equipment manufacturer and a member of the TVS Group, is coming up with a new traction motor for electric vehicles.

“The traction motor is our first step towards the new things that are happening in India. The motors will be of 1 kWh, 3 kWh and 5 kWh and will be able to power, e-rickshaw and e-autos. This is the area we think the EVs will come first,” Aravind Balaji, Joint Managing Director, Lucas TVS, told Auto Components India.

Lucas TVS supplies to over 90%

of automotive manufacturers in India and exports to North America and Europe. It started with starters and dynamos, and over the years, commenced providing complete system solutions for auto electricals, specialised motors for air compressors, stop-start systems, engine cooling modules, ignition products, diesel fuel injection systems etc.

Lucas TVS has established R&D and Product Proving and Reliability testing facilities, which have been recognised by the Department of Science and Technology of Government of India. “We will focus on electrical and electronic products.

We will expand in the area we are growing well,” he added.

About the traction motors, D Baburaj, Senior General Manager- Marketing, Lucas TVS said, “The whole world is going towards electric motors and we want to be present in that.

To start with, we are concentrating on e-rickshaws and e-autos. To be more precise, we are starting with e-rickshaws in the NCR where they are predominantly used. We are working with 3 selected customers and we will supply the traction motors to them in a couple of months.”

PHOTOGRAPHY Bhargav TS

“The new motors are Brush Less DC (BLDC) motors and they will be manufactured in our Pondicherry facility. The output of the motor will be around 1 kWh to a maximum of 1.7 kWh. For the e-autos, we have developed the motor and will do the validation with a renowned customer in 3-4 months. It will be of 3 kWh output. We have been supplying 28 28 AUTO COMPONENTS INDIA NOVEMBER 2018

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the BLDC motors for white goods applications like refrigerators and compressors,” he added.

A similar technology has also been developed for two-and three-wheelers which is also in the development stage. The motors will be out for validation in 6-8 months.

The BLDC motors have longer life and since they are permanent magnet motors, they have higher torque.

Being the latest technology, the whole automotive industry is looking for new products and a few are using them for their engine cooling fans on a trial basis.

About the regulations in the EV segment, Baburaj said, “Regulations are only for the full unit and there is no specific regulation for our product.

Our company and the group follow a standard that is required to meet the regulations. We treat this new motor as an automobile motor and follow all specs applicable. That is why the quality of the product is much better than the Chinese motors.”

Lucas TVS is ready for the EVs and also the IC engines. “With the EV there will be some disruptions in the short term. In the long-term it will be an opportunity for us. We are looking at it in a positive way. With the upcoming norms, changes will be mostly in creating more efficiency and we are doing that. Start/stop, change of starter motor are also required and we are working on them. These will also comply with the CAFE norms that will come after the BS-VI. For passenger cars and commercial vehicles, we are working on high vision seat alternators, smart motors and on electronics controllers

COVER STORY and sensors,” Balaji said.

Adding to his points, Baburaj said, other than the gear reduction starter and high-efficiency alternator, OEMs are also looking for better alternators. The company is looking for a combined starter generator system and has developed in both the 12 volt and 48 volt system. The 12 volt system is being used in a few hybrids now. With the BS-VI, people will slowly shift to the 48 volt, he said.

“With the regenerative braking, whatever energy is lost is being recovered. The new system is in the final stages of validation. When people start using it, we will be ready to supply that. A starter will be there in the vehicle and it will be used in the cold conditions. The new system will also be in the vehicle and will be used only when the vehicle is stopped, for example in a signal.

The driver need not use the starter motor to start the engine again. They can just start the vehicle by pressing the pedal. These can be seen in the hybrids,” Baburaj said.

Another major trend that is coming along with the BS-VI is light weighting. Lucas TVS is also ready with the products for this. Many of the group companies are making forged and cast components to bring in the lightweight products. “To meet

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Aravind Balaji, JMD, Lucas TVS

the fuel efficiency norms, it is very important to reduce the weight. We are looking at every way to reduce the cost and weight,” Balaji said.

Baburaj said they have approached the light-weighting requirements and have a starter motor with a power to weight ratio of 200 W/kg. Now, they have come up with a new motor that has a power to weight ratio of 600 W/kg. “We have done this by using different and better components and technology. In the alternator, we have reduced the weight wherever it is possible.”

In order to meet the new environmental strategies of India, Lucas TVS has developed stop-start systems, integral starter generators, emission control products like urea pumps and brushless motor technologies. The company has developed innovative products, manufacturing systems and processes, which had brought growth in business. They have also helped Lucas TVS to be one of the few companies in the World to be awarded the Deming Application Prize and the Deming Grand Prize, by the Union of Japanese Scientists & Engineers and to set benchmarks in the industry.

The company is working on different future projects. One such

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development is the small motors or what they call as the smart motors, where no alternator will be required.

“In the long run, when we totally switch over to EVs the alternator may not be needed. So, we are thinking of diversification and of electromagnetic parts where we concentrate more on electric motors, mechanical components etc. We are also working on EPAS, ABS and compressor motors.

We are supplying the compressor motor in large numbers to WABCO. They are being used in vehicles manufactured in Germany. We have also started supplying ABS motors to the company. We have developed an electric vacuum pump. So far, it has been a mechanical pump fitted on the alternator,” Baburaj said. ACI

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1. E-Rickshaw 48V 1Kw BLDC Motor 2. E-Auto BLDC Traction Motor 48V 3Kw 3. BLDC Traction Motor for 2W & 3W 29 29 WWW.AUTOCOMPONENTSINDIA.COM

AUTO COMPONENTS INDIA NOVEMBER 2018

C OVER STORY SEG Automotive offers solutions to reduce vehicle emissions Story & Photos: Bhargav TS

T Juergen Schneider, Vice President Technology and Products, SEG Automotive Germany GmbH, Christoph Holzl, Press Officer, SEG Automotive Germany GmbH and Anil Kumar MR, Managing Director & President, SEG Automotive India

he Germany-based SEG Automotive, manufacturer of starter motors, electrification components and generators, is working on several new products for improving fuel economy and in turn reducing CO2 emissions.

Recently, the company launched a whitepaper which discusses vehicle pollution that has been impacting countries, including India, and offers solutions to address the problem effectively.

The paper also discusses engine efficiency strategy for India that focuses on mild hybrid technology for compact cars and light commercial vehicles.

SEG Automotive was established

in 1913 as part of the Bosch group to manufacture generators, regulator switches and headlights. SEG Automotive India, the company’s Indian arm founded in 1989 as Bosch Ltd, was one of the first local companies to produce starter motors and generators in India.

In January 2018, SEG Automotive was acquired by Zhengzhou Coal Mining Machinery Group Co (ZMJ). It now operates as an independent company. The company has 3 manufacturing facilities each in Naganathapura and Hassan, in Karnataka, and in Chennai.

According to Anil Kumar MR, Managing Director & President, SEG Automotive India, “The internal combustion engine (ICE) coupled to highly efficient start/stop motors and advanced

mild hybrid drivetrains is the best option to go with and to reduce significant amounts of CO2 emissions during the life cycle of passenger cars and light commercial vehicles in India.”

SEG Automotive India provides solutions for all segments of the automotive industry including three-wheelers, passenger cars, commercial vehicles, offhighway vehicles, stationary engine applications, and across all drive technologies.

The company believes that though there are talks of complete electrification between 2025 and 2040 as a part of the Paris declaration, that will happen only in phases.

“The main trend (guiding product development) is the CO2 reduction which is driving our product portfolio and 2025 is a milestone. We see indications to this from some governments and discussions in the regions where the new milestone regarding the CO2 target is set. If you follow the Paris declaration targets, then by 2025 electric vehicles will still have a market share of about 15%, which means that 85% of the cars will still have combustion engines. And, hence, we need to do something about that, and increase the efficiency of internal combustion engines,” Juergen Schneider, Vice President Technology and Products, SEG Automotive Germany GmbH, said.

The Indian automotive industry will be moving to BS-VI norms

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COVER STORY 48V BRM – Facilitaitng Mild Hybridisation z z z z z z z

A 48V hybrid currently and in the near future constitutes the most echient solution for minimising CO2 emissions over the life cycle in markets with a suboptimal energy mix (e.g. China, USA, India, Germany).

The conventional alternator is replaced by a 48V Boost Recuperation Machine (BRM). It employs the braking force recovery technology (“recuperation”) familiar from Formula 1 to reduce fuel consumption by up to 15%.

In the medium term, 48V will be indispensable for achieving CO2 emission targets - after all, 85% of new vehicles will still be equipped with an internal combustion engine in 2025.

Starting torque: 56 Nm Recuperation power: up to 12 kW Boost power: up to 10kW Efficiency: up to 88%

CO2 and fuel saving options z z

Enabling for comfortable engine Start/Stop, regenerative braking, torque assistand engine load shift.

Additional CO2 and fuel saving of about 15% (cp. Start/Stop)

Additional Customer Value z z z z

No electric shock protection needed Proven and robust inverter technology Electrical machine with high synergies to generatorproduction In series with premium OEM

in 2020. SEG, with its global experience in offering solutions to Euro VI vehicles, has already started its work on BS-VI with the Indian manufacturers to make them future-ready. “Being a Tier 1 supplier with a focus on future technologies, we are working for another big challenges coming in by 2022 in the form of CAFE norms. We have already begun the discussion with our customers to reach the fleet average of 113 gm per km. There are several technologies which work in combination including high efficiency of generators, start-stop technology of starters and also the use of mild hybrids.

Being a full-line product supplier, customers would get the right choices to select the best suitable one,” Kumar said.

to 8% CO2 emission and fuel consumption in compact cars.

The motor automatically shuts down the engine when the vehicle idles, hence reducing fuel consumption and improving the overall fuel economy. This

is achieved with the help of sensors at the pedals and the crankshafts. The engine can be instantly reignited by pressing the clutch, avoiding the hassle of going through a conventional ignition method. SC60 start-stop

SC60 Starter Motor can reduce up to 8% of CO2 emission

z SC60 starter motor In order to reduce CO2 emissions the company is ready with its new SC60 starter motor. This 2.2kg motor can reduce up 31 31 WWW.AUTOCOMPONENTSINDIA.COM

AUTO COMPONENTS INDIA NOVEMBER 2018

COVER STORY Start/Stop motor, Kumar said, “We introduced Start/Stop technology first in India in 2008.

However, it was mostly fitted in larger cars. The new SC60 motor has been developed focusing the Indian market for smaller combustion engines: it is among the smallest of its kind in the world and can be fitted on to compact cars, yet it provides up to 1.2kW starting power.”

z 48V Boost Recuperation Machine

Baseline Generator

48V Boost Recuperation Machine

starter motor, with reliability of more than 250,000 starting cycles, is an ideal fit for the small petrol and diesel engines in the Indian market to realise the benefits of the startstop function. SEG currently manufactures this starter motor locally with high local development and application contribution.

About the company’s new SC60

SEG is also betting big with its new 48V Boost Recuperation Machine (BRM) for diesel hybrids. This motor, when coupled to an ICE, uses brake force recovery technology to charge a 48V lithium ion battery. It converts the kinetic energy produced by braking to electrical energy, which then is stored in the battery. This stored energy functions as a ‘torque booster’ to reduce the turbo lag from diesel motors and it can even be employed in an additional ‘Coasting’ function for relaxed yet efficient driving.

According to the company, the 48V BRM can produce as much as 10kw (13bhp) and 56Nm of torque from 12kw (16bhp) of energy recuperation.

BRM employs the braking force recovery technology (recuperation) familiar from Formula 1 to reduce fuel consumption by up to 15%. In the medium term, 48V will be indispensable for achieving CO2 emission targets - after all, 85% of new vehicles will still be equipped with an internal combustion engine even in 2025. The solution also proves beneficial for consumers - in contrast to EVs and PHEVs, the cost of the unit is recovered

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through fuel savings.

BRM is a cost-effective and easy-to-implement mild hybrid solution, as it replaces today’s generator at its actual location in the drive belt. In the case of regenerative braking, where the battery gets charged during braking, the BRM uses the charged energy to boost the IC engine when needed. The BRM also enables the coasting feature, where the ICE/electric motor is turned-off above a certain speed and the BRM provides enough energy stored in the battery earlier to counter friction forces and wind, to keep the vehicle moving at a constant speed. These solutions help reduce CO2 emissions by up to 15%, Schneider explained.

Replacing ICE is still a big challenge. It remains doubtful whether this is possible beyond a premium segment less inclined to e-mobility. E-mobility is not going faster because many people are not buying EVs. The SEG white paper has identified 2 main present personal disadvantages: high acquisition cost, and limited charging infrastructure. In addition to these are the risk factors of uncertain resale value, range restrictions and long charging time.

Talking about the electric mobility, Schneider said, “The reduction of CO2 will drive a change in mix of mobility. We cannot rely totally on EVs for mobility. There will be change towards electrification. But it will be step by step. While electric cars will be used for shorter distances and in some other cases, longer distance could still be covered by ICE or hybrid vehicles.” ACI

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C OVER STORY Search on for possible future of sustainable mobility solutions The third convention hosted by ICAT on October 11 and 12, 2018 focused on new powertrain technologies, reducing emissions, moving towards BS-VI emission norms and electric vehicles.

Strory by: Gunjan D Bidani & Sukhpreet Singh

T

he 2 day convention organised in New Delhi by the International Centre for Automotive Technology (ICAT), revolved around the future of powertrain technologies. Its timing was very appropriate as the talks on alternative fuel options such as hydrogen fuel cells, electric vehicles and others are gaining momentum. Right from large players such as Mahindra & Mahindra to analyst firms to startups such as TwentyTwo Motors were present at this convention discussing the importance of sustainable mobility solutions.

Dinesh Tyagi, Director, ICAT said,

While electric vehicles are the way forward, hydrogen fuel should also be explored and if required, exploited for a country like India due to the volume of vehicles and the limited availability of raw materials such as Cobalt and Lithium.

P Balendran, Executive Director, MG Motor India Limited said, the Indian OEMs have improved their designs to meet the next generation demand. â&#x20AC;&#x153;Not only design, the future of vehicles will be electric as well as autonomous.

Although it is out of context for a powertrain technology convention, but electronics taking care of the

driving dynamics would mean lower number of accidents. The new mobility solutions would take over, but it will take some time to come to EV standards.

Charles Frump, Managing Director, Volvo Auto India, also spoke about the importance of BS-VI readiness for which Volvo as a brand has existing as well as upcoming products. The biggest challenge for Volvo would be to bring in 1 million electric cars on the road by 2025 globally. Frump also said that plug-in technology would be the way forward.

R K Malhotra, Director, Research and Development, Indian Oil said, the largest challenges for the Indian automotive market currently are the initial cost of battery and having the required charging infrastructure. The challenge also lies in the sourcing of raw materials which are not available in India. This would mean entering into a free trade agreement with lithium-rich or lithium-controlling countries. Under the new technologies, a proper ecosystem for electric vehicles as well as alternative fuels would eventually be needed to create a sustainable mobility solution.

Apart from the availability of raw materials such as lithium, which is a huge concern for

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C OVER STORY India, companies including start-ups discussed how specific components in internal combustion engines can be made better.

One such company present at the convention was Zygor Energy which has proposed to various OEMs for using spark plugs and intake valves supplied by the company. Inder Sharma, Founder and Owner of Zygor Energy, stressed the need of upgrading the scale of such components which make a vehicle more fuel efficient and reduce emissions by about 25%. This is made possible by using multiple electrodes which result in better combustion of the fuel and air mixture going in a petrolpowered engine’s cylinder.

Dinesh Tyagi, Director, ICAT addressing the gathering

Sharma said that the new spark plugs have been thoroughly tested in the US. By getting assistance from NITI Aayog, Zygor Energy made the move to bring this technology to India. The new spark plug works on the ‘Conde Effect’ where the multiple electrodes in it are spiralled and help complete combustion. “Internal Combustion Engines are not going anywhere for another 30 to 40 years and they are here to stay,” Sharma said. During his presentation, he pointed out that the new spark

plugs lowered emissions and their life cycle was substantially higher than the conventional ones. Based on the tests conducted by Zygor Enegy in the US, the spark plugs lasted over 1 lakh km.

The new components are being pilot tested in New Delhi/NCR region wherein a CNG vehicle has also been taken into account.

A Maruti Suzuki WagonR fitted with a CNG kit also resulted in better fuel efficiency as well as less loss of acceleration. Such pilot projects have accelerated the understanding towards what a sustainable future for mobility could be.

Zygor Energy is working to bring about a mass-produced vehicle that has unlimited range. For that there would be 2 sets of batteries, wherein 1 battery unit would be running the vehicle, while the other unit would be charging.

Sharma said that this technology would not be available in mass production in the near future.

Devesh Pareek, Manager, Electronics, ICAT, continued with the various applications where ICAT tests various automotive components at its facility in Manesar. The investment of Rs 1,100 crore for these facilities is in line with the testing for premium products as well as components which are coming up in the advent of electric mobility. He said that ICAT encouraged start-ups to test their new mobility solutions in its test facilities. He supported new mobility solutions such as electric vehicles. He said, “In an electric vehicle the losses that happen at the wheel for the energy transferred from a battery

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are substantially less than in an internal combustion engine.”

Pareek believes that an electric powertrain which is already efficient can be made better by using better electronics. ICAT has the capabilities to update electronics such as controllers etc which do most of the decision-making in a vehicle without major modifications. Regeneration of energy such as regenerative braking is also another area where ICAT is working. Pareek said that if regeneration of energy can happen, it will increase the overall efficiency of a vehicle, especially in the electric powertrains.

An experiment conducted by ICAT at one of its test facilities showed that for heavy vehicles used in public transportation, regenerative braking is imperative. Pareek said that a rugged electronic system should be able to withstand the high current values during regeneration of electricity and similarly the battery needs to be able to withstand the high current for a short period of time.

Sameer Jindal, Director, MG Motors India, spoke about the trends in China. He spoke on the trend of electric vehicles in China and elaborated on a possible model for India, which may not be the same as China’s, but similar. Jindal said heavy incentives by the Government and further support by the local government bodies, greatly pushed forward the e-mobility solutions.

The convention revolved around new and sustainable powertrains that would propel the vehicles of the future. Right from public transport, to commercial vehicles to agricultural equipment and others, the most important aspect has been the ability to conceive a sustainable mobility solution with minimum carbon footprint. ACI

C OVER STORY BorgWarner to make variable cam timing in Chennai plant Story & Photos: Bhargav TS

A

s the introduction of BS-VI emission norms is round the corner, all the OEMs and component

manufactures are gearing up to bring in new technologies and localise them. BorgWarner, a global product leader in clean and efficient technology solutions for combustion, hybrid and electric vehicles, recently expanded its Kakkalur facility near Chennai by installing a new line to manufacture advanced engine timing and variable cam timing (VCT). With the expanded 1,500 sqm of manufacturing space to its existing 35,100 sqm facility, BorgWarner is ready to meet

the increasing demand from the steadily growing Indian automotive market, meeting BSVI norms. It is also preparing to supply to the growing Southeast Asian automotive market.

BorgWarner plans to deploy the VCT technology with a major global and domestic automaker on diesel and gasoline applications. According to the company, the VCT technology improves engine efficiency, performance and fuel economy.

The new production line will be complementing the existing global facilities producing VCT technology and will help the company meet the global customer needs with local production. Apart from new VCT, the Kakkalur facility has been producing silent and roller chains, tensioners, and other products for variable valve timing applications. It can produce about 3 million automotive chains a year.

Al Moster, Director, Application Engineering, Product Manager, Chain & TSC, BorgWarner Morse Systems said, â&#x20AC;&#x153;Our VCT system contributes greatly to making engines considerably more efficient while reducing emissions and enhancing performance.

The new VCT line at the Chennai plant complements a number of existing global facilities producing VCT technology and strengthens BorgWarnerâ&#x20AC;&#x2122;s ability to support global customers with local production. We are now ideally positioned to support car manufacturers in complying

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COVER STORY INTERVIEW “We will focus on hybrid electric while supporting ICE development,” says Al Moster, Director, Application Engineering, Product Manager, Chain & TSC, BorgWarner Morse Systems.

the camshaft and on the camshaft a VCT module is fixed. We supply the whole system. It is basically a chain, 1 or 2 VCTs, the sprockets, hydraulic touching device on the chain system that helps control and manage the noise, load and thus it increases the efficiency of the drives. We tune every drive specifically for each customer.

We simulate the drive dynamics, we decide the turning of the tensioner upfront and then we confirm it on the customer’s engine. So these are all the types of custom engineering that have to be done for every single customer and we do that all here in India.

Q: How do you see the ICE growth going forward? What are all the challenges you foresee in the Morse Systems division?

Moster: We are tracking the market very closely. Our strategy is, to move our product portfolio along with the market and be overweight towards hybrid electric. We are developing products with that type of road map in mind. Lot of our future developments will be focused on hybrid electric, even though we have to continue to evolve and support the ICE. Q: Apart from emissions, OEMs are also looking at reduction in NVH, how do you plan to address it?

Moster: All our customers are looking at improving the efficiency, downsising and improving the noise performance.

Our systems, being mechanical, do generate noise. For the past 5 years we have been working on this and will continue to work, because when the hybrids come into play, customers will be much more sensitive to some of the noises generated by the IC engines.

Developing lower NVH technology for our mechanical systems is going to be a key trend for us.

Q: How VCT is going to benefit the end-customers?

Moster: VCT is going to give big savings in fuel economy. We can say that VCT delivers fuel economy and performance improvement for more customer strategies. For some customers their focus might be on the emissions and that may be how they calibrate the VCT, especially for the exhaust phasers. Generally speaking, most of the VCT systems today are focused on fuel economy and

performance improvement as part of the downsising trend.

Q: BorgWarner VCT is a global product and now you are bringing it to India. What kind of customisation you will be making to suit the Indian conditions?

Moster: Quite frankly, every VCT application in the world has some customisation to it, just like every timing drive system in the world has some customisation. Evey engine is different, so every single application we apply has some customisation.

We have some core elements, that we try to keep common like the internals of the VCT and then we have to customise them for different customers applications. Sometimes the travel of the VCT needs to be changed, the package space needs to be changed etc. We are customising our VCT for the Indian market based on the customer requirements.

Q: When you say VCT system, what are all the components that go into it?

Moster: We supply the timing systems, so we have a chain from the crank to

Q: Any plan to bring more new products to India?

Moster: You can see continuous evolution of our products. What are going to be new will be the chain drive products, specifically developed for P2 and P3 (location of the electric motor in the vehicle.

P2 is before the transmission and P3 is after the transmission) products.

BorgWarner has developed the entire P2 and P3 modules that we sell to the customers. We develop special low friction, low noise chains for that space. We have around 25 active application around the world and soon we will bring some of them to India, since the French and Japanese customers are applying them. I don’t know when, but certainly in the next 5 to 7 years.

Q: Are you looking at exporting the made in India VCT? Moster: Our strategy is to do the engineering locally and manufacture it here. What we will use for India is to support Southeast Asia also as we do not have any plant there.

If we see opportunities come up for VCT business in Southeast Asia, certainly India would be our target manufacturing region.

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AUTO COMPONENTS INDIA NOVEMBER 2018

COVER STORY

L-R: Pei Wang, VP and GM, Asia, BorgWarner Morse Systems; R Murali, director 8: Plant Head, BorgWarner Morse Systems India; AI Moster, Director, Application Engineering, Product Manager, Chain & TSC, BorgWarner Morse Systems; and Michelle Du, VP, Global Supply Chain Management, BorgWarner Morse Systems.

with the new regulations which aim to increase technological development to improve fuel economy, innovation, environmental protection and energy efficiency as well as the quality and safety of vehicles and auto parts produced in India.”

VCT is used in engines to advance or delay intake or exhaust valve timing. Consequently, intake or exhaust valve timing may be adjusted based on engine operating conditions to increase

combustion efficiency and decrease emissions. Additionally, engine power output may be increased across a wider range of engine operating conditions.

A VCT mechanism varies the phase of the valve opening and closing relative to the crankshaft as a function of engine operating conditions. Depending on the camshaft (exhaust, intake, or both) being actuated, 4 types of variable cam timing systems are available: intake-only; exhaustonly, where only intake or

exhaust valve timing is varied; dual-equal, where intake and exhaust timing is varied equally; and dual-independent, where the intake and exhaust timings are varied independently.

The Kakkalur plant, originally established as a joint venture in 2002, became a wholly-owned BorgWarner entity in 2008. “We are excited to open our new line for producing more advanced technologies designed to help customers meet new BS-VI emission regulations. To meet the new emission norms all the OEMs are refreshing their products and most of them are trying to bring new engines for their vehicles.

Therefore by producing the VCT locally will be a win-win situation,” R Murali, Director and Plant Head, BorgWarner Morse Systems India, said.

So far Morse Systems was mainly focusing on passenger car applications. Now the company is in talks with some commercial vehicle manufacturers for their LCV business. Murali said, “Currently we are working with a couple of CV makers so the focus for us will be both on passenger cars and LCV business.” ACI

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C OVER STORY Zygor Energy spark plugs to cut emissions from existing and new vehicles Zygor Energy, run by Inder Sharma, is working on reducing emissions in the existing and new cars. He explains how the simple replacement of a spark plug can do that.

Strory by: Sukhpreet Singh

M

ost of the powertrain components manufacturers are working on some innovative products to reduce the emissions and to meet the BS-VI norms. We recently met Inder Sharma, Founder of Zygor Energy Systems, who is a microbiologist by academics and an environmentalist at heart.

He believes that

Zygor Energy’s electric motor

while new emission norms and moving over to electric vehicles will be eventually happening, the existing vehicles running on internal combustion engines also need to be upscaled at a minimal cost. Adding components that will make an older vehicle adhere to BS-VI norms is a costly affair. But, Sharma’s solution is simpler.

The cross-section are area of ignition in a spark plug is ve very small.

Zygor E Energy’s new generat generation spark plugs ha have a spiral design w with more than 1 el electrode.

The net re result is the combustio of fuel combustion happening at a much dis greater distance from the plug.

“A lot of tec technologies exis today to exist curb pollution, but everything is related to post-combusti post-combustion process.

I always believed tto find a root cause of the pro problem and in this case, it is the incomplete i combustion in a cylinder. cylin So, if the combustion is complete c

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or full, there is less pressure on the catalytic converter to reduce the contribution of harmful gases coming out of an internal combustion engine,” Sharma said. The focus for Zygor Energy has been to modify the spark plug in order to increase the combustion without wastage of gases. This has resulted in about 20% reduction in emission, and 2% increase in fuel efficiency.

Over the last 80 years, the evolution of spark plugs has been minimal. There are companies like Bosch that have introduced multielectrode spark plugs which haven’t been successful due to their design. Sharma opined that the challenges with the spark plug were the design and experimentation but in 2013, the designers used a crown with the spark plug in between. This crown was specially designed to be fused in a spark plug design.

The result was that fuel was getting ignited even 50mm away from the spark plug.

After rigorous testing for about 5 years and a number of

COVER STORY physical pilot applications, the spark plug has received a global patent. Currently a pilot project for these spark plugs is ongoing in Delhi in association with NITI Aayog. So far, according to Sharma, the results have been positive as there is no reduction in acceleration in CNG vehicles as well.

Another aspect which was enquired about was the strategies implemented in the US to reduce emissions and if they can be used in India.

According to Sharma, the US has a very different model with different mindset as well as different economies of scale.

Resources in America are high and so is the value of the currency. The strategy for India needs to be different due to the lack of resources such as crude oil for the time being and the weaker currency power. Another hurdle is the fuel quality which is available in India versus what is available in other developed countries including the US. There are more stringent fuel standards in abroad than those in India and stricter pollution control norms.

Sharma also feels that the political system also needs to create awareness to change the fundamental understanding with the people and their mindset.

And in case someone does not follow rules or has a vehicle that is polluting more than a certain set limit, that person should be fined heavily and made an example of. Pollution is the major concern area but the Government has to create the awareness for people to avoid using vehicles if they emit more pollution.

With respect to the automotive

sector, Zygor Energy is also looking at electric vehicles.

They are currently researching on using the least number of batteries without affecting range of a certain electric vehicle or for that matter have a higher range, according to Sharma.

The company is looking at options wherein not only does the electric motor uses the least amount of energy, but also generates electricity on the move. Although Sharma agrees that this kind of technology will take time to be put into practical application, but, once put into mass market segment, there would be no need of a charging station.

According to a presentation made by Sharma, 2 sets of batteries would be used in an electric vehicle. While one set is running the vehicle, a small

Inder Sharma, Founder of Zygor Energy Systems

amount of that energy is being used to charge the second set of battery. This, although, means that there would be no losses of energy which may become a hurdle in real-world applications. â&#x20AC;&#x153;That said, I feel a successful model would be when, in real-world application, we are able to take a vehicle from say Delhi to Mumbai on a single charge,â&#x20AC;? stated Sharma with a very optimistic voice.

Sharmaâ&#x20AC;&#x2122;s belief on the fact that this is possible does hint at the possibility of what could be the future of electric vehicles.

However, with respect to the scarce availability of resources, he also agrees that until the time the electricity generated is not through a renewable energy source, it would not be logical to say that it is the sustainable mobility solution.

While there is the possibility of an emission-free electric vehicle, hydrogen fuel cell technology should also be considered. The opportunities are endless for such start-ups to build a niche in the plane of what a sustainable future could be. However, without the right policies in place, it will become a task, Sharma said. ACI 43 43

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AUTO COMPONENTS INDIA NOVEMBER 2018

C OVER STORY GMTC-I develops future-ready automotive products Story by: Bhargav TS & Sricharan R

G

eneral Motors Technical Centre India (GMTC-I), an engineering and research centre of General Motors (GM), is working on new products for the upcoming trends in the world market. The Detroit-based GM is moving towards the vision of zero crashes, zero emissions and zero congestion.

GMTC-I is helping the global leader to bring in the best future-ready products.

GM and its subsidiaries and joint venture entities sell vehicles under the brand names of Chevrolet, Cadillac, Baojun, Buick, GMC, Holden, Jiefang, Opel, Vauxhall and Wuling.

Around 85% of GM’s total vehicle variants are being worked at GMTC-I and it plays a very significant role in GM’s global plans.

Brian McMurray, Vice President, Engineering and Operations, GMTC-I told Auto Components India, “We are focused on the vision of the company that is zero crashes, zero emissions and zero congestion. Zero emission is the ultimate goal and to achieve this we need to take several steps. From an internal combustion engine perspective, we will continue to work on the

engines and will make it more efficient for quite a long time. At the same time, we will also work on electrification. When you have

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a vehicle that can do more than 300 km, it means you are close to eliminating the range anxiety for the customer.”

“Some of the new engines we produce are of cutting edge, state of the art technology. Still they are affordable. Now, we have the Active Fuel Management (AFM), or Cylinder Deactivation technology, which can shut down any number of cylinders to capitalise on the most efficient method to move a vehicle. This is a big deal,” he added.

GM recently launched the new technology in the lightest Cadillac ever made with the lightest 2-litre engine. AFM is a General Motors engine technology that shuts down half of the engine’s cylinders in light driving conditions to improve fuel economy. The new technology saves fuel by using only half of the engine’s cylinders during some driving situations – such as highway cruising — and then seamlessly reactivates the other cylinders when a driver needs

COVER STORY more power for acceleration, climbing a gradient or hauling.

AFM uses a combination of simple hydraulic valves and sophisticated software to switch off the cylinders when the driver doesn’t need full power. When more power is required, the system seamlessly re-engages the additional cylinders. The primary benefit of Cylinder Deactivation/ AFM is to achieve higher fuel economy without downsising engines. The technology can improve fuel economy by up to 12% without sacrificing performance. He said that the new development has good response and it has set a new benchmark.

About electrification which is another major trend of the future, McMurray said GM is ready and has recently launched the Bolt. He also mentioned that the next generation Bolt is coming up, and there are other EV products that will be released in 12 months. Some elements of the EVs have been done in GMTC-I. McMurray said that GM is coming up with more new engines to compete in the global market.

The car maker is coming up with a range of small and large engines with maximum fuel economy.

“It is not just a global propulsion problem, but a vehicle problem. We need to work on the aerodynamics and make sure to eliminate energy loss. We also need to work on the electrical system, design and manage the air around the vehicle.

New generation tyres, resistant braking system and much more are being designed to get to zero crashes, zero emissions and zero congestion. With everything is in place, we will come out with a series of products.”

Engineering is a global function for General Motors and the India design centre is an integral part

of it. GMTC-I houses a design studio and an engineering centre.

The India centre contributes to a significant percentage of the GM global programmes, including design, analysis and development of vehicles and propulsion systems.

The VP stated GMTC-I was part of the development and their expertise was used in the new engine and the new transmission.

With the market changing quicker than ever before, McMurray said the technical centre in India plays a major role at the global level.

“With the market changing quickly, what is relevant today might not be relevant tomorrow.

It will change. So, when the new

technology comes in, we may not be ready for it but, we will adapt to it very quickly. This is where the engineering powerhouse comes in, where we will be working on new technologies and adapting to new technologies,” McMurray, said. ACI

Brian McMurray, Vice President, Engineering and Operations, GMTC-I

REEV In the recently-held 37th FISITA World Automotive Congress, the global automotive technology capability of General Motors Technical Center India (GMTC-I) unveiled a locally- built prototype electric vehicle (REEV), designed exclusively for the national REEV student competition. Unveiling the vehicle, General Motors Vice President of global propulsion systems, Dan Nicholson, said, “The world-class engineering capability we have at GMTC-I in Bengaluru is playing a significant role in GM delivering its commitment to create a world with zero crashes, zero emissions and zero congestion.”

As a part of GM’s global engineering operations, GMTC-I offers India’s leading designers and engineers the opportunity to work on cutting-edge global technology projects, and the potential for global careers, he said. As Mary Barra, CEO of GM, has said, “We are seeing more change in the automotive industry in these five years, than we have seen in the last 50.” “I believe that designers and engineers will be at the forefront of this change,” Nicholson said.

Brian McMurray, GMTC-I, Vice President of Engineering and Operations, said the intellectual horsepower of GM’s designers and engineers in India was further demonstrated when FISITA accepted the team’s 71 technical papers covering various innovation areas. “GMTC-I plays an important role in GM’s global core business: designing and engineering world-class vehicles that inspire the passion for safer tomorrow,” he said.

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C OVER STORY Witzenmann India expands capacity for domestic market, exports Story by: Bhargav TS

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anufacturers want to minimise noise and vibration from the exhaust systems of the new generation cars, and even commercial vehicles, to offer maximum comfort to the passengers and customers. This is made possible by decoupling engine from the exhaust system and allowing specified movement by employing flexible coupling elements. Witzenmann India, the wholly-owned subsidiary of the Germany-based Witzenmann Group, is a leading manufacturer of flexible metal tubes, expansion joints, metal bellows and other automotive components. It has expanded its Chennai plant with an additional line to manufacture expansion joint pipe assembly and cooling supply systems.

The automotive sector, which contributes 85% of the company’s India business, is growing strongly with the upcoming BS-VI emission norms. In addition to the auto sector in India, the company aims to gain business for its products from the railways, aerospace and chemical industries. It is also targeting the export markets, especially China where several European OEMs have their manufacturing facilities.

and analysts predict that India will be the number 3 by 2030. This will give us big boost. We are also planning to bring new products to India which will have a niche market initially. Currently we are expanding in the automotive sector especially in the engine-related pipes and piping systems, where we are a larger player in the European market,” said V Chandrasekhar, President and CEO, Witzenmann India Pvt. Ltd.

“Our automotive business has been growing rapidly over the past few years. We anticipate this growth to continue, going forward, with new emission norms round the corner. We are catering to all the automotive OEMs in India with a significant market in our product segments. YoY in the automotive sector we are growing at around 20%. India is a fast growing economy

In India, Witzenmann has 2 facilities, each in Chennai and Kolkata.

Witzenmann India has a strong presence in the passenger car segment with over 50% market share in the supply of exhaust gas decoupling elements, exhaust gas duct and exhaust gas recirculation lines to key OEMs including Hyundai Motor India, Maruti Suzuki India, Mahindra & Mahindra, Honda Cars India, Tata Motors, Renault India and others.

The company believes that the BS-VI norms will help it enhance its connect with India’s commercial vehicle segment and is working closely with the CV manufacturers.

In the last 10 years Witzenmann India manufactured more than 10 million decoupling elements for cars and commercial vehicles for the local market. This success story is now to be continued in the industrial and rail transport sectors as well.

So far the group has invested about Rs 800 million in both the facilities.

“The automotive and commercial vehicle industry of the subcontinent is also growing at a high rate. In order to meet the growing customer

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COVER STORY requirements, we are expanding the existing liner and hydraulic bellows production units and adding a new assembly line,” Chandrasekhar said.

The decoupling element connects the “moving” engine section of the exhaust gas system with the “rigid” area of the vehicle. This is primarily to compensate for the relative (tilting) movements of the engine which occur especially with transverse fittings. With the decoupling element, the gasconducting components such as the manifold and the down pipe are relieved from mechanical tension to the extent that the principle of lightweight construction can be implemented here.

To decouple the engine vibrations, the vehicles engine/transmission is elastically connected to the chassis via the engine mounts.

With changing output torque, load changes lead to a typical engine pitching in vehicles with front wheel drive and an engine rolling in vehicles with rear wheel drive.

In contrast, poor road excitations mainly result in irregular, mainly translational engine movements.

Both engine movements caused by load changes and those induced by poor road excitations lie below 20Hz. The local manufacturing of bellows and liners this year has helped the company achieve complete localisation of its automobile exhaust decouplers. The company, which started with supplies of 200,000 decouplers to Hyundai per annum in 2008, today caters to all the major OEMs.

orders from the German truck major, Daimler for its BharatBenz brand. “When the BS-VI norms are in place, the flexible components will be in huge demand, especially for the commercial vehicles. For this, we have wide range of products, including the requisite flexible elements that are curved and readymade for the individual application.

Cast-iron connectors, firmly welded to the thin-walled stainless steel offer an additional technological advantage that allows optimal solutions to be attained even in extremely difficult assembly scenarios,” BS Karthic, Team Manager, Sales, Witzenmann India, said.

increasing its market share in the coming years, and for passenger cars it will retain the current share.

To grow further it is targeting railways, large engines, agriculture equipment, and off-road equipment.

“This will open a large market share for us” he said.

In order to reduce the weight of the products that Witzenmann manufactures, it has worked on an alternative technology which is called spherical joint, which saves weight by 50%.

Going further, the company will be

In CVs, the company will be

z Commercial Vehicles Witzenmann’s success in the passenger car segment has also garnered the attention of commercial vehicle manufacturers and has led to the company bagging 47 47 WWW.AUTOCOMPONENTSINDIA.COM

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COVER STORY focusing only on flex tubes. Karthic said, “When we started supplying, the parts were stiffer than the new generation ones. So we decided to offer spherical joint, which saved weight and offered great flexibility.

In future, we are planning to use less thick sheet metal to decrease weight. Flexible exhaust gas lines contribute significantly to reduce nitrogen oxides in the combustion process. In oil, fuel and cooling circuits, the advantages of flexible metal lines are their absolute gas and diffusion tightness, long life span and temperature resistance. An essential criterion, especially when they are being built close to exhaust manifolds, turbochargers or the exhaust system.”

Bonfiglioli sets up new facility in Chennai ACI Bureau

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onfiglioli Transmissions Pvt Ltd, the Indian subsidiary of Bonfiglioli Riduttori S.p.A., a world leader in manufacturing gearboxes, gearmotors and drive systems, continues its expansion with a new manufacturing facility in Chennai. Its operations commenced from September 2018.

z Expansion In terms of volumes, this year, Witzenmann is making 2 million decouplers and currently utilising 80% of the installed capacity. Currently major production volume of around 6.5-7 lakh goes to Hyundai, and 6 lakh for Maruti Suzuki.

Now it is the 100% supplier to Hyundai and is eying a big share of business from other OEMs as well. “We started with 200,000 parts per year and today we are at 2 milllion. We always want to have room for current capacity utilisation and a third round of expansion is happening in the existing space. Last year growth was higher owing to exports to Ford in Thailand and Suzuki in Japan. “In the first year we recorded a turnover of Rs 20 crore and this year we are targeting Rs 100 crore. Last year, we touched Rs 70 crore,” Chandrasekhar said.

The new 132,000-sqft- facility is adjacent to the existing plant at the SIDCO Industrial Area in Thirumudivakkam. It houses modern assembly lines, a global R&D centre and test labs, all built to the highest quality and safety standards, consistent with Bonfiglioli locations worldwide. With a capacity of 75,000 units a year, the new facility will enable Bonfiglioli to serve its existing and new markets and customers in off-highway, construction, mining, agriculture and material handling applications.

In her recent visit to Chennai, Sonia Bonfiglioli, Chairman of Bonfiglioli Group said, “We believed in the potential of this country since 1999, when we laid the cornerstone in Chennai. We have grown over the years, investing in plants, research and development centers, and highly specialised staff. India is a key country for

Established in 2001, Witzenmann India started catering to the industrial sector with high-quality products such as metal hoses, expansion joints, metal bellows, pipe supports and hangers. In 2006, a metal bellows assembly operation was set up in Kolkata. In 2008, the company set up the manufacturing facility in Chennai to cater to its first automotive customer – Hyundai Motor India. On starting manufacturing and assembly in 2008, the Tier II supplier’s products found their way into the Hyundai i10 and later into the i20. After bagging the Hyundai orders, it got new business from Fiat, Volkswagen and Tata Motors. ACI 48 48 AUTO COMPONENTS INDIA NOVEMBER 2018

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Bonfiglioli, and the good results up to now show we were right when we started the business in Chennai. This expansion in India is part of the company’s global investment strategy in production and assembly facilities. We are convinced that our factories are the first step in bringing value to our customers. With high-tech, real-time smart production and superior solutions, we will be able to cater to the growing, evolving needs in India and in our overseas markets across the US, Italy, China and Germany.”

This new investment is part of a wider expansion plan for India, which includes the existing facility in Chennai and a plant in Mannur, located close to Sriperumbudur, both focused on making gearboxes and gear motors for mobile machinery, wind turbines and industrial processes.

Meanwhile, the recently-opened assembly plant in Pune, provides 90,000 units a year, serving customers in the food, packaging, cement, steel, pharmaceutical, textile, material handling, sugar, power generation, paper and water treatment sectors.

Bonfiglioli’s 2017 revenue in India reached Rs 7,332 million, equal to 91.65 million euros, with a growth of more than 80% over the past 5 years. With the new facility in Chennai, the company expects to continue its growth next year also. ACI

C OVER STORY NGK Spark Plugs to enter mass markets with new products Story by: Sukhpreet Singh

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he proposal of introducing electric vehicles in India has been a disruptive move to curb the tailpipe emissions.

However, in the current state of taxation and norms on EVs, the consumers are skeptical, and they have many apprehensions.

The manufacturers of key parts for internal combustion engines (ICEs) are also pessimistic about their future. Still they are getting ready for the change of the consumer mindset to the electric vehicles.

At the recently-concluded ‘Clean India, Green India’ initiative, NGK focused on new products for ICEs that would reduce emissions, before being phased out in a couple of decades. Keisuke Makino, Managing Director, NGK Spark Plugs India, and Sudipto Sanyal, Vice President, NGK Spark Plugs India, said that the future of IC engines is cleaner and with their majority market share, NGK would focus on quality components to bring down emissions.

When enquired about the BS VI emission norms Makino said, “New technologies for diverse products could lead to new spark plugs, so we are launching them.

Our future plans are that we want to bring more products suitable for BS VI emission norms which contribute to the environment.

One has to understand the

impact of IC engines on the environment.” Alongside NGK, the company also plans to introduce its second subsidiary, NTK, with products for the mass market products. Makino believes that in terms of technology, NGK has an upper hand as it brings out quality products at competitive prices.

Rs 100 crore in the new facilities and plans to expand the spark plug facility as well. In the next 5 years, NGK plans to employ close to 600 people contributing to the employment in India. With the recent demand for alternative fuels for the commercial vehicles, Sanyal is very positive about biofuels and other options.

About the global market share of NGK and how he sees India in the global market of the future, Makino said that in the Asian countries, NGK has a history of over 14 years. In India, it is just a little over 10 years. “India is a very important market for NGK. And our endeavour is to bring the highest quality product suitable for the new generation of vehicles and the new norms.

Our effort is to bring in products to create a better driving experience to the customers,” Sanyal said.

The products from NGK include the recently introduced spark plug for CNG three-wheelers, though there is no requirement of CNG- specific spark plugs. All the products offered by NGK can be used for CNG vehicles also. The new sensors, to be introduced with the BS VI emission norms, will be one of the flagship products of NGK. The company plans to promote its NTK brand as well. The new brand will be leading in the market requirement for new sensors once BS VI comes in to place, he said.

“With the consideration by the government for alternative fuels in three-wheelers, spark plugs and sensors will have major roles to play in curbing pollution and in making BS VI successful,” Sanyal said.

Although the move towards electric vehicles will happen in the future, what would be more important for brands like NGK is to be prepared for new emission norms and to bring out products compatible with alternative fuels. ACI

Sanyal said that NGK has invested 49 49 WWW.AUTOCOMPONENTSINDIA.COM

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C OVER STORY Shell’s new Advance AX7 engine oil to improve fuel efficiency Story by: Gunjan D. Bidani

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ransferring race track technology usable for Indian roads, Shell Lubricants India has launched Advance AX7, a semi-synthetic, premium 4-stroke motorcycle engine oil. Celebrated MotoGP Rider of the (Alma) Pramac Racing Team, Danilo Petrucci, along with Mansi Tripathy, Country Head, Shell Lubricants India, unveiled the new product from Shell’s portfolio.

The company claims that the Advance AX7 enhances the mileage of the motorcycle by 3 km/l as compared to a premium mineral oil. Equipped with Active Cleansing Technology, Shell promises more efficiency and better protection for the engine.

Apart from aiding the longer life of all critical parts running in the engine, this oil does not degrade even at high temperatures. Shell Advance is made from pure and clear base oil, combining with a motorcycle-specific additive pack with unique Active Cleaning Technology. It helps to cleanse and keep the engine cleaner.

A clean motorcycle engine helps provide better efficiency, performance and protection.

involvement in premier-class motorcycle racing has helped develop the Shell Advance lubricant range for the road.

With the Advance range of engine oils, bikers globally can benefit from the cutting-edge technology developed on the track. The transfer of knowledge gained from this experience to Shell’s products is central to the Technical Partnership with Ducati, as MotoGP provides the most extreme test bed for Shell’s products. If it’s good for MotoGP, it works even better on roads.”

Tripathy said that “the twowheeler engine oil market in India is consistently growing at a healthy CAGR of 7.2 per cent as per a Kline & Company 2017 report. In line with this growth, we are committed to innovating

About the increasing enthusiasm among the youth to ride higher capacity bikes, Petrucci said, “Using the right lubricant is critical in ensuring the engine health of such bikes. Shell’s 50 50 AUTO COMPONENTS INDIA NOVEMBER 2018

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to meet the on-road challenges of bikers, and even to surpass their expectations. With the Shell Advance AX7 10W-30, we want to focus on providing powerful and exhilarating riding experiences to bikers.”

Gareth Flood, Chief Marketing Officer, Shell Lubricants India, said, “The Indian consumers are becoming increasingly passionate about their bikes and are avid followers of global racing series such as Moto GP. By bringing a MotoGP rider to India for launching the AX7 10W-30, we are attempting to engage more closely with our consumers and offer products according to changing market dynamics and trends. Shell Advance is central to powering Ducati bikes on the track in extremely testing environments and this itself is a testament to its superior on-road performance.”

The relationship with Ducati began in 1999, supporting Ducati Corse in the World Superbike Championship, before joining forces to contest the MotoGP World Championship together.

The partnership has since stormed to seven Riders’ World Titles in MotoGP (2007) and the World Superbike Championship (1999, 2001, 2003, 2004, 2006, 2008), amassing over 150 race wins. Shell claims that Ducati not only uses Shell products on the track, but also chooses Shell Advance Ultra motorcycle oil as the first fill for every Ducati road bike that leaves its factory. ACI

C OVER STORY Amara Raja, Johnson Controls tie-up to bring new battery technologies ACI Bureau

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mara Raja Batteries Ltd and Johnson Controls, Inc. have signed a technology collaboration agreement to bring a new wave of battery technologies to India. Expanding on their 20 year partnership, the 2 companies will share and improve product design and manufacturing technologies enabling higher performance across Starting, Lighting and Ignition (SLI), Enhanced Flooded Batteries (EFB) and Absorbent Glass Mat (AGM) batteries. These advanced batteries are fundamental to enabling sophisticated consumer features and stricter emission standards in automotive vehicles.

As part of this collaboration, Amara Raja will license Johnson Controls’ proprietary PowerFrame grid technology. This patented technology is up to 66 percent more durable and more corrosionresistant than other grid designs.

PowerFrame grid technology has been tested in multiple cities around the world, in the most

extreme, real-world conditions, across the full range of automotive low-voltage battery products. The advanced grid technology is also critical to meeting performance requirements associated with the BS-VI environmental norms going into effect in 2020.

Jayadev Galla, Vice-Chairman and Managing director, Amara Raja Batteries Ltd, said, “We offer innovative and the most advanced technologies to our customers, and our partnership with Johnson Controls has been a great enabler to our growth over the last many years. We have laid out a clear road map for longterm strategic growth and will continue to make investments in technology capabilities, capacity building, brands and distribution.

The new technology collaboration agreement with Johnson Controls will help us bring continued advancements in the products and technologies that meet our customers’ future needs. This is synergistic to our motto of ‘Gotta be a better way.”

Joseph Walicki, President, Power Solutions, Johnson Controls, said, “Johnson Controls has been at the forefront of offering the advanced battery solutions to meet the ever-increasing demands of automotives. Our PowerFrame grid technology coupled with the EFB and AGM products that we manufacture provide the highest reliability and optimal performance to meet our customers’ present and future needs. We are very pleased with

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the successful growth of Amara Raja over the years and are excited to strengthen our partnership through this technology collaboration agreement.”

A company with 26% equity each from the Galla Family and Johnson Controls Inc., USA, Amara Raja Batteries Limited is the technology leader and one of the largest manufacturers of lead-acid batteries for both industrial and automotive applications in the Indian storage battery industry.

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New factory

In order to meet the growing demand, recently the battery manufacturer has also laid the foundation stone for its third automotive battery plant at Amara Raja Growth Corridor Chittoor, Andhra Pradesh. Amaranatha Reddy, Minister for Industries, Food Processing, Agri-Business, Commerce and Public Enterprises, Government of Andhra Pradesh laid the Foundation Stone. Dr Ramachandra N Galla, Chairman, Amara Raja Group and Vijayanand S, CEO, Amara Raja Batteries Limited, were present along with the senior management team of Amara Raja.

In the first phase, the new facility will have a capacity of 6.5 million units. The estimated investment for the first phase is Rs 700 crore and it will employ 1300 people at its full capacity. The plant is designed to eventually scale up to 10.8 million units, making it one of the largest facilities of its kind in the country. ACI

C OVER STORY Classic Legends unveils engine for new JAWA Motorcycles ACI Bureau

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lassic Legends Pvt. Ltd., a lifestyle start-up, formed in 2015, to re-introduce to today’s consumers the rich heritage and legacy of classic brands in a new avatar, has unveiled the new engine for the soon-to- be-launched JAWA Motorcycles in India. Classic Legends aims to become India’s first true lifestyle company and provide opportunities to consumers to relive the heritage of classic brands by co-creating exciting product and service offerings along with the motorcycling ecosystem.

The company was formed by three industry stalwarts, Anand Mahindra, Anupam Thareja and Boman Irani, who have come together to launch products that capture the brand DNA and ethos, of these iconic brands.

The brand Jawa motorcycles will be launched first in India while other brands will come later. Classic Legends would leverage the best of its partner capabilities in design and engineering along with the global expertise, to design and launch products that capture the DNA and ethos, of the JAWA.

motorcycling which will create renewed fervour for retro-classics.

“The new JAWA engine is a befitting testament to the old one. It packs 27 bhp and 28 Nm of torque with a generous mid-range and a flat torque curve for an unwavering, consistently powered ride. The brief we took upon ourselves was always to build an engine that had the Jawa DNA,” a company release said.

“Working closely with one of the world’s leading engine specialist at the technical centre in Varese, Italy, not only did we build an engine with a near flat torque curve and generous mid-range, but also a motor strong enough to last a lifetime. Piece by piece bringing together Classic and Sporty all in one. However it was not just the aesthetics and power delivery we tried to engineer. The unique exhaust note of the old JAWA was something that we were in love with and we wanted our engine to have a unique sound, given that replicating the tone of a classic 2-stroke on a modern day 4-stroke would

be a big challenge. A maverick team of sound engineers in Italy worked extensively with us through countless cycles of harmonic pipe combinations and multiple other permutations to discover a sound that was worthy of the new JAWA,” the release added.

While the engine needed to be built with a reminiscent sameness it needed to be an engine of the future.

Hence, the engine has been built on a BS-VI ready platform. From the tuning of the fuel injection to the gearbox that completes the powertrain, one will get from this engine, what one seeks in a classic.

JAWA is a motorcycle brand from Czechoslovakia, with a 90-year legacy, which in its heydays exported classic, well engineered and rugged motorcycles to more than 120 countries. It entered India in the early 1960’s. The twin aspects of JAWA motorcycles - its beautiful design and strong performance character helped it not only to win hearts but also win many world titles. ACI

The company will bring to consumers a totally immersive approach to experiencing motorcycles and the associated lifestyle with it. The longer-term roadmap of Classic Legends would be to open an entire ecosystem of lifestyle experiences which are exciting and immersive for consumers. The brand will unveil a new chapter in the world of classic 53 53 WWW.AUTOCOMPONENTSINDIA.COM

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O EM Hyundai Santro takes new avatar Story by: Bhargav TS

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wenty years ago when the Korean car maker Hyundai entered the Indian market, many were sceptical about its competence to succeed. When the company launched its first car Santro on September 23, 1998 all eyes turned to the new tall boy design car, with first inclass features. Sceptics turned to be believers. Its refined, peppy engine and well-finished interiors helped Hyundai Santro script its success story here. To add more flavour to the Santro, Hyundai roped in the then rising Bollywood star Shahrukh Khan, who had just started on his journey with films like Dilwale Dulhaniya and Kuch Kuch Hota Hai. Hyundai understood the Indian market and approached it with humility and honesty, cared for the Indian consumers and brought global best-in-class features in its products along with the friendly and helpful sales and service personnel. All these helped the Korean company to grow to be the second largest carmaker in the country in 2 decades.

need and demand the company started to work on its new hatchback, code named AH2. After intensive market study Hyundai developed the new car and took nearly 3 years to complete it. For this AH2 project, the company had invested nearly $100 million in the last 2 years to bring back the ‘All New Santro’.

Y K Koo, MD & CEO, HMIL said, “Since its first launch, Santro created history with its numerous segment-first innovations and became the Complete Family Car for millions of Indians. The all-new Santro is based on 6 key pillars: Modern Stylish Tallboy design, Comfortable and Premium Cabin, New Age technology, Customer-Centric Safety, All Round Performance and Complete Peace of Mind.

These make it a game changer and benchmark product in the Indian auto industry.”

After extensive testing and validation, Hyundai unwrapped the covers of the new Santro

that has taken a new avatar on October 23, 2018, to carry on from where the older Santro had left off. The product will be positioned in the mid-compact segment, which is currently dominated by market leader Maruti Suzuki’s Celerio, Wagon R and Tata’s Tiago. The overall design theme of the new Santro is based on “Rhythmical Tension” that exudes a Refined yet Sporty Image. It is plotted between the Eon and Grand i10 in the company’s line-up and carries a different design language with LED DRLs and the full-face wide cascading grille. In the previous Santro the Hyundai logo was placed in the centre of the grill but in the new Santro it is at the top of the bonnet.

The headlamps are swept back.

With these changes the front has the looks of a sporty, premium car. The side profile of the car has got some nice styling lines, creases and kink in the window line allowing the new Santro to be more edgy. The rear of the car looks nice and neat.

Santro has a story. Hyundai India stopped its production in December 2014, though the car has been the bedrock of the brand in India since launch. There was still demand for the car and there were people ready to pay a premium to own it. Santro was axed from the line-up to make way for other, more profitable new cars such as the Grand i10 and the new Elite i20. Even after a year of discontinuity, the name Santro was in the air. Sensing the

Hyundai’s Corporate Brand Ambassador Shahrukh Khan and Y K Koo, MD & CEO, HMIL along with the ‘All New Santro’ 55 55 WWW.AUTOCOMPONENTSINDIA.COM

AUTO COMPONENTS INDIA NOVEMBER 2018

O EM faster. The 7 inch touchscreen infotainment system comes with Apple CarPlay, Android Auto and MirrorLink. Being an affordable car there are lot of plastics inside the cabin and the quality levels have gone down. The seats are comfortable, have enough thigh support and have high seating posture. The rear flat seat cushions ensure all 3 passengers can be seated comfortably.

Interiors of the new Santro looks premium with the dual-tone beigeon-black themed dashboard

Like its predecessor, the new Santro carries the ‘tall boy’ stance and made only few changes in the specs. Now the length is 3610mm, width is at 1645mm and the height is 1560mm. With the increase in length and width, there’s plenty of space inside the cabin. Similar to the other Hyundai cars, the interior of the new Santro looks premium. It gets a dual-tone beige-on-black themed dashboard and the centre of attraction is the design of the air-con vents, first in class features like rear AC vents and a reverse camera.

To ensure a comfortable cabin experience even in the harshest Indian summers, it comes with a best-in-class 135cc compressor motor that cools the cabin much

The all-new Santro is powered by a 1.1L four-cylinder petrol engine that produces about 69PS of power at 5,500rpm and 99Nm of torque at 4,500rpm. It also comes with a factory-fitted CNG option with this engine, albeit with an 59PS/84Nm tune. The previous Santro buyers loved the combination of space, price and efficiency it offered. Now Hyundai wants to widen its scope by making it easier to drive and live with by offering an automatic gearbox with a single clutch.

Known as an AMT, the single clutch automatic is perfectly suited to do duty here as it is inherently more efficient than regular automatics, and is also more affordable. The new Santro has a manual mode as well.

The new Santro is built on a new platform along with the application of 63% Advanced High Strength Steel (AHSS) along with High Strength Steel (HSS), helping to achieve prominent static and dynamic stiffness with improved structural connectivity.

Additionally standard ABS with EBD and driver airbag provides uncompromised safety.

The B-segment has seen Maruti loses its dominance over it with the Renault Kwid being successful which opened the segment to new players. While Hyundai has strong products in other price points, its B-segment challenger, the Eon, hasn’t been competitive enough.

Hyundai is hoping this new car gives it a better shot and targets to sell at least 10,000 cars every month. ACI

Hyundai kick started its India innings on September 23, 1998 by laucnhing its first car Santro 56 56 AUTO COMPONENTS INDIA NOVEMBER 2018

In the Hyundai test track at the Sriperumbudur factory we drove the AMT version and were very impressed with the performance.

Once you crank the engine it idles smoothly. The newly developed AMT gets the electric actuation as against hydraulic and that makes relatively smooth and jerk-free. The new transmission is so smooth that a common man can’t say whether it is AMT or CVT. This AMT takes off as soon as you press the accelerator, making it nice to drive in city traffic. However, there is a bit of jerkiness, as on all AMTs, but Hyundai seems to have improved the manner in which the gearbox and engine work together.

Considering the other AMTs in the market, this AMT performs very well especially when the gears go down, it moves quite smoothly.

The shifts seem a bit smoother and the speed with which the gears engage manually when you push on the lever seems to be a bit quicker.

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A LLIED INDUSTRIES BFW Smart Plant in Hosur shifts manufacturing paradigms ACI Bureau

B

harat Fritz Werner Ltd. (BFW), India’s leading solution provider in the area of machine tools, is pioneering a paradigm shift among manufacturing industries to become globally competitive with smart solutions. BFW’s new manufacturing facility in Hosur, Tamil Nadu, is a ‘Factory of the Future’, and the plant is an engineering masterpiece.

The company is a front runner in digitisation and use of Artificial Intelligence (AI) in the manufacturing industry. BFW was the first company to get all its approvals online when the government of Tamil Nadu opened its single window clearance portal.

Ravi Raghavan, Managing Director, BFW said, “BFW has always been a leader in introducing new technologies and environmentfriendly initiatives. Manufacturing is a core sector that maps a country’s growth. We wish to lead the industry in raising the bar for manufacturing processes and hope that together we can enable progress in India.”

In the first phase, the factory,

spread across 60,000 sqft, has significant number of modern machines to enable integration of existing foundry facility with machining capability. The second phase will be spread over another 60,000 sq ft area. The Industry 4.0-compliant factory is fully automated and AI-enabled. The manufacturing process here is designed to take it to the next level through digitisation and superior engineering. Such processes ensure cost efficiency, increased manpower productivity, and shortened manufacturing time.

Earlier in the year, BFW set up a solar power project that supplies power to the entire facility in Bengaluru. Its 980 kWp solar project generates 15 lakh units of energy which helps the company in meeting its power requirements.

This plant will help BFW offset 1350 tonne of carbon emission every year.

The `Manufacturing Day 2018’, third in the series, organised

by BFW, provided a platform for the Industry to push for Smart Solutions and make Indian manufacturing globally competitive. With the theme, `Towards Globally Competitive Indian Manufacturing’. The sessions focused on three important topics: Innovation, Factories of Future and Entrepreneurial spirit.

The Chief Guest, Kamal Bali, MD, Volvo India said, “Manufacturing has to become the centre piece of our conversations.

In India everything is stacked against manufacturing. We are 17% of the global population

58 58 AUTO COMPONENTS INDIA NOVEMBER 2018

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but we contribute only 2% to global manufacturing. Every manufacturer has to wear two hats for the industry to evolve. We have to promote our companies as well as the manufacturing industry.

Manufacturers have to become conscious of branding. To be a global leader, India has to create a culture of manufacturing.”

Sonam Wangchuk, Engineer, Innovator and Education Reformist, and a Ramon Magsaysay Award winner, in his key-note address, said, “Innovation is important but we have to keep sustainability in mind. Innovation solves problems in every area of life –be it education, living standards or any other area. Sometimes innovation can be made out of thin air. We applied simple high school science principles to the elements of earth, sun, and ice to create sustainable solutions in the harsh environment of Ladakh and we have found that this is enough to bring winters alive in Ladakh.”

In the session on `Factories of the Future’, the speakers said the factories will have to adopt digitisation to create sustainable Smart Manufacturing enterprises.

Disruptions will be endemic and manufacturing processes will need to be flexible to adapt. The session focused on various facets of such manufacturing facilities.

The following session highlighted why the aspirational entrepreneurs are the backbone of manufacturing along with the producers. Success stories of entrepreneurs in the manufacturing sector fascinated the audience. ACI

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