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Western India: an automotive powerhouse

Autocar Professional Bureau — Sun, 23 Jun 2024 19:11:27

India’s western region, particularly Maharashtra and Gujarat, has always been an important hub in the country’s automotive industry. The western region's strategic location, robust infrastructure, skilled workforce, and conducive business environment have collectively made it a magnet for both domestic and international automotive giants. Automakers such as Tata Motors, Mahindra & Mahindra, Maruti Suzuki India, Bajaj Auto, and MG Motor India, have major operations in this area. Major component suppliers like Schaeffler, Varroc, Bosch, and Minda also have a noticeable presence here. This is what makes the western region a force to reckon with, among India’s key automotive hubs, including those in the North and South.

An estimated Rs 89,000 crore is slated to be invested by leading passenger vehicle OEMs like Maruti Suzuki India, Tata Motors, Hyundai Motor India, Mahindra & Mahindra, and MG Motor India, in the western belt, over the next three to five years to drive capacity to nearly 1.8 million units annually, to cater to both ICE and future EV products. A similar investment is likely from key Tier-I component suppliers to support the future growth and expansion plans of their OEM customers.

Korean carmaker Hyundai is likely to spend around Rs 6,000 crore in revamping the General Motors plant in Talegaon (Maharashtra). The plant will be revamped into a nearly-130,000-unit facility. JSW MG Motor India, on the other hand, will invest Rs 5,000 crore to set up its second plant in Halol (Gujarat) and augment capacity by almost 1,50,000 units annually. India’s largest carmaker Maruti Suzuki India has committed an investment of nearly Rs 16,000 crore to set up a mega 1-million-capacity plant — its second facility in Gujarat — that is likely to be commissioned by FY29.

Source: ICRA, CMIE

These mega investments while target readiness to meet future demand from a growing Indian market, also come in the wake of the industry's rapid transition towards electric mobility with EVs fast emerging as new sustainable mobility solutions.

Electrification is receiving a major push from the government that intends to drive up to 30% penetration by 2030, and is incentivising both EV manufacturing as well as demand by virtue of various subsidies.

The rise of the western region as an automotive powerhouse can be traced back to the 1950s, when after India’s independence, Maharashtra, with its capital Bombay (now Mumbai), was one of the first states to undergo rapid industrialisation. The establishment of industrial zones and the Mumbai-Pune corridor paved the way for the automotive sector's growth. Moreover, cities like Pune, Chakan, Nashik, and Aurangabad, too, evolved as the go-to destinations for global automotive companies to set up their manufacturing bases from where they could cater to both the domestic and overseas markets.

Gujarat also followed suit with its pro-business policies, strategic port locations, and industrial parks — all attracting substantial investments from global players. Today, Tata Motors, Suzuki Motor Corporation, MG Motor India, and Honda Motorcycle & Scooter India, are some top names that are operating state-of-the-art facilities in Gujarat’s Sanand, Vithalpur, and Halol.

Factors driving investment in western India

The proximity to major ports like Mumbai, Kandla, and Mundra facilitates seamless export and import activities, enhancing the global competitiveness of automotive companies based in the region. Furthermore, the presence of well-developed industrial zones, logistics parks, and excellent road connectivity like that offered by the Mumbai-Pune expressway, provides a solid foundation for manufacturing and supply chain operations in the region.

The western belt also boasts a rich talent pool, with numerous engineering colleges and technical institutes, contributing to a steady supply of skilled professionals, and the focus on R&D and innovation, supported by
the likes of Tata Motors European Technical Centre as well as the Automotive Research Association of India (ARAI), both housed in Pune, ensures that the region remains at the cutting edge of the advancements in auto technology.

Therefore, the auto industry in West India significantly contributes to the local and national economy. Maharashtra and Gujarat together account for a sizable share — nearly 25% — of India's automotive production and exports. The industry's growth has a multiplier effect, stimulating ancillary industries such as steel, rubber, plastics, and electronics.

This feature was first published in Autocar Professional's June 15, 2024 issue.

Use of on-board chargers in EVs: Enhancing consumer experience

Autocar Professional Bureau — Sat, 22 Jun 2024 12:08:17

In recent years, the global automotive landscape has witnessed a significant surge in the adoption of EVs, indicating a growing confidence among consumers in this eco-friendly mode of transportation. This trend underscores the informed decision-making process of individuals who recognise EVs as a practical and sustainable choice for achieving optimal performance and eco-conscious commuting.

One key technological advancement enhancing the EV experience is the advent of On-Board Chargers (OBCs). To comprehend how OBCs contribute to a smoother and more hassle-free daily commute, it's essential to first understand what OBCs are and how they operate.

What is an OBC?

An onboard charger, also known as an OBC, is a built-in device in electric vehicles (EVs) that converts alternating current (AC) power from an external source, like a Level 2 charging station or even a home outlet, into direct current (DC) power to charge the vehicle's battery.

Essentially, it acts like a translator, taking the language of the grid (AC) and turning it into the language of the EV battery (DC). This is crucial because EV batteries can only be charged with DC power.

On board chargers come in various capacities, typically ranging from 3.3 kW to 22 kW. The higher the capacity, the faster the charging speed.

Advantages of using OBC

The convenience factor is paramount as it allows EV owners to recharge their vehicles at home or any location with access to an AC power outlet. This significantly reduces dependency on public charging stations, providing users the flexibility to manage their charging needs at their convenience. Moreover, OBCs empower vehicles to tailor their charging experience by selecting the optimal speed based on available power sources and individual time constraints. Additionally, the cost-effectiveness of charging at home further underscores the economic advantage of OBCs, as it generally proves to be more economical compared to utilising public charging infrastructure.

Heavy chargers versus OBC

The drawbacks associated with bulky chargers in Electric Vehicles (EVs) extend beyond mere spatial concerns, impacting both functionality and efficiency. These sizable chargers pose a dual threat by occupying valuable space within the vehicle, potentially encroaching upon cargo capacity and compromising passenger comfort. Furthermore, the added weight of these chargers can detrimentally affect overall performance, a critical consideration for smaller EVs where space optimisation and efficiency are paramount.

Beyond the physical constraints, the increased weight of these chargers introduces complexities in their systems and components, leading to potential escalations in maintenance costs and repair intricacies over the vehicle's lifespan. While heavier chargers may offer faster charging speeds, this advantage comes with a trade-off – the potential inefficiency arising from increased energy losses during the conversion process. In essence, the quest for swifter charging may be counteracted by the need for more frequent refuels, eroding the anticipated benefits.

Ease of refuelling in EVs

In the ongoing debate between EVs and Internal Combustion Engine (ICE) vehicles, a pivotal aspect under scrutiny is the refuelling (or charging) experience. Comparing the ease of use for each reveals distinct advantages for EVs. The convenience factor is paramount as EV owners can charge their vehicles at home overnight or during the day while parked, eliminating the need for dedicated trips to gas stations. Moreover, EVs offer accessibility by allowing users to plug into any standard outlet for charging.

The familiarity of plugging in, akin to charging other electronic devices, renders the process intuitive for most users. This simplicity is complemented by the flexibility of choosing charging times based on individual schedules and needs. On the contrary, ICE vehicles present inherent limitations. The refueling process involves dedicated trips to gas stations, often causing inconvenience and interrupting daily errands.

The volatility and unpredictability of fuel prices further add to the limitations of traditional internal combustion vehicles. In summary, the advantages of EVs in terms of convenience, accessibility, familiarity, and flexibility underscore their potential to revolutionise the refuelling experience when compared to traditional ICE vehicles.

Onboard charger in electric 4-wheelers

Over the past decade, with the advent of the Onboard Charger, the global landscape of electric 4-wheeler adoption has undergone a remarkable transformation, with sales surging from 17,000 units in 2010 to an astounding over 10 million units in 2022, representing a staggering 588-fold increase. The market share of electric vehicles in the global passenger car segment has witnessed a notable ascent, evolving from negligible figures in 2010 to over 14% in 2022, signifying substantial progress and a paradigm shift in the automotive industry.

In contrast, India, commencing from a smaller initial base, has displayed promising growth potential in the electric vehicle domain. While sales were negligible in 2010, 2022 saw over 4,25,000 electric 4-wheelers sold in the country, marking a significant milestone. The market share of electric cars in India, though still in the early stages of adoption, has reached around 1.5% of total car sales in 2022, reflecting a gradual but noteworthy shift towards sustainable mobility in the Indian automotive market.

The future of onboard chargers

The future of onboard chargers (OBCs) in the electric vehicle (EV) realm is poised for a transformative trajectory, mirroring the rapid advancements in EV technology. One of the key focal points is the quest for faster charging, with the anticipation of ultra-fast charging systems, including 800V and beyond, becoming mainstream. This evolution promises charging times that can rival traditional gasoline vehicles, envisioning the addition of hundreds of kilometres of range in mere minutes.

Advanced OBCs are expected to introduce dynamic power allocation, intelligently managing power distribution between battery charging and auxiliary functions to optimise both speed and efficiency. The integration of bi-directional charging, commonly known as vehicle-to-grid (V2G), will empower EVs to contribute power back to the grid, balancing demand and potentially generating income for vehicle owners. Furthermore, OBCs will seamlessly connect with smart grids and home energy management systems, embracing vehicle-to-everything (V2X) connectivity to optimise charging based on electricity rates and grid needs.

Personalisation will also play a significant role, allowing users to define charging profiles based on preferences for speed, time, and energy sources. Beyond charging, OBCs are set to evolve into comprehensive systems, monitoring battery health and performance in real-time, providing valuable insights and potentially extending battery life. Predictive maintenance features will anticipate potential issues with the OBC or battery, enabling proactive interventions and preventing breakdowns. Additionally, over-the-air updates for OBC firmware will ensure that these crucial components stay up-to-date with the latest features and bug fixes, reflecting a dynamic and forward-looking landscape.

The incorporation of On-Board Chargers (OBC) in electric four-wheelers has significantly accelerated the widespread adoption of Electric Vehicles (EVs), establishing them as a practical and reliable choice for commuters. The seamless compatibility of OBCs with the widely embraced CCS2 charging standard stations ensures that EV users can embark on longer rides without the anxiety of running out of charge. Building on the proven success of OBCs in electric four-wheelers, their introduction to electric two-wheelers has the potential to revolutionise the automotive market, posing a formidable challenge to traditional Internal Combustion Engine (ICE) vehicles. This expansion not only strengthens the competitive edge of EVs but also marks a transformative shift in the dynamics of the automobile industry.

Dinesh Arjun is the CEO and Co-founder of Raptee Energy. Views expressed are those of the author.

This feature was first published in Autocar Professional's June 15, 2024 issue.

Bosch offers software, services, and smart technology for modern mobility

Autocar Professional Bureau — Wed, 19 Jun 2024 14:31:50

Mobility has never been easier, safer, and more convenient, thanks to a blend of software, services, and smart technology. At Bosch Tech Day 2024, Bosch showcases its range of solutions and products for today's and tomorrow's mobility.

Software Platform for Logistics Specialists

Bosch’s digital service platform addresses the challenges of the transportation and logistics industry, offering a marketplace with central access to digital solutions across various aspects of logistics. It allows seamless integration of separate services and data, enhancing driver management, fleet management, routing, parking, and more. Collaborating with providers like Webfleet, Bosch integrates value-added services without additional IT projects.

Deterministic Middleware Solutions

ETAS’s middleware solution supports the development of automated driving systems by integrating various functions and ensuring accurate virtual testing. This reduces the need for physical test kilometers, enabling faster and safer development of new driving functions.

AI Vehicle Application Generator

ETAS’s AI-driven generator allows the creation of personalized vehicle functions using natural language, simplifying the integration of new features for OEMs, dealers, rental companies, fleet owners, and drivers.

Act-by-Wire Technologies

Replacing mechanical connections with electrical signal lines, act-by-wire technologies offer new functions for critical driving situations, enhance vehicle agility, and open up design possibilities for vehicle interiors. Bosch’s Vehicle Motion Management software optimally controls these systems.

Connected Services for Fleets

Bosch connectivity solutions, including the Retrofit Efficiency Module and Vehicle Health, help fleet operators optimize vehicle use and reduce downtimes by providing real-time data and predictive maintenance insights.

Cockpit and ADAS Integration Platform

Bosch’s vehicle-centric and zone-oriented architecture integrates infotainment and driver assistance functions into a single system, reducing electronic system complexity and enabling advanced features in compact and middle-class vehicles.

Interior Sensing Solutions

Bosch’s sensor and software solutions for interior sensing enhance safety by detecting driver distraction and drowsiness, and enable comfort features like automatic seat and temperature settings.

Connected Map Services

Bosch’s connected map services use swarm data and infrastructural sources to provide real-time driving environment information, improving driver assistance functions and enabling proactive driving adjustments.

By combining these advanced technologies, Bosch continues to drive the future of mobility, making it safer, more efficient, and more enjoyable.

Bosch Vehicle Motion Management transforms driving experience

Autocar Professional Bureau — Wed, 19 Jun 2024 14:30:09

Bosch's Vehicle Motion division is transforming mobility with integrated chassis solutions that enhance safety, dynamics, comfort, and driving enjoyment.

Launched in early 2024, this division unifies expertise from braking, steering, vehicle motion software, occupant protection systems, and vehicle dynamics sensors. The division's offerings include hardware-agnostic software, act-by-wire solutions, and an extended braking portfolio featuring a brake-by-wire actuator.

Key innovations from Bosch Vehicle Motion

Vehicle Motion Management:

A cross-domain software solution controlling vehicle motion in six degrees of freedom.
Coordinates braking, steering, powertrain, and suspension.
Optimises vehicle dynamics, handling, and efficiency.
Simplifies vehicle architecture and integrates systems via central vehicle computers.

eBrake to Zero:

Ensures smooth, jolt-free braking, enhancing comfort in stop-and-go traffic.
Uses optimal control of the electric motor and braking system.
Prevents motion sickness and reduces braking noise.

Data-Based Services:

Includes a "road perception" service using sensor data to warn drivers of hazards like aquaplaning, ice, and potholes.
Merges vehicle data with weather service information for enhanced safety and comfort.
Adjusts vehicle dynamics and driving strategies automatically.

Act-by-Wire Technologies:

Replaces mechanical connections with electrical signal lines for steering and braking systems.
Enhances vehicle safety, comfort, and interior design flexibility.
Reduces installation space and improves noise and vibration behavior.

Brake-by-Wire System:

Comprises a brake-by-wire actuator and an ESP system.
Transmits braking requests via signal lines, eliminating mechanical connections.
Allows for innovative interior designs and dynamic braking performance.

By-Wire Brake Actuator and Pedal:

Light, flexible actuator for precise hydraulic pressure control.
The brake pedal transmits braking requests electronically, enhancing safety and personalisation.

Steer-by-Wire System:

Eliminates mechanical linkage between the steering column and gear.
Uses actuators for steering feel and wheel positioning.
Customisable feedback and adaptable for automated vehicle designs.

These advancements by Bosch Vehicle Motion Management offer innovative, cross-domain functions and simplified vehicle architectures, promising a safer, more dynamic, and comfortable driving experience. The division continues to push the boundaries of mobility solutions, setting new standards in the automotive industry.

Autocar Professional’s June 15, 2024, issue is out!

Autocar Professional Bureau — Tue, 18 Jun 2024 16:50:42

Cover Story

Our top story this time is on India’s used car market. The used car market industry sold a whopping 5.17 million units in FY23 — a 56% rise from seven years ago — and is projected to reach 10 million units by FY28. Our comprehensive story brings you all the details about how this market is doing and what is driving its growth.

Western India Special

This is a Western India Special issue and we have featured some important auto companies that are based out of western India. Maharashtra and Gujarat continue to play a pivotal role in the region when it comes to the auto sector.

Data from the Federation of Automobile Dealers Associations (FADA) and ICRA show the importance of the region in the auto industry and the contribution of different states in the overall western Indian auto market.

FY24 was a big year for Tata Motors. The company showed remarkable turnaround during the year and its CV, PV and JLR divisions have achieved significant milestones.

In Conversation

In a special interview with Autocar Professional, Reji Mathai, the Director of ARAI spoke about how the premier testing agency is transforming itself to prepare for the upcoming regulations.

How you can read this issue
Autocar Professional magazine is available through all good newsagents and for download from Magzster. You can also buy one-off copies of Autocar Professional magazine – contact Ganesh at ganesh@haymarketsac.com. Alternatively, never miss an issue – subscribe to Autocar Professional magazine today.

Mihup.ai helps cars talk the talk

Autocar Professional Bureau — Wed, 12 Jun 2024 17:37:31

In India, it’s no secret that consumers are now getting used to the idea of digital voice assistants in premium cars. Digital voice assistants have been around in cars since 2004 in overseas markets, and since then the feature has been liked by users looking for high-quality products and more diverse uses for them. For the uninitiated, think of it as the Alexa of cars, says Tapan Barman, Co-founder of Mihup, a tech start-up that has designed and developed AI-based voice assistants for automotive brands like Tata Motors. The deep-tech company specialises in conversational and generative AI-powered applications for the automotive sector since 2019.

While voice AI technology enables seamless and intuitive communication between the vehicle and its driver, there have been challenges for the Indian ecosystem where you have hundreds of languages and thousands of dialects to deal with. For successful application in a country like India, a robust natural language understanding system is essential for interpreting driver commands accurately to help reduce the likelihood of misunderstandings or misinterpretations that could lead to unsafe situations.

This was a challenge that prompted Tapan Barman and Biplab Chakraborty, Co-founders of Mihup to establish their start-up in 2016, with the mission to bridge the gap between human and technology, with a Make in India AI voice assistant applications.

Barman says that it took the company a few years to commercially develop a product that’s vocabulary-based and has a phonetic imprint approach. Mihup’s software is able to interpret not just the words used in communication, but the emotions and context behind them as well, claims Barman.

This approach to AI has been path-breaking and has helped Mihup carve a niche in the voice application bolstered by a focus on creating a product that is both multilingual and vernacular in a diverse language/dialect set-up. Barman claims that the system that they have developed successfully recognises 50 Indian dialects like Hindi and Hinglish; Tamil and Tamilish, Bengali and Benglish, Telugu, Marathi, Punjabi, Haryanvi, Kannada and Marwari. Barman claims that the latest product iteration has factored in many of the limitations that ChatGPT and other large-language model (LLM) applications have been known to offer, including fabricated or fake information. Likewise, OpenAI is being targeted these days in a number of defamation and copyright infringement lawsuits.

Hybrid nature

One of the key features of the Mihup Virtual Agent is its hybrid nature, allowing operation even in the absence of an internet connection. The bot is integrated into the car's infotainment system and data is secured as it is not saved anywhere. Unlike Alexa or Siri, which necessitate internet connectivity, Mihup functions independently of the internet and it can execute all tasks that do not rely on data retrieval.

That’s not all, by understanding and adapting to individual preferences and driving habits, these systems can provide tailored recommendations, route suggestions, and operational guidance, optimising driving efficiency and minimising downtime.

New market opportunities

The Automotive Voice Recognition System market size which is roughly USD 3.06 billion in 2024, is expected to reach USD 6.09 billion by 2029, growing at a CAGR of 14.77% during the forecast period (2024-2029), according to market analyst Mordor Intelligence.

According to Barman, several major truck makers in India are also considering the idea of including a voice assistant in their vehicles. While specific names aren't disclosed yet, he suggests that this trend isn't limited to a single manufacturer but is a growing consideration across the industry. On advancements in application of conversational AI, Barman says it can also be adapted for communication in commercial vehicles (CVs) and can be extended to 2-wheelers also.

Like in cars, voice AI based technology in CVs will enable seamless and intuitive communication between the vehicle and its driver. Equipped with advanced speech recognition and natural language processing capabilities, these systems allow drivers to interact with their trucks using simple voice commands, eliminating the need for manual inputs and reducing distractions on the road. One of the key advantages in conversational AI for trucks is the ability to provide real-time updates and safety alerts to drivers. Through voice prompts and responses, the vehicle can alert drivers to potential hazards, upcoming road conditions, and maintenance requirements, enabling them to take proactive measures and make informed decisions while on the road, says Barman.

Barman says the journey has been nothing short of transformative, upon partnering with Tata Motors in 2019. Since then, the collaboration has grown from initial deployments to widespread integration across numerous models and applications. “Initially, we launched the Mihup AVA voice assistant on edge in just a few models which has now expanded across vehicle models and various use cases. The journey has been marked by continuous innovation and adaptation to meet the evolving needs of drivers and passengers alike,” says Barman. Recently, the company says it has taken a step forward with the launch of the hybrid model of Mihup AVA. This new offering combines the best of cloud-based and on-edge technologies, enhancing the voice assistant's capabilities and expanding its applications and hence considered as a significant development. The model allows for seamless updates and integration of the latest AI advancements and further expands the scope of the voice assistant. “We are excited about the introduction of custom LLM and Gen AI use cases in our voice assistant which will revolutionise the conversational experience inside vehicles, across the entire automotive landscape of India,” says Chakraborty.

Software upgrades possible

As with any software application, the versions get outdated or obsolete with new versions and keeping that aspect in mind, the Mihup software can also be upgraded. Barman says this is possible due to its advanced learnability model that means Mihup can also learn the typical usage pattern and preferences of the user from their day-to-day use and push the relevant updates for a customised user experience.

Safety approach

Mihup claims that its voice assistant system aims to reduce driver distractions by allowing users to control vehicle functions through voice commands and minimising the need for touchscreens. This approach aligns with safety directives from organisations like NCAP, emphasising the importance of reducing distractions to enhance road safety. Explains Barman: “Our approach at Mihup.ai focuses on minimising distractions by integrating advanced conversational AI into vehicle systems. Having to press multiple screens and buttons to get even the most basic tasks done is inherently distracting. Voice is the most natural form of communication and when you have a technology that can understand your spoken words almost as well as another human, any debate over its applicability becomes redundant. This technology allows drivers to manage vehicle functions through voice commands, significantly reducing the need to interact with touchscreens for basic functions.”

Integration of technologies

The possibility of integration of technologies like biometric recognition and gaze detection into automotive solutions, further makes them the go-to choice as safety enhancers. Barman says this technology ensures that vehicle functions are accessible only to authorised users, enhancing security. Biometrics can adjust vehicle settings such as seat position, mirror angles, and driving preferences automatically, based on the identified driver, creating a safer and more personalised driving experience. By monitoring the driver’s gaze, this technology can alert if the driver is not paying attention to the road. If the system detects that the driver is distracted or drowsy, it can issue alerts or take precautionary actions, such as reducing the vehicle’s speed or even safely pulling over added Chakraborty. "We are dedicated to pushing the boundaries of what conversational AI can achieve in automotive safety. By incorporating these technologies, we not only meet but also exceed safety standards, ensuring our vehicles are safer, smarter, and more connected. We are proud to be at the forefront of this technological evolution, delivering solutions that improve safety outcomes and driving experiences for all road users,” Barman said.

This feature was first published in Autocar Professional's June 1, 2024 issue.

Infineon supports E/E architecture transformation with new AURIX™ microcontroller family

Autocar Professional Bureau — Mon, 10 Jun 2024 13:57:01

With the shift towards electrified and autonomous vehicles, there is an increasing transformation of the vehicle’s electric/electronic (E/E) architecture towards zonal controllers that offer centralised computing to control various functions of a car, global microelectronics and semiconductor systems giant Infineon Technologies has introduced its latest AURIX™ TC4x family of microcontrollers.

With the latest introduction, Infineon is geared to meet the automotive industry’s requirements of zonal architectures, with its advanced solution that offers power distribution, diagnosis and monitoring, gateway control, as well as power actuation – the key attributes of a zonal architecture.

The company’s transition from the earlier AURIX™ TC3x to TC4x family brings about capabilities such as performance enhancement, and versatility, offering rich connectivity features, as well as enhanced safety and security by conforming to the functional safety requirements such as ASIL-D functional safety, and symmetric and asymmetric cryptography.

While it has been a leader with its AURIX™ TC3x family of microcontrollers that runs at up to 6 cores, operating at 300MHz, and 16MB NVM (non-volatile memory), the TC4x, on the other hand, has a new 500MHz TriCore™ v1.8 setup, with up to 6/6 lockstep cores, and up to 24MB NVM. It also has data routing engines for CAN and Ethernet communication, as well as improved timers.

The new chip offers three hardware accelerators – CAN Routing Engine (CRE), Data Routing Engine (DRE), and Cyber Security Satellite (CSS). While the TC3 had a hardware security module, with the TC4x, the company has adopted a slightly different concept of cybersecurity real-time module for performance increase.

As per Infineon, the upgrade offers up to 15 times CSRM performance compared to the previous module, along with more stringent security standards such as the ISO 21434. This solves performance bottlenecks, and is post-quantum ready as well. The company says with the TC4x, it is future proofing with respect to cybersecurity standards.

With its new offering, Infineon is laying the ground for electric, intelligent, and connected cars of the future, and is strengthening its position as the most-preferred solutions provider for the automotive industry globally. The TC4x series fosters the trends of e-mobility, advanced driver assistance systems (ADAS), automotive electric/electronic architectures, and affordable artificial intelligence (AI) applications.

The company says that the Infineon AURIX™ platform has become the first-choice automotive architecture for high-growth and safety-critical applications such as powertrain, safety, assisted and autonomous driving as well as domain or zone control. Given the growing vehicle complexity and the enablement of AI implementations, significant focus has been placed on the AURIX™ TC4x ecosystem to ensure fast time-to-market and ease-of-use.

With its scalable family concept, the AURIX™ is a key ingredient for dependable electronics and software-based applications. Consequently, demand and revenues for the AURIX™ microcontrollers are expected to grow strongly in the coming years. For instance, as per Infineon, a leading European car manufacturer is slated to have about 35 AURIX™ MCUs on-board a new car scheduled to be produced around the middle of this decade.

The new AURIX™ TC4x family supports both eMobility and the advancement of automated driving. It offers enhanced connectivity as well as advanced safety and security. Additionally, as per Infineon, new SOTA (Software Over the Air) features will help fulfil the demands of car manufacturers for fast and secure car-to-cloud connection, enabling updates in the field, plus diagnosis and analysis during vehicle usage.

More information on AURIX™ TC4x can be obtained from the product brochure.

Abilities India to drive revenue growth with patented technologies in the new fiscal

Autocar Professional Bureau — Fri, 07 Jun 2024 16:10:42

Abilities India Pistons & Rings Ltd. (Abilities India), a prominent manufacturer in the automotive industry specializing in Pistons, Piston Rings, Gravity Casting, Pressure Die Casting, and Coatings, proudly announces the grant of its second patent for its innovative High-Pressure Die Casting (HPDC) process. This cutting-edge technology is set to reduce the weight of pistons for two- and three-wheelers by 10-15%, leading to an annual aluminium saving of 307.5 tons based on the current production of 20 million vehicles. By 2030, this saving is expected to increase to 461.25 tons annually, with corresponding carbon emission reductions of 920 tons per annum currently and 1380 tons per annum by 2030.

Abilities India plans to leverage this patented technology both domestically and internationally while also developing critical components to support the self-reliance goals of major Indian Original Equipment Manufacturers (OEMs).

The company reported a notable revenue of Rs 128 crore in FY24 and is set for substantial growth driven by technological advancements. It aims to achieve a top line of approximately Rs 225 crores by FY 2026 and increase its EBITDA from 14% in FY 2024 to around 16% by FY 2026. To support this growth trajectory, Abilities India will double its R&D team size and increase R&D fund allocation to 3% of revenue. The current manufacturing facility, covering 5 acres with a built-up area of 14,153 square meters, will be expanded by an additional 3000 square meters in FY25/26 with an investment of Rs 20 crores, adding to the Rs 17 crores invested in FY24.

Traditionally, pistons for gasoline and diesel engines are manufactured using the Gravity Die Casting (GDC) process, which is optimized for mass production but limited by thicker wall thicknesses and higher machining allowances. In contrast, Abilities India's HPDC process revolutionizes piston manufacturing by using high pressure to shape molten metal within a mould, allowing for intricate contours and precise geometry with minimal machining. This innovation is applicable to various piston types and represents a significant advancement in engine component technology, meeting stringent emission regulations for both 2-stroke and 4-stroke engines. The HPDC process addresses the automotive industry's evolving needs for lightweight, high-performance components and tightening emission standards.

Sunil Arora, Chairman and MD, Abilities India Pistons & Rings Ltd. said, "At Abilities India, we are dedicated to pioneering research and technological advancements within the auto components industry. Our second patent underscores our unwavering commitment to innovation and sustainability in automotive manufacturing. With the development of this cutting-edge manufacturing process, we are improving engine performance and actively reducing emissions, thus shaping the future of automotive technology. This milestone reinforces our position as leaders in sustainable and efficient solutions for the global mobility domain."

Tushar Arora, Jt. MD & CEO, Abilities India Pistons & Rings Ltd. commented, "Our newly patented High-Pressure die-casting process is a game-changer for the automotive industry. By reducing piston weight, we are enhancing fuel efficiency and engine performance while also cutting down on material usage and carbon emissions. We are excited about the transformative potential of this technology."

Packing light: Lightweighting car batteries

Autocar Professional Bureau — Thu, 06 Jun 2024 17:25:18

As the electric vehicle (EV) revolution gains momentum in India, battery manufacturers are faced with the critical challenge of reducing the weight of their batteries to increase energy density, extend range, and lower costs. Indian original equipment manufacturers (OEMs) and independent battery makers are rising to this challenge, embracing innovative materials and technologies to create lighter, high-performance batteries.

The importance of battery lightweighting cannot be overstated. As R&D executives and industry CEOs recently discussed at the Autocar Professional Vehicle Lightweighting Conference, battery packs currently occupy nearly 50-60% of a vehicle's space and contribute even more to the vehicle’s overall weight, making them 20–30% heavier compared to conventional vehicles. The common goal is to produce lightweight, high-performance batteries to address this issue. Battery makers are following multiple strategies to address the issue of weight. First, many of them are trying to change the chemical composition of the batteries, trying to introduce materials that have a greater power-to-weight ratio.

A second method being tried out is around the battery pack itself, with OEMs trying lighter components to fix the battery in place, instead of the traditional metal enclosures, clamps, and so on. Finally, they are also trying to address the problem of battery size by addressing the underlying concern of range, by introducing swappable batteries.

Innovating with battery chemistries

The first, and possibly the most obvious method, is to try to innovate around the chemistry of the battery to come up with more power-efficient technologies. A case in point is the partnership between India’s Omega Seiki Mobility with Bengaluru-based EV battery manufacturer Exponent Energy to build high-performance battery packs. This, the Indian company says, has enabled their electric three-wheeler OSM 'Stream City Qik' passenger vehicle to achieve a range of close to 126 kilometers on a much smaller 8.8 kWh battery pack compared to its peers.

Chairman and Founder Uday Narang, is aiming for even greater efficiency in the future.

"Our future batteries will be designed to increase the specific energy of the battery pack by about 50% while reducing production costs by 30%, which is our long-term target for future models. We are aiming to develop future batteries that are about 40% lighter, resulting in increased range and smaller battery pack size," he said.

Gurugram-based Batx Energies is adopting a different strategy — that of eliminating cobalt and nickel from the batteries. These cells, known as LFP batteries, are expected to have higher energy density. "We are looking to develop high-capacity anode materials like silicon and advanced cathode materials such as high-nickel compositions, innovative electrolytes, including solid-state and gel-based variants, to improve safety and energy density," said Vikrant Singh, Co-founder and Chief Technology Officer of Batx Energies.

Meanwhile, others claim to have made great strides on the LFP front, including Bengaluru-based Oben EV. The company’s flagship product — Oben Rorr electric motorcycle — has a 4.4 kWh LFP battery that delivers a claimed range of 180+ km for their mass market premium electric bike. The company is working on advanced versions of smaller LFP batteries which will have a high energy density, meaning they can store a large amount of energy in a relatively small space, said Madhumita Agrawal, CEO and Founder at Oben.

Randheer Singh, CEO and Director of ForeSee Advisors and a former Director of Electric Mobility at the Government of India's NITI Aayog, is advising one of India's major conglomerates on its transition to electric mobility for its upcoming battery gigafactory in North East India.

Singh says, "Several EV OEM and battery makers are in the advanced stages of introducing solid-state batteries with two or three times higher energy density than lithium-ion batteries while being 30-40% lighter."

A 'weighty' issue

Besides experimenting with newer materials, battery makers and OEMs are also trying to shave off some extra weight by coming up with alternative housing for the battery, or even getting rid of it altogether.

According to Singh, some of the battery vendors are attempting to include structural components within battery packs, potentially leading to savings of up to 20 kg per vehicle.

Delhi-based Okaya Power Group, which entered the EV space in 2020 with Okaya Electric two-wheelers, is trying out various materials for its battery enclosures. “We are looking at polymer enclosures that will support electromagnetic interference (EMI) shielding and offer the highest fire protection while fulfilling the core objective of getting the most mileage from a single charge," said Okaya Electric's Director, Anshul Gupta.

Battery enclosures traditionally made from aluminium are now transitioning towards lighter composite plastics, as seen in models like BMW's iX and General Motors' Chevrolet Bolt EV.

Thanigesh Arumugam Parthsarathi, Research Analyst Mobility at Frost & Sullivan, pointed out that Tesla's 4680 battery and BYD's Blade Battery are driving advancements in lightweighting and offering superior sealing capabilities and flame-retardant properties.

Even as some players are trying to come up with lower weight enclosures for the batteries, others are considering a more drastic step — totally eliminating metallic enclosures altogether. This battery technology, according to Duraibabu Sreenivasan, Regional SBU Head — IMEA AMC, and Gurmeet Kaur, Country Head, Henkel Adhesives Technologies India, shows a shift first from "Battery Module to Pack" to "Cell to Pack" and then "Cell to Chassis." Some OEMs have already made EVs with cells woven into composite bonded panels while others have successfully contributed to the industry's lightweighting targets by using say, nominal 2.2 pounds (~998 grams) of adhesives instead of heavier rivets and welds, thereby helping reducing a vehicle's overall weight by 55 pounds (-25 kgs).

Doing away with big batteries

It is not just the chemistry of the cell and the structure of the enclosures that companies are tinkering with, to get rid of excess weight. Some are attacking the problem from a very different angle. Instead of trying to make batteries lighter, they are trying to eliminate the need for huge batteries altogether. This is being sought to be done by making it as simple to swap a depleted battery. The flip side is that most of the current EVs (especially 4-wheelers) have fixed batteries that cannot be detached from the vehicle.

'Charging' forward

India's Battery Production Linked Incentive (PLI) initiative aims to accelerate battery lightweighting as new industry players, including ACME Cleantech Solutions, Amara Raja Advanced Cell Technologies, Anvi Power Industries, JSW Neo Energy, Lucas TVS, and Waaree Energies, have bid for incentives totaling Rs 3,620 crore to expand battery capacity by 10 Gigawatt hours.

Additionally, Ola Cell Technologies, Rajesh Exports, and Reliance New Energy Battery Storage have been awarded 30 GWh of bandwidth will focus on lightweighting. Says Randheer Singh, as government has tapered the subsidies, EV makers will automaticlaly move towards higher energy density and lower weight battery packs.

Mattter Group's Mohal Lalbhai says that the Government of India's Battery PLI scheme will help accelerate the development of lightweighting with the entry of newer players experimenting with new cell chemistries, manufacturing indigenous cells, and manufacturing facilities that will provide battery manufacturers with an end-to-end supply chain, as the majority of cells are currently imported from other Asian countries. Singh also emphasised the implementation of AIS 156 Part 2, which has seen the emergence of connected batteries with RFID tags and is set to prioritise lightweighting while adhering to aspects such as protecting battery packs from overcharging and thermal runaway, ensuring environmental resilience, mechanical integrity, ageing, and performance under a variety of conditions.

This feature was first published in Autocar Professional's June 1, 2024 issue.

Lightweighting: a key engineering mantra

Autocar Professional Bureau — Thu, 06 Jun 2024 17:02:49

As the automotive sector undergoes a transformative shift towards electric and hybrid vehicles, reducing vehicle weight has become paramount for optimising energy consumption and extending battery range. Moreover, OEMs are also pushing the envelope to stretch every ounce of the costly fuel when it comes to enhancing the efficiency of conventional ICE vehicles.

Optimising vehicle weight is one mantra for sustainability, and lightweighting has emerged as a crucial trend in the automotive industry due to its profound impact on various aspects of vehicle performance, efficiency, and sustainability.

On May 23 and 24, Autocar Professional hosted its annual virtual seminar — Vehicle Lightweighting Conference — that centred its discussions on the prevailing global trends in automotive lightweighting, and explored how sustainability-driven regulatory actions are influencing lightweighting strategies of automakers, as well as the industry’s collaborative approach in addressing the myriad challenges.

The virtual event brought together industry experts of the likes of CV Raman, EC Member and Former CTO, Maruti Suzuki India; Anand Kulkarni, Head of EV Programmes, Tata Passenger Electric Mobility; Glyn Jones, MD, Gestamp India, and Ritesh Agrawal, SVP and Head – Sourcing, Auto Sector, Mahindra & Mahindra, among others. The industry leaders discussed upon the various aspects of lightweighting, including its key drivers, cost implications, design limitations, and supply chain challenges, among others.

On its first day, the event was kicked off by Maruti Suzuki India’s CV Raman, who showcased a detailed presentation, outlining the key lightweighting drivers, of which, tightening emission standards such as the Corporate Average Fuel Efficiency (CAFE), as well as stringent safety norms – of the likes of Bharat New Car Assessment Programme (BNCAP) – were highlighted as the two key regulatory drivers of lightweighting.

According to Raman, there have been a slew of regulatory changes both on the safety, and emissions front, in the last seven years, which has led to an adverse effect on the customers’ affordability of passenger vehicles due to their rising prices, thereby depressing the demand at the lower end. “While the CAFE-II norms kicked off in India in CY22, the next round is slated for CY27, which will make emission targets even more stringent – to 95g/km of CO2. Simultaneously, the safety regulations are also becoming more stringent, with the notification of the BNCAP that was launched in October 2023. All of this is increasing the vehicle cost, weight, development time, and its complexity,” he remarked.

Lightweighting enabling sustainability

Raman mentioned that sustainability needs to be looked at not just from an efficiency improvement perspective, but from an overall greenhouse gas (GHG) reduction standpoint, and therefore, there need to be interventions at both product, and process levels, to reduce the overall GHG.

“It is here at the product level that lightweighting, by virtue of material technology – with the use of environment-friendly, and lightweight materials such as advanced high-strength steel – can significantly contribute to more sustainable vehicles,” he pointed out. Raman cited the example of the Maruti Suzuki Swift hatchback which has seen a significant weight reduction of nearly 100kg over its four generations, starting 2005. “Since the launch of the Swift in 2005, we have changed the powertrain and platform twice, and with the new Suzuki ‘Heartect’ platform underpinnings, the new fourth-generation Swift is the lightest yet,” he mentioned, while adding that the use of advanced high-strength steel (AHSS) and ultra-high-strength steel (UHSS) is enabling carmakers to usher in an era of lightweight, yet robust vehicles that are high on efficiency. The new Swift, launched in India on May 9, sees an increased implementation of UHSS from 6% to 17%, while AHSS has grown from 2% to 4% in the latest iteration. “We have enhanced the usage of these materials in structural parts that have significantly higher minimum tensile strength requirements."

The keynote was followed by a panel session discussing the key drivers and challenges of vehicle lightweighting, and according to Anand Kulkarni, Chief Products Officer, Head of HV Programs and Customer Service, Tata Passenger Electric Mobility, “OEMs have been eyeing switching to lighter and stronger materials as they vie for more efficient vehicles, but have to compromise due to cost and supply chain challenges. This has become a tough balancing act which extends beyond steel to aluminium, and composites, among other materials. The most plausible solution must be taken by factoring in all the interlinked parameters," Kulkarni added.

Optimising weight in EVs

Kulkarni also touched upon the critical aspect of optimising weight of the current-carrying wiring harness in an EV. He explained that high-voltage systems allow for the reduction in the size of the conducting wires as they then need to transmit lesser current to generate the same output power at the motor.

“Every doubling of voltage can therefore reduce the amount of copper (conductor) required by up to 45 %, thereby contributing to weight reduction. That is why EVs are increasingly moving to high-voltage systems of the likes of 350V, and 800V systems among other architectures. Moreover, avenues of flat wiring harnesses are also currently being evaluated, alongside other areas, bases their integration and cost constraints,” Kulkarni said.

According to Ritesh Agrawal, SVP and Head — Sourcing, Auto Sector, Mahindra & Mahindra, “Despite the lack of an engine, EVs come with an added baggage of the battery pack which tends to increase the weight by up to 350kg. It is imperative to counter it by lightweighting techniques to enhance the range per charge.”

An SUV specialist, Mahindra & Mahindra (M&M) has achieved weight reduction to the tune of 200 kg to meet the current CAFE requirements by implementing a mix of materials such as aluminium, and high-tensile steel.

However, Agrawal raised the challenges associated with lightweighting, and said, “While over 175 grades of steel are now available in India, advanced materials such as UHSS are not produced in the country due to economies of scale. Since the supply chain is largely dependent on countries outside of India, there is a huge risk to it. Uncertain volumes often result in either excess or shortage of materials, leading to inventory costs, and obsolescence risks.”

To address these challenges, M&M employs technologies like hot stamping of sheet metal panels which offers higher structural strength at lower costs, as well as implementing honeycomb structures for weight and cost reduction. “Additionally, advancement in engine technology such as integrating the engine oil cooler, allows for cost reduction throughparts integration,” Agrawal pointed out. Emphasising on certain aspects of design can also contribute to lightweighting, and with the concept of digital twins, there is an opportunity for companies to reduce cost while implementing lightweighting materials into a design,” said, Srikumar Srinivasan, Delivery Head – Automotive, Tata Elxsi.

“While we are a bit far off as far as proportions are concerned, several aspects of lightweighting are creeping into the sector, which is a welcome development,” he said.

In an exclusive one-on-one interaction session, Sushil Mane, Senior Director, Technology and Customer Support, and Simulation and Design Support, Altair, said, “The digital tools and strategies available today provide engineers with extensive opportunities to reduce structural weight throughout the design process.”

“The integration of optimisation techniques in the early stages of the design process offers engineers a significant advantage in creating lightweight structures,” he added.

Advanced materials and lightweighting technologies

The second day of the virtual conference focused on the various materials, design, and process technologies available to induce lightweighting in vehicle platforms, and the product. Speaking in a panel discussion, Dr K Subramanian, SVP, Product Development, Ashok Leyland, said, “Lightweighting is not just about the structure, but also about rethinking whether some of the legacy parts are necessary. Therefore, it is about innovatively eliminating what we do not need.”

“Lightweighting takes on a new level of significance as we move to new propulsion systems such as EVs and hydrogen, which require vehicles to be more efficient,” he added. From a material standpoint, Dr Subramanian revealed that commercial vehicle major Ashok Leyland is exploring several options, including advanced steel, and aluminium, in select areas of the vehicle. The company is also looking at composites, as well as introducing plastics into crash-absorbing systems because certain classes of materials offer better crash-force absorption characteristics.

Although carmakers use steel to make the body shell and various components, the shift to aluminium is also happening.

“We are trying to see in which parts composite materials make sense. I think born-electric vehicles is where we need to bring composites as it is proving difficult for one-to-one replacement of existing parts,” he pointed out.

Structural lightweighting in vehicles

As a global leader in lightweighting structures, Gestamp has observed a significant and rapid adoption of weight reduction technologies in India. According to Glyn Jones, MD, Gestamp India, “The use of hot-stamping materials has increased by about 40 % compared to 2016. However, the current market situations in the country pose challenges, particularly due to the insufficient localisation content, impacting both Gestamp and its clients.” “Having said that, the adoption of advanced steel and stamping technologies in India has seen a paradigm shift. At Gestamp, we have leveraged advanced tools and technologies, including Computer-Aided Analysis (CAA) data and G-lab models to enhance our capabilities,” Jones said. He further highlighted a new aspect of the lightweighting process — giga-casting — which while offers vehicle weight optimisation by stamping the entire chassis as a single member, remain problematic in terms of the environmental impact because of the currentneed to import the raw materials to the country.

According to Rahul Nikhanj, Head, Projects and Production Technology, Asahi India Glass (AIS), “When it comes to vehicle lightweighting, glass is usually not the first thing that comes to mind. However, it occupies more than 30 % of the vehicular space. While vehicles have traditionally been adding about 50kg weight owing to the glasses, with modern features such as sunroofs, the glass weight in the vehicle has increased to up to 70kg. We can offer up to 11-14 % weight reduction through lightweighting techniques in glass. While the thickness of the side window glasses has reduced from 3.2mm to 2.8mm, we are now seeing the trend move towards the industry adopting even 2.5mm to 2.6mm of the side tempered glasses.” Nikhanj explained that despite the reduction in the thickness, there is about 11 % enhancement in weight reduction, without compromising on the strength of the glass.

As per IV Rao, Former Engineering Head, Maruti Suzuki India, and Distinguished Fellow, Transport and Urban Governance, TERI, “It is important to optimise all parameters to get the best out of a vehicle’s configuration. Innovative engineering like integration of parts, and usage of lightweight materials helps in reducing vehicle weight.”

Design critical for lightweighting

Talking specifically about the Indian market, Rao said that India is a price-sensitive market, and automakers must configure vehicles in a way that meets the price equation. Some of the commonly-adopted engineering methodologies at Suzuki included combining various parts into a single system, as well as removing fasteners in favour of joining techniques like spot welding.John Johnston, Chief Engineer, Body Structures, Tata Technologies, said that the importance of lightweighting has increased in the last 20-25 years, and has particularly reached a new level with the advent of electric vehicles. “While the philosophy of reimagining the entire vehicle with the advent of EVs gives a huge opportunity for lightweighting, the challenge is to do lightweighting in low-cost vehicles,” he said, while adding that the industry’s approach has fundamentally changed, wherein more lightweighting-related topics are being taken up at the conceptualisation stage of the project itself. “It is all in the initial planning. We find that vehicle packaging and dimensions can be whetted at the conception stage, so getting the targets right in the beginning helps save cost and time,” said Johnston.

Steel works lightweighting wonders

In an exclusive fireside conversation being the last session of the event, Kinshuk Roy, EVP — Application Engineering and New Business Development, JSW Steel, said that steel is a wonder material from a lightweighting perspective. Sharing his thoughts, Roy said that with the advancements in advanced-high-strength, and ultra-high-strength steel, vehicle manufacturers can achieve significant weight savings without compromising structural integrity — a crucial factor for enhancing driving dynamics, and improving the vehicle efficiency. Lightweight vehicle structures are essential not only for improving the fuel economy for ICE automobiles but also increasing the driving range of EVs by offsetting the weight of power systems like batteries, he explained. According to Roy, “Beyond the use phase, factors such as material production emissions and end-of-life recyclability play a pivotal role in determining the overall environmental footprint. Initiatives like the government's vehicle scrapping policy signal a step towards enhancing recyclability and sustainability within the ecosystem.”

Processes like hot stamping and hydroforming complement the use of high-strength steel, enabling the fabrication of complex components with improved efficiency.

While the automotive industry grapples with the rapid pace of technological advancements, Roy underscores the need for collaboration and innovation. He emphasised that processes like hot stamping and hydroforming complement the use of high-strength steel, enabling the fabrication of complex components with improved efficiency. “Moreover, multi-material design approaches involving magnesium and aluminium offer further optimisation opportunities, albeit with unique challenges.” The two-day seminar brought about thought exchange among industry experts on the nuances of lightweighting, including weight optimisation design philosophies, material trends, and process technologies such as giga-castings, which are emerging as modern-day solutions to slash vehicle weight and offer safer, and more sustainable products.

This feature was first published in Autocar Professional's June 1, 2024 issue.

Vehicle lightweighting: The road to sustainability

Autocar Professional Bureau — Thu, 06 Jun 2024 16:46:17

In a world beset by climate change and multiple challenges, the automotive industry the world over is undergoing a radical transformation driven as it is by the twin imperatives of reducing its environmental impact and meeting stringent emissions and safety standards. While companies have been evaluating and adopting various measures to produce more efficient vehicles, lightweighting has emerged as a key methodology to slash vehicle weight.

The engineering mantra not only enhances fuel efficiency, particularly important in the era of Corporate Average Fuel Efficiency or CAFE norms that govern several global markets, including India, but it also directly contributes to reducing CO2 emissions. What’s more, it also enhances vehicle safety with the use of various advanced materials such as high-tensile and ultra-high-strength steel, that are lighter yet stronger.

EVs push the lightweighting envelope

As per industry studies, a 10 % reduction in a vehicle’s weight can result in 6-8% fuel economy improvement, as by the laws of physics, lighter vehicles require lesser energy to accelerate and maintain speed and therefore consume less energy. As automakers strive to comply with the ever-tightening CO2 emission targets, this drop in fuel usage directly correlates with a reduction in the vehicle’s greenhouse gas emissions, thereby making lightweighting a vital strategy to conform to the latest emission standards, as well as inch closer to the overarching goal of sustainability.

Furthermore, as the mobility ecosystem shifts towards zero-tailpipe-emission vehicles or EVs, the lightweighting methodology gains even more importance as range optimisation is amongst the biggest problems for engineers to solve in the EV domain. A lighter EV offers more out of every charge and, therefore, higher range is a key product USP to determine the market penetration of this emerging drivetrain technology in the automotive sector.

By reducing EV weight through optimised use of innovative light but strong materials like high-tensile, and ultra-high-tensile strength steel, and composites, manufacturers can either extend the range of their vehicles or even reduce the size and cost of the battery pack, required to achieve a certain range. A smaller battery makes EVs more affordable and practical, further accelerating the shift from internal combustion engine (ICE) vehicles to electric mobility.

In addition to environmental benefits, lightweighting also enhances the vehicle’s driving dynamics and safety as lighter vehicles typically exhibit better handling and acceleration due to the lower centre of gravity, thereby improving the overall driving experience for the consumer. The usage of certain advanced materials such as high-tensile- and ultra-high-tensile steel helps reduce vehicle weight, while maintaining or improving its crash performance.

Key challenges

Regulatory compliances around the world have set ambitious targets for fuel economy and emissions. For instance, while the European Union has mandated a fleet-wide average of 95 grams of CO2 per kilometre from 2022 to 2024 for the passenger vehicle segment, in India too, the CAFE-III norms that kick in from CY2027 mandate a similar emissions requirement.

According to CV Raman, Executive Committee Member, Maruti Suzuki India, “These stringent regulations mean that both the development time as well as complexity inside vehicles are increasing. Having said that, we must look at the problem not just from an efficiency perspective, but from a broader greenhouse gas (GHG) emissions perspective.”

Moreover, in comparison with compared with Europe, India’s GHG emissions from the transportation sector are significantly lower. While the transportation sector contributes 29% of the GHG emissions in Europe, in India it only stands at 13%. Furthermore, passenger vehicles in India only contribute 2.2% to the nation’s GHG emissions, while it is over 15% in Europe. “Therefore, for our unique challenges, we require India-specific solutions to solve the GHG emissions problem,” said Raman. It is here that to achieve the significant weight reduction required for sustainability goals, the automotive industry employs a range of strategies to slash the kilos and shed grams from every possible area of a vehicle by leveraging advanced materials, innovative design approaches, and cutting-edge manufacturing processes.

However, this rapid shift to such sustainable materials and products is also leading to a significant increase in the final cost of the vehicle, thereby making it a difficult task for them to be sold, particularly when they are targeted at price-sensitive buyers. According to Ritesh Agrawal, SVP and Head – Sourcing, Auto Sector, Mahindra & Mahindra, “Beyond a point, particularly when it is guided by stringent norms, one must bear the cost of lightweighting. It is a well-accepted fact that for every kilogram of weight reduction in a vehicle, there is a cost increase of up to five dollars.”

Optimising the supply chain is also a key concern when dealing with some innovative and advanced materials that might not necessarily be locally available in a geography. For example, ultra-high-strength steel (UHSS) which offers superior strength compared to regular steel, is gaining popularity in the automotive industry, but is locally unavailable in India due to the“lack of economies of scale,” as per Agrawal.

Advanced materials, design, lightweighting processes

Selection of materials plays a critical role in lightweighting, and some of the key materials widely accepted in the automotive industry include Aluminium, high-strength steel (HSS), ultra-high-strength steel (UHSS), magnesium, and carbon-fibre-reinforced polymers (CFRP), among others. While aluminium is widely used for its high strength-to-weight ratio, it is also increasingly replacing traditional steel in many automotive components such as engine blocks, crankshafts, and heads. However, there is a cost attached to this since aluminium is priced higher than steel. On the other hand, with a density about one-fourth that of steel, magnesium is one of the lightest structural metals available, and is also being used in applications such as transmission cases and steering wheels.

Carbon fibre-reinforced polymer composites, which offer dual benefits of very high strength and lightweight, are ideal for high-performance vehicles but are also expensive. Although traditionally CFRP has been used in high-end sports cars, advances in manufacturing techniques are making it more accessible for mainstream models as well. Despite material technology being a strong pillar of the lightweighting exercise, it is not complete without innovative design, which is also crucial in reducing vehicle weight. As a result, topology optimisation, which leverages computer algorithms to optimise the material layout within a given design space, helps improve the structural efficiency of a part, or monocoque, thus, reducing weight.

Moreover, multi-material design that deploys the strategy of combining different materials in a single component to leverage the strengths of each material also helps minimise weight. Furthermore, by integrating multiple functions of a vehicle into a single component, OEMs can reduce the total number of parts and, consequently, weight. For instance, several independent ECUs are now being replaced by a central ECU or a zonal architecture, particularly with the advancing E&E architectures in electric vehicles.

Lastly, advanced manufacturing processes are also essential for turning lightweight designs into reality. Some of these commonly adopted processes include hot stamping which involves heating steel blanks before stamping them into complex shapes. This process allows for the use of UHSS that are difficult to form at room temperature, thereby resulting in lighter, yet stronger components.

A recent entry into the lightweighting world is that of additive manufacturing or 3D printing, which enables the creation of highly optimised, complex shapes that would otherwise be impossible to produce with traditional manufacturing. Furthermore, hydroforming too, is an industrywide process that uses high-pressure hydraulic fluid to form metal parts into lightweight, and strong structures, often used in automotive chassis and body components. All in all, lightweighting — which is now a megatrend in the global automotive industry — is a critical strategy in OEM and component manufacturers’ quest to meet their sustainability targets. The adoption of advanced materials, innovative design approaches, as well as cutting-edge manufacturing processes are now facilitating significant weight reduction across the industry. This engineering methodology will continue to evolve in the coming years and continue to address the industry’s focus on reducing vehicle weight towards meeting the broader goal of mitigating climate change.

This feature was first published in Autocar Professional's June 1, 2024 issue.

Metal Forming Expo reaffirms position as premier exhibition for sheet metal working

Autocar Professional Bureau — Thu, 06 Jun 2024 16:07:13

The recently concluded Metal Forming Expo, held at the Bombay Exhibition Centre in Goregaon East, Mumbai, from May 16-18, 2024, has once again cemented its status as India's leading exhibition on sheet metal working, metal forming, laser cutting, and manufacturing technologies. The event featured 106 exhibitors, 7,409 attendees, and 941 VIPs from across India.

Held concurrently with the India Welding Technology Show, the second edition of the Metal Forming Expo provided a comprehensive platform for manufacturing professionals to source machinery, connect with industry peers, and collaborate with stakeholders. This dynamic event fostered numerous networking opportunities, strategic partnerships, and business growth. Additionally, it served as a valuable marketplace for small and medium enterprises (SMEs) to gain visibility, attract potential customers, and explore export opportunities.

Chaitali Davangeri, Director of Future Market Events, expressed her delight at the event's success: "We are thrilled with the response received at the Metal Forming Expo in Mumbai. The enthusiasm and participation we witnessed were remarkable, showcasing the unwavering commitment and innovation within the metal forming and sheet metal working sector. We look forward to creating future editions that drive innovation, expand business networks, and contribute to the overall growth and modernization of India's manufacturing industry."

Machinery Galore at the Metal Forming Expo

The expo featured renowned players like A Innovative International, ADK Engineering, BDS Machine, Bodor Laser, Energy Mission, Fledon, GVK Metal Forms, Hindustan Hydraulics, KMT Water Jet, Laser Technologies, Max Photonics, MB Jigson Hydraulics, Mehta CadCam, Messer Cutting, MS Cut, Purvaj, Sahajanand Laser Technology, and Suresh Indu Laser, among others. They showcased the latest machinery and technologies in sheet metal working, laser cutting, bending and forming, precision engineering, punching and stamping, CNC machining, welding, joining, surface treatment, CAM/CAD software, automation, and robotics. These innovations cater to various sectors including manufacturing, engineering, automotive, and heavy industries.

Autocar Professional’s June 1, 2024, issue is out!

Autocar Professional Bureau — Tue, 04 Jun 2024 14:38:08

Top story

We deep dive into the world of automotive lightweighting and why has it become a focus area. With stricter regulations on emissions and a global push towards sustainability, automakers are under pressure to increase fuel efficiency to reduce greenhouse gas emissions. For ICE, lighter vehicles require less energy to move, leading to improved fuel efficiency. In the case of electric vehicles (EVs), reducing weight directly translates to increased range.

Lightweighting encourages the development of advanced materials such as carbon fibre, aluminium, and high-strength steel. While lightweight materials may initially be more expensive, the long-term benefits often outweigh the initial investment. We also engaged with some of the industry’s biggest R&D professionals to understand the progress and scope for further developments in this aspect.

Exclusive

We have an exclusive interview in this issue with Leapmotor’s ED – Mr Cao on the company’s views on the Indian market and how Leapmotor intends to build its presence there.

Spotlight

How an Indian tech company is using AI to drive voice recognition systems in automobiles.

Special report

The rise of the armoured car business in India.

Companywatch

A recap of the year for Tata Motors and Mahindra & Mahindra from an earnings standpoint and discussing the way ahead for the homegrown automotive majors.

Tata Motors ramps up R&D spending by 45% in FY24, focuses on EVs and hydrogen tech

Autocar Professional Bureau — Fri, 31 May 2024 14:33:41

Tata Motors Ltd. has amped up its research and development (R&D) spending by 45.1% to Rs 29,398 crore in the fiscal year 2024 (FY24) as compared to Rs 20,265 crore in FY23, according to the company's annual report. This marks a significant increase from Rs 15,339 crore spent in FY22.

The surge in R&D expenditure reflects Tata Motors' strategic focus on developing a future-proof product portfolio. The company is prioritising the expansion of its electric vehicle offerings, flex-fuel powertrains, fuel cell EVs, and hydrogen internal combustion engines (ICE). These efforts are accompanied by investments in infrastructure to support these new technologies.

Beyond core vehicle development, Tata Motors' R&D efforts encompass several other areas. The company is working on wireless battery management systems, high-voltage wireless charging, and advanced vehicle control strategies to maximise EV efficiency. Additionally, R&D is underway for high-performance electric trucks for the international market as well as battery electric vehicles (BEVs) for intermediate, light, medium and heavy-duty commercial vehicles across various voltage architectures.

Safety technology development remains another key area of investment. Tata Motors is incorporating advanced driver-assistance systems (ADAS), driver health monitoring systems, and connected vehicle platforms into its vehicles.

"The Company will continue its endeavour in R&D space to develop technologies, skill set, which will help the Company meet future product portfolio
requirements. This would be leveraged through multiple avenues like live projects, development of Proof of Concepts (‘PoCs’), new infrastructure/facility creation,
curated training programs for relevant areas & new methods/processes" the report notes.

Tata Motors' annual report further emphasises its commitment to sustainable mobility solutions. The company recently unveiled two state-of-the-art R&D facilities, including an engine test cell specifically designed for developing hydrogen ICEs and the supporting infrastructure for hydrogen storage and dispensing for fuel cell technology, in which Tata Motors has invested for several years.

Tata Motors' R&D efforts are also yielding results on the intellectual property front. In FY24, the company's India business was granted 333 patents and filed 145 design applications. Additionally, Jaguar Land Rover secured 337 patents and 279 design applications for its work on various alternative fuel technologies, ranging from battery electric to CNG, LNG, hydrogen fuel cell, and hydrogen-based ICE technologies.

Bosch expects 10-15% of trucks sold in India to be H2ICE by 2030

Autocar Professional Bureau — Tue, 28 May 2024 19:11:21

As the shift towards cleaner alternatives gains momentum, hydrogen internal combustion engine vehicles may see a penetration of 10-15 percent in the Indian truck market by the end of this decade, according to a global auto component major Bosch.

“We expect between 10-15 percent of all trucks sold by 2030 to be with hydrogen ICE technology,” Guruprasad Mudlapur, President of the Bosch Group in India and Managing Director, Bosch Limited told investors in a post-earnings conference call.

Hydrogen ICE vehicles are at a nascent stage in India and companies are testing the technology. Commercial vehicle makers are looking at hydrogen-powered ICE trucks for long-haul and heavy-duty segments, considering its potential to provide better total cost of ownership advantage over diesel engines. Last year, Ashok Leyland and Reliance Industries introduced India’s first hydrogen ICE-powered heavy-duty truck.

“Hydrogen ICE is currently undergoing a design maturity phase with most OEMs. We are working with them quite closely. Almost all OEM partners have trucks running within their premises or on the streets. We also have a truck ready and that is undergoing tests,” he noted.

The government of India has a scheme under the National Green Hydrogen Mission to support the development of technologies to use green hydrogen as a fuel in buses, trucks and four-wheelers, based on fuel cell-based propulsion technology or internal combustion engine-based propulsion technology.

Autocar Professional recently reported that the Automotive Research Association of India (ARAI) has received thirteen technical bids for pilot projects for using green hydrogen in the transport sector.

Tata Cummins Green Energy Solutions, a subsidiary of Tata Cummins Pvt Ltd, has also opened a new facility in Jamshedpur to manufacture hydrogen-powered internal combustion engines for medium and heavy commercial vehicles, alongside other low-to-zero emission technologies.

For vehicles powered by hydrogen, Bosch offers fuel injection system, electronic control unit, and products for the storage and supply of hydrogen. Mudlapur noted that the component maturity of the hydrogen ICE technology would take a while but it would not be a bottleneck.

Mahindra to amp up on touchscreens and connectivity, XUV.e8 interior patent reveals

Autocar Professional Bureau — Tue, 28 May 2024 14:08:55

The upcoming Mahindra XUV.e8 will feature a three-screen setup and a new two-spoke steering wheel, as confirmed by the interior design patents that have surfaced online. Pre-production prototypes also showed that the interior shares some similarities with the XUV700. The XUV.e8 will be the first born-electric SUV based on the brand’s INGLO platform when it goes on sale by year-end.

Mahindra XUV.e8: interior patents

The patent reveals that there will be three individual screens housed in a single casing spanning the dashboard’s entire width. It appears like an extension of the XUV700’s dual-screen setup with an additional passenger screen and is flanked by AC vents on either side. All three screens are expected to run on Mahindra’s Adrenox software.

The new two-spoke, flat-bottomed steering wheel appears to have a glass-like finish on the boss and would likely have an illuminated logo, much like the newer Tata SUVs; the steering also sports four toggle switches. Also, the XUV.e8 will carry over some switchgear, such as the HVAC and the centre console controls, from the XUV700. This interior layout could be shared with its coupe-SUV derivative, the XUV.e9.

Mahindra XUV.e8: what else do we know?

Conceptually, the XUV.e8 will be quite similar to the XUV700, sharing a familiar profile and three rows of seats. It is 4,740mm long, 1,900mm wide and 1,760mm high, with a 2,762mm wheelbase, making it 45mm longer, 10mm wider and 5mm taller than the XUV700; its wheelbase will be just 7mm longer than the XUV700’s.

Mahindra previously confirmed that the XUV.e8 will come with an all-wheel-drive system and battery pack of up to 80kWh. Power outputs could be anywhere from 230hp to upwards of 350hp.

The production-spec XUV.e8 is expected to debut in the coming months before it goes on sale by the end of the year. It will face competition from the Harrier EV that’s due sometime in early 2025.

BHP and Rio Tinto collaborate on battery-electric haul truck trials in Pilbara

Autocar Professional Bureau — Mon, 27 May 2024 16:19:56

In an industry first, BHP and Rio Tinto have announced a collaborative effort to test large battery-electric haul truck technology in the Pilbara region of Western Australia. This initiative aims to accelerate the deployment of battery-electric haul trucks, advancing their shared goal of achieving net zero operational greenhouse gas emissions by 2050.

Partnering with leading manufacturers Caterpillar and Komatsu, the trials will involve independent testing of their battery-electric haul trucks, including assessments of battery performance and static and dynamic charging systems under Pilbara conditions. Two CAT 793 haul trucks will be trialed from the second half of 2024, and two Komatsu 930 haul trucks will be tested from 2026 at mine sites in Western Australia’s Pilbara region. Caterpillar and Komatsu will each provide one truck to both BHP and Rio Tinto for these trials. BHP will trial the Caterpillar trucks, while Rio Tinto will trial the Komatsu trucks. The outcomes of the trials will be shared between BHP and Rio Tinto.

The collaboration highlights the companies' dedication to technological innovation and environmental sustainability. The outcomes of the trials will be shared between BHP and Rio Tinto, aiding both in optimising their future deployment strategies for battery-electric haul truck fleets. Ongoing testing, development, and refinement of truck and battery design are anticipated with each manufacturer. This will inform the approach for testing a larger number of haul trucks and the potential deployment of battery-electric haul truck fleets into each company’s operations.

Geraldine Slattery, BHP President Australia, stated “Operational decarbonisation relies on breakthroughs in technology and partnerships like this will help drive our industry forward. We are thrilled to work with Rio Tinto, Caterpillar, and Komatsu on these trials. Replacing diesel as a fuel source requires us to develop a whole new operational ecosystem to surround the fleet. We need to address the way we plan our mines, operate our haulage networks, and consider the additional safety and operational considerations that these changes will bring. This is why trials are so critical to our success as we test and learn how these new technologies could work and integrate into our mines. We’ve already seen a step-change reduction in Scope 1 and 2 operational greenhouse gas emissions through switching some of our supply to renewable electricity, and we are looking to build on that progress through development of battery-electric technology to reduce diesel usage across our operations.”

Simon Trott, Rio Tinto Iron Ore Chief Executive, remarked “This collaboration brings together two leading global miners with two of the world’s biggest manufacturers of haul trucks to work on solving the critical challenge of zero-emissions haulage. “There is no clear path to net zero without zero-emissions haulage, so it’s important that we work together to get there as quickly and efficiently as we can. Testing two types of battery-electric haul trucks in Pilbara conditions will provide better data, and by combining our efforts with BHP we will accelerate learning. “As we work to repower our Pilbara operations with renewable energy, collaborations like this move us closer to solving the shared challenge of decarbonising our operations and meeting our net zero commitments.”

This initiative underscores BHP’s and Rio Tinto’s commitment to sustainability and sets a precedent for industry-wide collaboration in addressing climate change. The trials are a pivotal step towards the broader adoption of battery-electric technology in mining operations, aiming to significantly reduce diesel usage and greenhouse gas emissions.

EV Battery Safety: Optimal battery pack design considerations

Autocar Professional Bureau — Mon, 27 May 2024 14:34:34

Crafting an optimal battery pack design for electric vehicles (EVs) is a multifaceted endeavour that demands meticulous attention to detail, particularly concerning safety standards like the AIS 156 standard upheld by governments worldwide.

These standards serve as the bedrock for establishing critical design parameters, performance criteria, and safety protocols necessary for regulatory approval and seamless integration into electric vehicles.

Central to this intricate process is the selection of the appropriate cell chemistry, a decision deeply intertwined with safety considerations. While prevailing wisdom often categorises lithium-ion chemistries, such as NMC, as more thermally volatile, and others, like LFP and LTO, as safer alternatives, the reality is nuanced.

Cell chemistry matters

The choice of cell chemistry must align with anticipated environmental conditions, steering clear of oversimplified categorisations. For instance, in regions characterised by high ambient temperatures and limited thermal management capabilities, opting for LTO or LFP chemistries may appear prudent. However, with advancements in thermal management technology, NMC cells can also be harnessed effectively. Thus, the selection process hinges upon a comprehensive understanding of the operational environment's temperature profiles.

Once the ideal chemistry is identified, rigorous cell characterisation becomes imperative. This entails subjecting cells to extensive testing under varied temperatures and charging conditions to delineate performance boundaries, particularly concerning thermal runaway – a phenomenon that can have catastrophic consequences if left unchecked. Once these critical thresholds are established, attention pivots towards battery architecture design, with safety emerging as the guiding principle. Crucial considerations encompass cell form factors (such as pouch, prismatic, or cylindrical), cell connections, series-parallel configurations, spacing between cells to optimise thermal dissipation, and the integration of fire suppression systems aimed at containing thermal events, should they occur.

Fire risks and thermal management

Material selection within the battery pack emerges as a pivotal aspect in mitigating fire risks. Incorporating non-flammable components and deploying circuit breakers facilitate the swift isolation of malfunctioning cells, effectively preventing overcharging and the potential for thermal runaway. Furthermore, ensuring the seamless connection between the battery and vehicle electronics is paramount to forestalling potential malfunctions that could precipitate thermal events. Effective thermal management systems stand as indispensable safeguards for maintaining safe operating temperatures within the battery pack. The choice of cooling technology is contingent upon several factors, including voltage requirements, vehicle platform, and available space. Passive cooling methods suffice for low-voltage systems, while more intricate solutions, such as liquid cooling or plate cooling, are favoured for higher voltages. Emerging technologies like immersive cooling, where cells are submerged in a dielectric liquid to facilitate efficient heat dissipation, hold promise in bolstering both safety and performance.

The new trend towards replaceable batteries presents a fresh set of challenges. As humans interact with the battery during replacement procedures, there's an elevated risk of accidents, such as inadvertently dropping the battery, potentially compromising its structural integrity.

Moreover, the act of charging replaceable batteries within a domestic setting, especially in instances of low load capacity and improper wiring, can exert undue stress on the electrical infrastructure, heightening the likelihood of household fires. Consequently, there exists an urgent imperative to redouble efforts towards innovating fixed battery solutions that robustly adhere to stringent safety parameters. Continuous monitoring emerges as a linchpin of battery safety. By harnessing cloud-based monitoring systems to aggregate thermal data from batteries, pre-emptive measures can be swiftly implemented to manage and, if necessary, shut down batteries on the cusp of thermal runaway. The deployment of IoT devices, intricately interconnected with batteries, stands as a proactive measure, enabling the dissemination of early warning signals to users, thus forestalling potential accidents before they take place.

Conclusion

The pursuit of optimal battery pack design for electric vehicles demands a holistic approach, underscored by meticulous attention to cell chemistry, rigorous characterisation, robust battery architecture design, effective thermal management systems, and continuous monitoring mechanisms. By steadfastly addressing these critical areas and spearheading innovations in fixed battery solutions, electric vehicle batteries can confidently emerge as a reliable, sustainable, and, above all, safe power source for the burgeoning transportation sector.

Pankaj Sharma is the Co-Founder at Log9 Materials. Views expressed are of the author.

18,000th Durr robot to paint Audi Q6 e-tron in Ingolstadt

Autocar Professional Bureau — Mon, 27 May 2024 13:53:46

Durr, a leading mechanical and plant engineering company, has produced its 18,000th painting robot, which will be used by Audi in Ingolstadt. This milestone robot, an EcoRP L033i, is equipped with Durr’s latest EcoBell4 atomizer featuring 4-main needle technology, allowing for rapid color changes with minimal paint and rinsing agent losses.

Durr is outfitting a new top coat line for Audi in Ingolstadt to paint the interior and exterior of the new Audi Q6 e-tron series. The milestone robot will be installed in May in the interior paint booth. The six-axis painting robot, equipped with Durr’s latest EcoBell4 atomizer, can complete color changes in just four seconds due to its patented 4-main-needle technology. “This application technology enables us to connect our three most frequently used colors directly to the atomizer, significantly reducing paint and rinsing agent consumption,” explained Sven Veit, Director Manufacturing Engineering Paint Shop at AUDI AG. The EcoBell4 atomizer technology helps Audi save operating costs and protect the environment by reducing VOC emissions.

Top coat is applied to the exterior of the Audi Q6 e-tron.

The new top coat line will include a total of 28 robots and corresponding application technology. Durr is also providing a quality measurement cell to measure paint layer thickness, structure, and shade, and a cleaning station where two EcoRS Clean F robots will use feather rollers to clean the car bodies. For this project, Audi will also use Durr's EcoSupply P special color supply system with pigging technology, which allows for flexible and unlimited consecutive color applications.

Durr's journey with painting robots began in 1998 when it supplied its first RP7 robot to Nissan in Spain. The company is now on its third robot generation, introduced in 2016, which benefits from a modular structure that places the color changer and metering pump on the robot’s front arm, ensuring fast color changes with minimal paint loss and rinsing agent consumption.

At the end of April, Durr delivered the milestone robot to Audi at its Bietigheim-Bissingen headquarters. “We are always prepared to take on a challenging project. After all, painting a large volume of cars to a high-quality standard is what we do every day. New at Audi are the numerous innovations we are implementing for the first time: the EcoBell4 with 4-main needle technology and high transfer efficiency painting technology. This is what makes the project so special,” said Dr. Lars Friedrich, Head of Division Application Technology at Durr.

Neuron Energy partners with Hexall Motors to power double front wheel L5 category EVs

Autocar Professional Bureau — Mon, 27 May 2024 12:59:25

Neuron Energy, a manufacturer of lithium-ion batteries for electric two-wheelers and three-wheelers, proudly announces a strategic partnership with Hexall Motors. This collaboration marks a significant milestone in the electric vehicle (EV) industry with the introduction of a new product from Hexall Motors.

Hexall Motors has unveiled a pioneering L5 category vehicle featuring a double front wheel. This innovative design, which has been patented and approved by the Automotive Research Association of India (ARAI), is set to revolutionise the market, the company shared. As part of this partnership, Neuron Energy will supply 1000 custom-designed battery packs to Hexall Motors over the next year, starting from June 2024.

The collaboration is expected to generate an annual revenue of Rs 20 crore for Neuron Energy. The supplied battery packs are 16 KWR fast-charging high-speed units, specially engineered for light commercial vehicles (LCVs). Neuron Energy has tailored these battery packs to meet the unique requirements of Hexall Motors’ new vehicle, ensuring optimal performance and efficiency.

“We are thrilled to partner with Hexall Motors on this innovative project,” said Pratik Kamdar, CEO & Co-Founder of Neuron Energy. “Our advanced battery technology will provide the necessary power and reliability for Hexall’s new double front wheel EVs, supporting their vision of transforming urban mobility. By leveraging our innovative battery packs, this partnership paves the way for future growth and expansion in our business. It underscores our commitment to pushing the boundaries of what is possible in the electric vehicle industry.”

Highlighting the importance of this collaboration, Devesh Parekh, Co-Founder of Hexall Motors, stated, “For any EV vehicle company, having robust energy storage systems and battery packs is crucial, as they represent almost half the cost of the electric vehicles and are critical for overall performance. Our vehicles are very different and new in this category, with unique configurations. Therefore, we needed special battery packs with advanced Battery Management Systems (BMS), high-speed charging, and a higher range to meet the needs of our vehicles. We sought a partner who could work collaboratively with us and understand our technology. With Neuron Energy's battery packs, we found exactly that. Neuron Energy developed a product that perfectly met our requirements, making this partnership very critical for us.”

Hexall Motors' new vehicle, set to debut in the Delhi NCR region, offers substantial cargo volume, making it the preferred choice for last-mile delivery companies, particularly for transporting electronic goods and oversized cargo. With a container depth of 8.5 feet, it stands out as one of the largest in its segment. The double front wheel design enhances stability, providing a safer and more reliable option for urban transportation.