AUTO COMPONENTS INDIA OCTOBER 2020 by Next Gen Publishing Pvt Ltd

www.autocomponentsindia.com Vol 7 Issue 08

` 100

October 2020

COMPONENTS

Smart Battery Nutrunner by Atlas Copco

INDIA

Voice of the AutomotiVe SupplierS

Efficient Combustion Engines ICE Go Parts and Wear Parts The Calls for Flex-engines Grow Louder n Etrio Retrofit eLCV n New Ingenium Engine Family n

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Content October 2020

COMPONENTS

INDIA VOICE OF THE AUTOMOTIVE SUPPLIERS

Cover Story

Efficient Combustion Engines The Bosch pursuit of a technology-neutral powertrain development roadmap takes into consideration efficient combustion engines.

06 Newscast

AUTO COMPONENTS INDIA n OCTOBER 2020

Castrol Restart and Headstart

Cabin Air Filtration

Isuzu partners TASL

Praj and ARAI MoU

Lab on Wheels

State options to overcome GST revenue shortfall

New MSME technology centre

GDP growth contracts

DPIIT proposes measures

Two year loan moratorium extension?

Skoda Auto India partners PPS Motors

Appointments at SIAM

Appointments at ACMA

Inverted Energy lithium battery

14 Mobilised n

Smart Battery Nutrunner by Atlas Copco Schaeffler TruPower

The Calls for Flex-engines Grow Louder Years after directing two-wheeler manufacturers, the calls for deploying flex-engines across automotive segments grow louder.

28 Special Reads n

Etrio Retrofit eLCV

32 Trending

Environmentally Sound Management of ELVs

36 International

New Ingenium Engine Family

40 #Trendsmap

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AUTO COMPONENTS INDIA

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As the supplier community strives hard to leverage the existing marketing potential and continues to innovate, it would be wise to prudently see-through Unlock 4.0 with those masks on.

Ashish Bhatia Executive Editor | a.bhatia@nextgenpublishing.net /autocomponentsindiaofficial /autocomponentsindia ACI Mag Views and opinions expressed in the magazine are not necessarily those of Next Gen Publishing Pvt. Ltd. Next Gen Publishing Pvt. Ltd. does not take responsibility for returning unsolicited manuscripts, photographs or other material. All material published in Auto Components India is copyright and no part of the magazine may be reproduced in part or full without the express prior written permission of the publisher Printed by Marzban Jasoomani Next Gen Publishing Pvt. Ltd., 105-106, Trade World, B-Wing, 1st Floor, Kamala Mills Compound, Senapati Bapat Marg, Lower Parel (W), Mumbai - 400013, India.. Published by Marzban Jasoomani on behalf of Next Gen Publishing Pvt. Ltd., 105-106, Trade World, B-Wing, 1st Floor, Kamala Mills Compound, Senapati Bapat Marg, Lower Parel (W), Mumbai - 400013, India. Printed at Spring Graphics, 215 & 238, Shah & Nahar Industrial Estate, Sun Mill Compund, Lower Parel (West), Mumbai 400013, India. Published at Next Gen Publishing Pvt. Ltd., 105-106, Trade World, B-Wing, 1st Floor, Kamala Mills Compound, Senapati Bapat Marg, Lower Parel (W), Mumbai - 400013, India.

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

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AUTO COMPONENTS INDIA n OCTOBER 2020

Asst Art Director Ajit Manjrekar

lobally, the second wave of infection, a possible lockdown, nodal agencies holding on to stimulus, and the currency losing its sheen are some of the key fear factors that businesses need to get a grip on. Sign of things to come, the changing trade dynamics with China has had a ripple effect on imports. China imports, overall, have declined by 29 per cent compared to a year earlier and pegged at USD 16.6 billion dollars for FY2021 as of current. It also hints at the positive churn of import substitution at a nascent level aimed at boosting domestic manufacturing. The news of the iconic Harley-Davidson Motor Company shutting shop in India, in line with its ‘Rewire’ strategy, a five-year outlay to restructure the business, eliminate redundancies including the exit from low-volume markets, like India, on the other hand, has dampened supplier sentiments. The largest two-wheeler market with a combined estimated sale of over 17 million bike and scooter units annually has failed to make a business case for the premium American brand. The move is expected to directly impact the supplier base to the entry-level Harley Street 750, manufactured at the Bawal plant, in Haryana. For instance, suppliers of the front forks, swingarm, body frame, cylinder head, engine parts, brakes and tyres to the Street 750 stand to lose business despite proving their global competency. In a ray of hope for the diehard Harley fans, a little birdie tells us that the brand could still be weighing options to keep its presence through an alliance. The announcement by Harley is not a one-off negative for the suppliers. It comes close on the heels of passenger vehicle manufacturer Toyota Kirloskar Motor deciding against scaling up India operations unless and until it is able to sweat the little over three lakh per annum units capacity above the current 1/3rd-1/4th utilisation levels. In effect, suppliers to Toyota are also expected to feel the heat. As the supplier community strives hard to leverage the existing marketing potential and continues to innovate, it would be wise to prudently see-through Unlock 4.0 with those masks on. Hoping, the ICE loyalists find the October read worth their while. Efficient combustion engines are here to stay.

Just in Time

Get a grip, suppliers

Newscast

Castrol Restart and Headstart Castrol India has stepped in to help manufacturers resume business by addressing their lubricantrelated requirements. To get their production back on track, Castrol has launched two new initiatives - ‘Restart’ and ‘Headstart’. The Restart initiative, led by a dedicated team of technical specialists will provide remote assistance and virtual technical support to manufacturers in the industrial segment. In the heavy-duty domain, lubricants will be tested. The Headstart initiative will help benchmark the best practices in lubrication across industries through a series of technical and interactive webinars. Claimed to deliver sustainable value addition and a premium customer experience, Castrol India wants to ensure a seamless restart of manufacturing operations.

AUTO COMPONENTS INDIA n OCTOBER 2020

Cabin Air Filtration

UFI Group launched the ‘Sofima D+FEND’ cabin air filter. Claiming to kill 99.9 per cent harmful bacteria and viruses such as SARS-COV-2, the filter acts as an antivirus unit. Composed of a non-woven fabric filter media, it incorporates copper ions said to destroy the cell barrier of viruses and bacteria. It additionally destroys the silver ions known to penetrate the nucleus. Antimicrobial and antiviral active substances are incorporated into the fibres itself made up of polymeric material. The silver and copper ions are claimed to be effective for a prolonged period, unlike conventional filters. The filters will be produced at the Sofima Filters India plant in Bahadurgarh. ISO 11155-1:2001 standard compliant, the filters are claimed to provide filtration efficiency of greater than 95 per cent for aerosol particles of 0.3 microns. The filters are non-toxic and have no Octisothiazolinone (OIT) known to be harmful. www.autocomponentsindia.com

Isuzu partners TASL

Isuzu Motors India and TVS Automobile Solutions (TASL) have partnered to inaugurate ‘MyTVS’ facility at Torque Isuzu, in Ahmedabad. Delivering multi-brand services under the brand ‘MyTVS’, the facility will provide services including general service and body or accidental repairs for multi-brand motor vehicles other than Isuzu vehicles. The facility staff is trained with a special focus on skill inventory, gap analysis and aggregate repairs for the multi-brand service. Operational within the Isuzu workshop premises, there will be some services which will be shared by the workshop and the facility. This coexistence model is expected to improve efficiencies and ensure better viability for the dealer while providing more reach for ‘MyTVS’.

Praj and ARAI MoU To promote green fuel technologies for transportation, Praj Industries (Praj) and Automotive Research Association of India (ARAI) have signed a MoU. Together, both the companies are looking to drive application development of advanced biofuels. Finding its usage in industry and transportation, biofuels are capable of reducing carbon footprint and improving tailpipe emissions thus having a positive impact on the environment. Propagating use of biofuels in various applications including Internal Combustion Engines (ICE) in the transportation sector, both the companies are working together to test and commercialise newer fuels with improved efficiencies, inturn, leveraging their complementary strengths in technology and application. Under this program, both the companies are looking to boost the rural economy while aligning to the AtmaNirbhar Bharat Abhiyan.

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Newscast

Lab on wheels Claimed to be India’s first, under a CSR initiative, Automotive Axles Limited (AAL) has donated ‘Lab on Wheels’. Launched by B.S.Yediyurappa, Chief Minister of Karnataka, the first such trailer was donated to the Government of Karnataka through a Saicorp Health Technologies Pvt. Ltd. (SHPTL) initiative. Designed to serve the rural population of India, especially in the state of Karnataka, the laboratory built on an AAL trailer is a part contribution to the state healthcare infrastructure among other solutions offered. The trailer lab is claimed to meet BSL2/3 laboratory safety standards. Built on a robust chassis, the spacious lab can be coupled with a tractor, jeep or any preferred light commercial vehicle as per the requirements across remote towns and pachayats to facilitate diagnosis.

State options to overcome GST revenue shortfall

At the 41st GST Council meeting chaired by Finance Minister Nirmala Sitharaman, Revenue Secretary, Ajay Bhushan Pandey informed of the total shortfall in GST collection pegged at Rs.2.35 lakh crore. The centre has placed two options before states to meet this shortfall. The first option is a special window in consultation with the Reserve Bank of India, at a reasonable interest rate for the borrowing of Rs.97,000 crore. The amount can be repaid after five years (of GST implementation) ending 2022 from the cess collection. In a second option, states can borrow the entire rupees 2.35 lakh crore shortfall under a special window. The government will provide a further relaxation of 0.5 per cent to the states’ borrowing limit under the FRBM Act.

AUTO COMPONENTS INDIA n OCTOBER 2020

New MSME technology centre

Union Minister for Micro, Small and Medium Enterprises (MSMEs) and Road Transport and Highways, Nitin Gadkari, recently inaugurated the MSME Center of Technology at Bhiwadi, Alwar District, in Rajasthan. Drawing attention to the manufacturing sectors’ contribution of 22-24 per cent to the GDP, the minister appealed to

the state governments to come forward and support technological excellence. He

asked them to provide land and other logistic support for the creation of extension

GDP growth contracts In an effort to balance lives and livelihood, the government is strategically removing restrictions and continue its efforts to curb the spread of the pandemic. In Q12021, however, the GDP growth has recorded a severe

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contraction of 23.9 per cent, the highest GDP contraction since 40 years. Marking the onset of India’s deepest recession, it is expected to continue until the second half of the current fiscal year. Other worrying indicators include a

centres in tier cities. The government is planning to provide loans for new technology and machinery and make 15 new technology centres besides upgrading the 18 existing centres in a bid to develop a pool of skilled workforce. Proactive support of the industry was also sought by the Union Minister speaking at the virtual launch.

39.3 per cent dip in manufacturing and job loss. “All indicators, be it mobility or consumption, are pointing towards a much weaker economic recovery,” cautioned Sunil Kumar Sinha, Principal Economist, India Ratings and Research.

Newscast

DPIIT proposes measures The Department of Promotion of Industry and Internal Trade (DPIIT) has proposed short- and long-term measures to help India become an auto components manufacturing hub. In the said proposal, the auto component sector will target five per cent of the global auto component trade and a four-fold increase in exports. In line with the AtmaNirbhar Bharat mission program, the measures proposed by DPIIT are an

outcome of discussions held with apex component industry associations and the respective ministries. According to DPIIT, this initiative will help push manufacturing in the 20 ‘champion’ sectors. In the short term, DPIIT has suggested the adoption of the scheme for Promotion of Manufacturing of Electronic Components and Semiconductors (SPECS) and a scheme under the Ministry of Electronics and

Information Technology (MEITY) for auto electronics and electric vehicles. The schemes will provide a 25 per cent incentive on capex for electronic components thus encouraging the reduction of imports. For long-term, DPIIT plans to bring auto components under the Production Linked Incentive (PLI) scheme to evaluate local content and offer a value addition to automobile companies.

Two year loan Skoda Auto India moratorium partners PPS Motors extension?

AUTO COMPONENTS INDIA n OCTOBER 2020

Image Courtesy: thehindu.com

The central government recently informed the Supreme Court on the possibility of extending the loan moratorium by two years as per the Reserve Bank of India (RBI) circular. On waiving interest on interest during the moratorium period, the centre, RBI and bankers association are known to have worked out a solution. The move follows the RBI directions to allow banks and other financial institutions to offer a sixmonth moratorium to all existing individual and corporate term loan borrowers until August 31. A bench headed by Justice Ashok Bhushan was hearing petitions filed by Gajender Sharma and lawyer Vishal Tiwari seeking to extend the moratorium period. www.autocomponentsindia.com

Skoda Auto has partnered with PPS Motors under the purview of the ‘INDIA 2.0’ project. This will help Skoda India to double its sales and service touchpoints by 2022. PPS Motors offers 18,000 sq. ft. of premium service space, 70 plus technicians and staff members, 10 mechanical stations and body shop bays, and service capacity of 5,500 plus Skoda auto vehicles per annum. Under the ‘INDIA 2.0’ project, Skoda Auto India will double its network penetration, and expand to 50 new cities, over the next three years. Commenting on the inauguration of the new facility, Zac Hollis, Brand Director, Skoda Auto India said, “To ensure preparedness for INDIA 2.0 launches, we are continually striving to expand our network reach, across the nation, so that maximum customers can experience our products as well as enjoy easy access to our customer centric aftersales solutions.”

Newscast

Appointments at SIAM The executive committee of Society of Indian Automobile Manufacturers (SIAM) elected Kenichi Ayukawa, Managing Director and Chief Executive Officer, Maruti Suzuki India Ltd. as its new President. Taking over the reins from Rajan Wadhera, Senior Advisor, Mahindra & Mahindra Ltd., and ExPresident, SIAM, Ayukawa, is expected to leverage the invaluable experience of leading the largest passenger vehicle manufacturing

company. Among other key appointments announced were Vipin Sondhi, Managing Director and Chief Executive

Officer, Ashok Leyland Ltd., as Vice President, SIAM and Vinod Aggarwal, Managing Director and Chief Executive

Officer, Volvo Eicher Commercial Vehicles Ltd (VECV) continuing as the Treasurer, SIAM.

Appointments at ACMA

AUTO COMPONENTS INDIA n OCTOBER 2020

Automotive Component Manufacturers Association of India (ACMA) announced the re-appointment of Deepak Jain, Chairman and Managing Director, Lumax Industries Ltd., as the President for a second term at the 60th ACMA Annual Convention. Averred ACMA Director-General, Vinnie Mehta, “A dynamic leader and a prominent manufacturer of auto components and systems, Deepak has led the association from the front in these challenging times facing the industry and the economy.

We look forward to his leadership in championing the cause of the auto component sector in ensuring sustainable growth and development.” In response, expressed ACMA

President, Deepak Jain, “The industry is going through one of the most difficult times ever. Notwithstanding the downturn and the disruptions, the industry needs to prepare

itself for the future. The industry has indeed been very resilient and as green shoots emerge; the component industry will have to ensure that it supports its customers well.” “We need to redouble our efforts to become a globally competitive industry through deep localisation, reduction in imports, enhanced exports and focus on innovation,” he stated. In another term extension, Sunjay Kapur, Chairman, Sona Comstar was reinstated as the Vice President for the term 2020-21.

Inverted Energy lithium battery Inverted Energy has launched lithium batteries for EVs. Claimed to be 20 per cent more efficient than the present generation, the batteries are said to have been indigenously designed and engineered. The new range of batteries will www.autocomponentsindia.com

be manufactured at the company’s facility in Okhla, in New Delhi. To be offered to select EV manufacturers, the batteries are both light-weight and compact. Claimed to be charged 50 per cent quicker and last up to five times longer, the battery does

not spill acid or emit fumes. The ‘Made in India’ battery is a step towards building future energy storage systems. Inverted Energy is in the process of applying for multiple patents related to the battery design that is claimed to make it unique.

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Smart Battery Nutrunner by Atlas Copco Pune-based Atlas Copco Tools and Industry Assembly Solutions launched a new range of cordless smart battery nutrunners. Story by: Deven Lad

AUTO COMPONENTS INDIA n OCTOBER 2020

torque wrench or a nutrunner is a popular go-to tool for working on fasteners like bolts or nuts with a controlled and specific torque. Taking into consideration its utilitarian features, Atlas Copco Tools and Industrial Assembly Solutions of Pune-based Atlas Copco (India) Ltd., launched a new range of cordless smart battery nutrunners. Aimed at critical industrial applications, it is a step up from the older generation of hydraulic wrench methods. The new range - SRB HA, is claimed to improve upon the expensive and time-consuming installation and maintenance processes associated with the older generation of nutrunners. Claimed to be an industry first, with a dual-trigger, it

Features Transducer Data collection Dual trigger HMI Screen No software required Setup straight from the box Smart 36 V battery

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minimises the risk of a finger pinch injury and significantly enhances the accuracy levels of the current controlled counterparts. Averred Chandrashekhar Pathak, Business Head India from the General Industry Segment of Atlas Copco Tools, and Industrial Assembly Solutions, “Presently most of the high torque battery tools available in the market are current-controlled tools. The accuracy of such current-controlled tools is questionable since the delivered torque output is far from the desired target torque.” “In several industries such current controlled tools are barred from final tightening as they are not considered reliable enough,” he said. The nutrunner range is powered by LithiumIon 36V battery technology with charging and health indicators.

Zero-defect assembly, maintenance and smart operations

Atlas Copco is set out to make the erstwhile expensive, time-consuming operations of the hydraulic wrench faster and cost-effective. The new nutrunner range is claimed to have helped the company achieve the goal with a proven tensor motor technology. Notably, the company has addressed operator safety and comfort requirements. Designed ergonomically, SRB HA smart battery nutrunner is on offer in three models. The new range offers clear operator feedback using multifunctional LEDs and the status display Benefits (OK/NOK) messages based on torque and angle readings. The entry level SRB Minimize the risk of injury HA digital version, for instance, features Shows live tightening results a ‘Set and Go’ function that is known to The highest volume of tightening per battery make it ready for use. The smart and connected models Increased accuracy, better process feature an internal Wi-Fi server that Simple interface, easy to use allows the operator to connect the Setup straight from the box tools to any mobile device. It is claimed NA to enable torque, angle and batch

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SRB HA Technical data/Model ETP SRB81-1300 HA

ETP SRB81 2400-HA

ETP SRB81-3400 HA

ETP SRB81-4000 HA

Square drive Torque range Speed Weight with battery Length CS distance

1” 720-2400 Nm 11 rpm 6.8 kg 428 mm 35.5 mm

1” 1020-3400 Nm 7 rpm 8.5 kg 441 mm 55.5 mm

1” 1200-4000 Nm 5 rpm 8.5 kg 441 mm 55.5 mm

¾” 390-1300 Nm 23 rpm 5.5 kg 378 mm 32 mm

FEATURES

Dual Trigger Socket Release Guiding LED Feedback Torque Transducer Permanent Magnet Motor HMI Display Internal Wifi Server for Data Collection Data Collection Presets (10) Batch Mode (10) Angle Monitoring Torque + Angle Strategy Torque Tolerances Live Data Collection Operator guidance SQS Configuration PF6000 Configuration

data collection without the need for an additional software. To further enhance the functionality and process control, the SRB HA features an accessory bus for a barcode scanner. It can also be integrated into overlying systems for live data feed and analysis. In addition, the connected model can

Smart

þ þ þ þ þ þ NA NA NA NA NA NA NA NA NA NA NA

also be connected to the PF6000. This enables the user to send a live feed to the controller and or another system in a bid to enhance process control and traceability. Standout features of the nutrunner, explained Pathak, include a strain gauge transducer and an inbuilt, Human-Machine Interface

Connected

þ þ þ þ þ þ þ þ þ þ þ þ þ NA NA NA NA

þ þ þ þ þ þ þ þ þ þ þ þ þ þ þ þ þ (HMI) with a digital display to show the real torque. “The programming and data collection capabilities will deliver significant value to our esteemed customers owing to its super fast tightening speeds, low noise, enhanced battery capacity and high overheat limits,” he opined. ACI www.autocomponentsindia.com

AUTO COMPONENTS INDIA n OCTOBER 2020

Digital

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Schaeffler TruPower

AUTO COMPONENTS INDIA n OCTOBER 2020

Schaeffler India’s Automotive Aftermarket division launches a great range of automotive lubricant under the Schaeffler TruPower brand

Story by: Team ACI eading industrial and automotive supplier Schaeffler India’s Automotive Aftermarket division has announced the launch of lubricant product range under the Schaeffler TruPower brand. It includes the complete range of engine oil, transmission oil, grease, coolant, hydraulic oil and shock absorber oil. Schaeffler has a longstanding reputation for providing customers with innovative solutions and top-quality products. Maintaining the same, Schaeffler TruPower lubricant will ensure true premium quality with true value for money. Schaeffler TruPower lubricants are now available in various convenient sizes at authorised distributors across the country. It offers a wide and comprehensive range of lubricants formulated to maximise the efficiency,

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performance and longevity of petrol and diesel engines. Providing details on this announcement, Mr Debasish Satpathy, Vice President Automotive Aftermarket says, “We always want to come up with a unique and complete solution for aftermarket customers. We find lubricant is a perfect value addition for our installers who are already using our transmission, engine and chassis products. Our program is extensive in range and covers updated specifications including those of latest BS-VI range. I thank my team for working very hard to develop this exciting new range.” He further elaborates, “Quality oil was our priority; thus, the lubricants have been formulated and developed using the same expertise which goes into the manufacturing of our known and trusted brands, i.e. LuK, INA and FAG. The new lubricant will give vehicle owners great peace of mind

Schaeffler’s AAM division now offers a comprehensive range of lubricant for all vehicle segments in various convenient sizes.

Schaeffler TruPower branded lubricants covers up to date specifications for engine oil, transmission fluid, grease, coolant, hydraulic oil and shock absorber oil.

Hi-tech & premium base oil with enhanced additive technology designed to meet demanding requirements for Indian vehicle parc.

demands and does more to improve performance and engine life. Schaeffler TruPower offers a new generation of lubricants formulated from world-class base oils along with a top range of additives. The new high-performance range of Schaeffler TruPower lubricant offers superior performance in non-stop protection required to extend the life of engines and transmissions. Schaeffler has been present in India for over 50 years. With 3 well-known product brands LuK, INA and FAG, 4 manufacturing plants and 13 sales offices, Schaeffler has a significant presence in India. Schaeffler is among the largest Industrial and Automotive supplier with sales of INR 43.6 billion in 2019 and around 2900 employees. The manufacturing plants

in Maneja and Savli (Vadodara), produce a vast range of ball bearings, cylindrical roller bearings, spherical roller bearings and wheel bearings that are sold under the brand name of FAG. The plant at Talegaon near Pune, manufactures engine and powertrain components for the front accessory drive system, chain drive systems, valve train, gear shift systems and a range of needle roller bearings and elements, under the brand INA. The fourth manufacturing location is based out of Hosur, producing a wide range of clutches and hydraulic clutch release systems for passenger cars, light commercial vehicles, heavy commercial vehicles and tractors sold under the brand of LuK. Schaeffler also has the largest after-market networks serving industrial and automotive customers. All of this is backed by dedicated engineering, research and development support based in India in support of product teams. ACI

AUTO COMPONENTS INDIA n OCTOBER 2020

and comfort while driving on city roads, national highways, rural farms or mine roads.” Today’s vehicles need a lubricant that keeps pace with their changing

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Key Developments

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Cover Story

Efficient Combustion Engines The Bosch pursuit of a technology-neutral powertrain development roadmap takes into consideration efficient combustion engines. Story by: Ashish Bhatia

AUTO COMPONENTS INDIA n OCTOBER 2020

he Bosch Group is pursuing a technology-neutral powertrain development roadmap. As part of a long-term strategy, the technology and services provider wants to stick to a systematic approach to attain its ambitious climate goals. To realise the ambitions, the company is focusing on activities with the potential to offer sustainable mobility. Speaking at the Automotive Component Manufacturers Association of India (ACMA) - 60th Annual Convention, averred Soumitra Bhattacharya, Managing Director, Bosch India,

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“Internal Combustion Engines will command 75-80 per cent of the demand by 2030 with the rest coming in from electric vehicles.” “It is important that India benchmarks itself against the best. We need to be obsessed about standards to move forward. Unfortunately with jugaad being a way of life here, the standards are low,” he quipped. Bhattacharya made a case for the Groups’ broad technology offensive that sets out both a batteryelectric path to sustainable mobility but equally considers efficient combustion engines besides setting a path for renewable synthetic fuels and fuel cells.

Cover Story Bosch Powertrain mix aimed at delivering affordable mobility with minimum emissions.

Expect electrical solutions to complement the combustion solutions. Speaking at the Bosch Group Annual Press Conference in Germany, Volkmar Denner, Chairman, Board of Management of Robert Bosch GmBH said,” “As climate action is stepped up, electrical solutions will be limited in the near term to complementing the combustion solutions that have dominated up to now.” A Bosch market research estimates two out of every three newly registered vehicles in 2030 to run on diesel, with or without a hybrid option. It is the reason for Bosch to continue its investments in the development of highly efficient combustion engines. Bosch’s next generation exhaust technology is claimed to have eliminated the NOx emissions from diesel engines completely citing the company’s individually conducted tests. Claimed Denner that Bosch is systematically refining the gasoline engine. This includes engine modifications and efficient exhaust gas treatment to bring down particulate emissions at a 70 per cent lower level compared to the Euro6

standard. Add to it, the company is confident of synthetic fuels making the combustion process carbon neutral. In a time of crisis, opined Denner, it would be a good proposition to offset such renewable synthetic fuels against the fleet consumption over-tightening the CO2 rules on the whole.

3R approach

In FY2020, Bosch limited made a provision of Rs.717 crore towards a 3R approach of restructuring, reskilling and redeployment initiatives. In line with

Soumitra Bhattacharya, Managing Director, Bosch India.

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AUTO COMPONENTS INDIA n OCTOBER 2020

Powertrain product portfolio

Cover Story

Types of exhaust-gas sensors

To meet the needs of a reliable analysis of the exhaust-gas composition, the basis of exhaust-gas treatment, vehicles must be equipped with different sensors known to be installed in the exhaust duct. The sensors in turn are integrated into the onboard diagnostic system. Bosch offers five types of exhaust-gas sensors.

Nitrogen-oxide sensors

Using a resilient and heat-resistant ceramic sensor element, the amount of nitrogen oxide (NOx), downstream of the Selective Catalytic Reduction (SCR) catalytic converter is measured. In some engines, the NOx sensors are included upstream of the catalytic converter. The sensors control the amount of AdBlue injected into the catalytic converter for SCR inturn to reduce NOx thus making them an important aftermarket inclusion.

AUTO COMPONENTS INDIA n OCTOBER 2020

Exhaust-gas temperature sensors

measurement, the sensor element is known to be regenerated by heating it up in order to standardise sensor condition for all measurements.

Differential-pressure sensors

Differential-pressure sensors measure the pressure difference of the particle sensor. It allows a study of the condition of the particle filter in order to trigger the demand-based and fuel-saving particle filter regeneration (selfcleaning). They are also used to control low-pressure exhaust gas recirculation.

The exhaust-gas temperature sensors can be installed across locations within the exhaust duct of diesel and gasoline engines. The sensors measure the temperature of exhaust gases. An electric voltage signal is sent to the Engine Control Unit (ECU). In diesel engines, they monitor the temperature of the particulate filter in turn contributing to the compliance with emission limits and fuel efficiency. They help protect the catalytic converters and turbochargers.

Lambda sensors

Particle sensors

Denoxtronic

Particle sensors analyse the amount of soot particle in diesel emissions using resistance measurement. The control unit based on the analysis studies the functionality of the diesel particle filter. Ahead of each

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Lambda sensors determine the amount of oxygen contained in exhaust gases. It helps the ECU determine optimal fuel efficiency to be injected in the combustion chamber. Used in gasoline, diesel and gas engines, they offer high measurement accuracy and are said to actively support engine efficiency and effective exhaust gas treatment. New lambda sensors are claimed to offer a 15 per cent fuel saving over the worn-out sensors. An exhaust gas treatment system, it is found largely in diesel vehicles. The system injects AdBlue into the exhaust duct. Together with SCR, it allows the conversion of NOx into water and nitrogen.

Cover Story Efficient Weichai truck diesel engine energy-efficient, and ecofriendly diesel engines. The alliance also extends to the mobile fuel cell and driver assistance systems, and beyond mobility to domains like Industry 4.0 for connected and digitised factories.

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AUTO COMPONENTS INDIA n OCTOBER 2020

Bosch and engine manufacturer Weichai Power of China set out to increase the efficiency of the latter’s heavy-duty commercial vehicle engines two years ago. After two years, the two are claimed to have attained a big leap in engine technology. They have successfully increased the engine efficiency to 50 per cent from an average of 46 per cent thermal efficiency level. Averred Dr Volkmar Denner, chairman of the board of management of Robert Bosch GmbH, “In increasing the efficiency by four percentage points, we have jointly reached a new milestone. Even though the diesel engine is nearly 130 years old, its development continues.” Of the opinion that for heavy loads to be transported over long distances, the diesel engine will remain the preferred choice for the foreseeable future, Bosch and Weichai are working to steadily refine this technology. Bosch and Weichai, China’s largest manufacturer of engines for commercial vehicles first began their strategic alliance in 2003. Over 17 years, the two companies have pooled their strengths and expertise in diversity initiatives. For instance, to supply the Chinese market with powerful,

Cover Story

single cylinder pumps and high-pressure rails among other automotive products. Known to have been the largest relocation project undertaken then, it had the former Adugodi site being converted with the ambition of making it the largest technology campus outside Germany. According to Bhattacharya, Bosch in India, is adapting to the current market developments with measures to manage resources and enhance operational efficiencies. As per a press statement, the company has undertaken several restructuring and transformation projects to secure future profitability and growth. The total revenue of Bosch Limited’s Mobility Solutions Business sector decreased by 23.7 per cent in the quarter ending March 31, 2020. Here, the total revenue of the powertrain division declined by 29.5 per cent.

Efficient exhaust-gas treatment with Denoxtronic.

AUTO COMPONENTS INDIA n OCTOBER 2020

the company’s efforts to capitalise on the inherent opportunities of mobility related projects. Amounting to Rs.399 crore, the total investments by Bosch are attributed to the expansion of the Bidadi plant and Adugodi campus. The Bidadi plant inaugurated on July 17, 2020, is known to be a step towards making Indian manufacturing more efficient, more flexible and sustainable. Featuring

the latest in Industry 4.0 solutions and carbon-neutral technology, it was built to boost competitiveness and meet the rising demand identified in the local market according to Denner. The Bidadi plant was built to act as a local hub for the company’s powertrain solutions and for the manufacture of common rail

Common-rail system CRS2-25.

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Fiscal 2021 outlook

On the outlook for fiscal 2020-21, the company according to Bhattacharya has been affected severely. “As a leading automotive technology company with 80 per cent of our revenues driven through mobility business, we have been affected severely,” he expressed. “ The auto sector as a whole will take four to five years to return to 2018-19 levels,” he opined. Commiting to being a technology agnostic partner to customers, government and stakeholders at large, Bosch since 2017, is known to have executed 79 BSVI projects in passenger cars and commercial vehicle segments with major Original Equipment Manufacturers (OEMs). In India, the company is expected to continue investing in competence development and developing solutions, designed in India for India. At the group level, the company anticipates challenges for the global economy in the current business year. Stated Denner, “To achieve at least a balanced result, we will make a supreme effort.” “Although, other issues are currently in the spotlight, we must not lose sight of the future of our planet,” he concluded. ACI With inputs from Deven Lad

Cover Story

The Calls for Flex-engines Grow Louder Years after directing two-wheeler manufacturers, the calls for deploying flex-engines across automotive segments grow louder. lex-engines or dual-fuel engines are back in the spotlight. At the 60th SIAM Annual Convention, Minister of Road, Transport and Highways and Micro, Small and Medium Enterprises, Nitin Gadkari drew the Original Equipment Manufacturers (OEMs) and suppliers attention to the flex-engines yet again. Speaking on the Government willingness to handover the industry a longterm regulatory roadmap and extend support in helping build the requisite infrastructure, he opined that the changing and advancing technology in the country had the potential to pave the way to make India a global export hub. The union minister pinpointed the flex-engine technology as a globally proven one and one that was deployed successfully by manufacturers. “I urge the industry to introduce flex-engine technology, a proven technology already being used by several companies in Brazil, the US and in Canada,” he stated. Gadkari underlined the potential of flex-engines in helping

AUTO COMPONENTS INDIA n OCTOBER 2020

Story by: Ashish Bhatia

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the Government of India attain its twin-objective: curbing pollution and reducing crude oil imports. Among leading manufacturers of the Flex-Fuel Vehicles (FFVs) globally are Ford, Volkswagen, General Motors, Honda, Nissan, Audi, BMW, Mercedes, Yamaha and Toyota. Indian manufacturers like Maruti Suzuki and Tata Motors have also in the past, expressed the willingness to pursue alternative fuels starting with CNG as an intermediate step. Supporting OEMs in this endeavour are also component manufacturers like Bosch, BorgWarner and MAHLE Speaking highly of alternative fuel choices like Compressed Natural Gas (CNG), Liquified Natural Gas (LNG) and ethanol for the future, the minister, lauded the industry for its transition to Bharat Stage VI (BSVI) emission standards. Citing the leapfrog deemed impossible initially, he expressed confidence in the industry’s capability of being able to similarly manufacture flex-engines for India on par with global countries. “The production of biofuels will be increased given the production surplus of foodgrains.

Cover Story Nitin Gadkari, Minister of Road, Transport and Highways and Micro, Small and Medium Enterprises

Why are companies not starting this in India? Think about it. Only a filter has to be changed,” he opined brushing aside apprehensions put forth by the industry of associated research work required to be carried out. The industry had advocated for a longer gestation period to be considered for existing technologies the industry is invested in, especially in the aftermath of the pandemic. The fuel filter referred to by the minister is crucial to dust holding capacity and filtration efficiency. The last major instance of flexengines being discussed with much enthusiasm was at the time of E100 bikes being prepared for launch in 2018. The TVS Apache RTR 200 Fi E100 was introduced as the only ethanol-powered production motorcycle powered by the SI, four-stroke, oil-cooled type engine. It featured the Twin-Spray-Twin-Port EFI, a closed-looped fuel injection system known to be controlled by a 16-bit Bosch microprocessor. Among its notable inclusions were the idling air controlled valve, manifold absolute pressure sensor, high-pressure twin spray, lambda sensor, temperature sensor and a fuel pump. It also featured the TVSM patented OilCooled Combustion Chamber (O3C) with ram-air assist claimed to reduce the engine heat map by 10 per cent. The bike stood out with its green graphics and a prominent ethanol logo on its 12-litre

The India feasibility

The Union Minister was quick to reiterate the Government’s commitment to providing an integrated fuel roadmap that would include phase-wise introduction and support for a conducive ecosystem. To support his call for introducing flexengines, Gadkari shared the government vision to increase the ethanol economy from Rs.20,000 crore to one lakh crore besides steps to encourage ethanol pumps across the country. On behalf of the government, the minister invited ideas and suggestions from the stakeholders in the interest of the overall sectoral recovery and growth. Acknowledging the minister’s call for introducing flex-engines in India, Kenichi Ayukawa, Chief Executive Officer, Executive Director and Managing Director at

Maruti Suzuki India Ltd., called upon the need to put the groundwork in place before making the leap. “There is a need for maximising production with a higher degree of localisation to be able to meet the export aspirations,” he exclaimed. Pawan Munjal, Chairman and Managing Director and Chief Executive Officer at Hero MotoCorp Ltd., said, “Engineering, innovation and research and development are the need of the hour.” Dr Pawan Goenka, Managing Director, Mahindra and Mahindra Ltd., stated, “The export aspiration is an opportunity for the supply chain and we should move ahead with optimism.” Opined Vipin Sondhi, Managing Director and Chief Executive Officer at Ashok Leyland Ltd., “We need to participate in the creation of international standards. Only intellectual property will drive the change we are hoping for.” Found in FFVs, flexengines have existed for a long time the world over and can be traced back to the 1990s with over a 100 offsprings. A flex-

TVS Apache RTR 200 Fi E100

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AUTO COMPONENTS INDIA n OCTOBER 2020

fuel tank. Priced at Rs.1.2 lakh and made available in select cities, the bike shared its underpinnings with the petrol RTR 200 4V.

Cover Story Kenichi Ayukawa, Chief Executive Officer, Executive Director and Managing Director at Maruti Suzuki India Ltd.

Pawan Munjal, Chairman and Managing Director and Chief Executive Officer at Hero MotoCorp Ltd.

AUTO COMPONENTS INDIA n OCTOBER 2020

engine or dual-fuel internal combustion engine differs from conventional engines as it can run on fuels other than gasolinelike ethanol and methanol. It can be extended to a desired ethanol or methanol to gasoline ratio from the same tank (for example 85 per cent ethanol and 15 per cent gasoline). Notably, according to Indian Sugar Mills Association (ISMA), the all India average of blending ethanol with petrol is pegged at 5.09 per cent for the period December 01, 2019, to June 22, 2020, compared to 0.67 per cent in 201213. For 2020-21, the government of India is targeting an average of 7.5 to eight per cent ethanol blend with petrol. The flex-fuel internal combustion

Bosch Flexstart system.

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Vipin Sondhi, Managing Director and Chief Executive Officer at Ashok Leyland Ltd.

engine system is designed to sense the alternative fuel concentration (ethanol) in the fuel. If the concentration of the alternate fuel is higher than desired, the system adjusts the engine for lean fuel combustion. The after-treatment system kicks in to remove the unwanted emissions through the exhaust. In case of a lesser concentration, the fuel injector and air intake valve are controlled to maintain a stoichiometric air to fuel ratio (the ideal ratio of air to fuel where all the fuel is burnt with no excess air for a gasoline engine is 14.7:1). The engines are specially built to withstand the higher ethanol octane rating (110 octanes) and corrosive properties including altered oxygen sensors.

Dr Pawan Goenka, Managing Director, Mahindra and Mahindra Ltd.

The flex-engines are deemed better to consumers buying conversion kits, another alternative to run the engine on dual-fuels. The fuel kits are claimed to offer ease of installation requiring connection to the injector connectors. Kit providers are offering technical support for 24 months from the date of purchase of the kit. In the case of the flex-engine, the fuel lines, gaskets, seals, injectors and rubber fuel hoses are all built to offer high corrosion-resistance. The internal engine components, valve seats, piston rings, valves among other components are also engineered to insulate against the high conductivity levels of ethanol. Electronic Control Module (ECM) that controls the fuel mixture, ignition timing and emission system is a key inclusion as per an alternative fuels data centre study. While FFVs share most components with the conventional ICE-powered vehicles and are claimed to be easy to produce, questions continue to be raised on the overall running efficiency and release of the plant-based (over petroleum-based) CO2 emissions released back into the atmosphere.

MAHLE electrical heaters for fuel systems.

Indiaâ&#x20AC;&#x2122;s global standing

According to the SIAM white paper on alternative fuels for vehicles, two-wheelers and passenger vehicles, 2008 onwards, have been material compatible with 10 per cent ethanol-blended fuel. All vehicles manufactured before 2008 do not have such a capability which increases their dependence on low renewable ethanol blends like E5. Diesel passenger vehicles and commercial vehicles, in comparison, are known to be material compatible with five per cent bio-diesel blended diesel. Two-wheelers and passenger gasoline vehicles are not compatible with methanol blended fuels. In India, OEMs and suppliers will need to make material changes and specifically calibrate the engines and components to be compatible with higher methanol blends for instance. The industry will also have to address operational challenges like cold start ability and hot re-start ability. In comparison to India, the US brought out the Open Fuels Standard Act in 2011. Aimed at putting a full stop to the oil monopoly, the country pushed for 50 per cent of cars to be run on flex-fuels by 2015, and up to 80 per cent by 2018 despite strong opposition. In another move to create a pull, retailers installing E85 pumps were handed over complimentary kits to educate motorists. By 2018, the FFV population in the US is known to have breached the 24 million mark and is claimed to be catered to by an approximate 4500 pumps providing E85 among other

Proposed roadmap

By 2025, based on fuel availability and infrastructure, two-wheelers can be expected to be E10 material compliant subject to a consistent year-round supply of fuel across all dispensing stations in the country as per SIAM recommendations. These vehicles will also be made compliant to three per cent methanol blend (M3). By 2030, the two-wheeler compatibility needs to go up to E20 and M3. In the case of three-wheelers, by 2025, the target is to attain E10 material and M3 spark ignition (S.I.) compliance. In the case of compression ignition engines (C.I.), the industry is targeting seven per cent biodiesel compliance. By 2030, S.I. three-wheeler E20 compliant engines on CNG or LPG are expected to be introduced. Between 2030 and 2047, the S.I. engine vehicles if on a dual-fuel system, will be specifically built for E20 compliance. By 2025, all new vehicles must be E10 material compliant besides being material compliant to gasoline fuel with M3. By 2030, E20 compliant S.I. cars will be produced and also made M3 compliant across the country. Between 2030-2047 E20 The production of biofuels is expected to increase given vehicles along with other types the production surplus of foodgrains.

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Cover Story

must continue to help the government reduce its crude dependence. Even as India moves towards flexengines in a bid to curb crude imports, the country remains heavily reliant on the United States, the largest ethanol supplier to India for six straight years. As per the India Biofuels Annual 2019 report, the countryâ&#x20AC;&#x2122;s five-year average consumption has surpassed its average production for the corresponding period with the ethanol imports likely to exceed 750 million litres. As the government encourages domestic second-generation (2G) ethanol production from biomass and other wastes and creates an ecosystem for flex-fuel, there is a lot left to do before India becomes a net producer of alternative fuels and benefits from flex-engines as envisioned. The government has a key role to play as it redirects OEM and supply resources in an already trying business environment. ACI With inputs from Deepti Thore

AUTO COMPONENTS INDIA n OCTOBER 2020

ethanol blends. In Brazil, with the 40year history of ethanol usage, ethanol stocks have hit a record high in May 2020, soaring by 82 per cent to 4.63 billion litres, attributed to low fuel demand. It is also known to have signed a Memorandum of Understanding (MoU) with India for promoting and assisting the latterâ&#x20AC;&#x2122;s ethanol programme. Together with the US, Brazil accounts for 75 per cent of the global ethanol production with 80 per cent of its fleet known to run on flex-engines. In Europe and China, interestingly, the call for looking beyond internal combustion engines in light-duty vehicles has cast a cloud over the FFVs strategy.

Special Reads

Etrio Retrofit eLCV Etrio validates its strategic focal shift to intracity logistics with the launch of India’s first retrofit eLCV. Story by: Ashish Bhatia

AUTO COMPONENTS INDIA n OCTOBER 2020

yderabad-based Etrio has hit the bullseye. When the company sensed a business case for electrifying light commercial vehicles plying for intracity logistics, it was well aware of the risks associated with the major strategic focal shift. In line with its vision to become a leading EV player in the segment, the company has moved a step closer to realising its goals with the official launch of India’s first retrofitted eLCV. Built on the Tata Ace platform, its the culmination of an over two-year journey, from prototype to commercialisation. Speaking ahead of the launch, expressed Deepak MV, Co-founder and Chief Executive Officer, Etrio, “This eLCV commercialisation is our success story and the official launch is the big validation of our vision to become a leading EV player in the intracity logistics space. The competitive eLCV will soon gain ground in the Internal Combustion Engine (ICE) dominated

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segment.” The Etrio retrofit eLCV is priced at Rs.7.75 lakh (On-Road price – Delhi). The vehicle comes with a five-year battery warranty up to 1.3 lakh kilometres and a five-year powertrain warranty up to 1.5 lakh kilometres. The company is also offering an up to one year warranty on auxiliary components to make it a sweet deal for potential customers of the niche product. The proto eLCV, built-in 2018, has since cleared many challenging stages leading to its commercialisation. This includes a client-demo in 2019 followed by a major breakthrough with Automotive Research Association of India (ARAI) certifying the eLCV. Overcoming these hurdles, added Deepak, helped the company draw the attention of commercial fleets operators who eventually agreed to deploy the eLCV on their intracity routes. Deepak attributed the initial success to the company actioning on insights pointing at passenger vehicles not making a good business case

for the company. “Etrio was quick to leverage the experience of retrofitting ICE-powered passenger vehicles as EVs for the foray into the light commercial vehicle segment,” he mentioned. Stated Deepak, gaining an “early movers advantage” meant that the EV design organisation graduated to Original Equipment Manufacturer (OEM)rank. Offering business owners a payload-carrying capacity of up to 750 kg, Etrio has established itself as a partner in progress to 10 plus fleet operators like Amazon, Delhivery, Ikea, Flipkart, Gati, Mahindra Logistics and BigBasket to name a few. Notably, during the pandemic, the onroad eLCV fleet is claimed to have covered in excess of 40,000 km carrying out over 10,000 delivery assignments. Overall, the eLCV test run is claimed to span over 1.5 lakh kilometres. Deepak attributes the success to a bundled offering including solutions like driver training for the logistics and e-commerce players. A data-driven approach backed by telematics and guidance on charging infrastructure setup is believed to have further helped the company earn customer trust.

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performance and power electronics health and performance through the integrated Etrio custom app. On Big data, Deepak added that the solution offers data-driven insights through the unique driver scorecards and thereby claimed to drive a significantly improved operational efficiency over the conventional LCVs.

Total Cost of Ownership A customer can look forward to saving 60 per cent of the operational cost. For instance, a running cost saving of rupees four per kilometre effectively translates to an Rs.2000 saving per month. Explained Deepak, the electrification exercise not only translates to a new lease of life for fleets, with a minimum five years’ extension, in the long run, the customer stands to benefit from the lower acquisition, lifecycle and residual value compared to diesel ICE-powered vehicles. An Etrio study on the cost of ownership in comparison to a new ICE and second-hand ICE powered Tata Ace brings out valuable customer insights. For instance, over a daily run of 80 km, the cost of the eLCV overlaps the Total Cost of Ownership (TCO) of a second hand Tata Ace. Over a daily run of 100 km, the TCO of the eLCV matches the

Setting it apart

The retrofit eLCV boasts of an intelligent 96V architecture. The www.autocomponentsindia.com

AUTO COMPONENTS INDIA n OCTOBER 2020

Deepak MV, Co-founder and Chief Executive Officer, Etrio

eLCV offers a certified range of 120 Km (chargeable with a 16A home socket) and comes with an up to 180 cu.ft closed, high deck load body. Powered by a 20 kWh Lithium-Ion battery (with cooling), it draws a rated motor power of 15 kW and delivers a peak torque of 120 Nm. Among other USPs are a compact eAxle and regenerative braking. To enhance ride comfort, it is fitted with a double chrome suspension, and offers automatic experience, 160/180 mm disc brakes at the front and the rear, 12 magnet pedal assist and waterproof electric connectors enhance the drive. On the safety front, the eLCV has a smart Battery Management System (BMS), IP67 design with multiple failure protection control, thermal management of complete systems besides advanced software controls. Among other value adds is the isolation protection, low flammability LFP cells and autocharging cutoff. On the connected front, the eLCV offers GPS, geofencing, remote immobilisation, predictive maintenance, drive diagnostics, cell health and performance feedback. For instance, it relays motor health and

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price of a new Tata Ace. Over a daily run of 140 km, studies show that the eLCV offers a significant TCO saving in comparison to both a new and second hand Tata Ace.

Transforming intracity logistics Claimed to be a first-of-its-kind initiative to transform and electrify intra-city logistics, Etrio, shared

Deepak, has a annual production capacity of 5000 vehicles. An alumnus of Tata Motors, Deepak opined, â&#x20AC;&#x153;It is a transformational move with the capacity introduction at this level. This

Scientific retro fitment

AUTO COMPONENTS INDIA n OCTOBER 2020

In a five-stage process, the retro fitment is claimed to be a quality-controlled process. Explained Deepak, the vehicle starts with a 150-point checklist followed by the stripping of the vehicle of its internal combustion parts. This includes the engine and the auxiliary removal, the removal of engine suspension like springs, brakes, tyres, auxiliary components removal, rear axle and components besides the exhaust assembly removal. It is followed by mechanical and electrical retrofitment succeeded by the testing and quality inspection process ahead of the rollout.

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outlook, in phase two of its growth, the company is aiming at building a strong revenue model and a deeper dealership level penetration. The focus will shift from a pure B2B strategy to B2C over the medium term said Deepak. With higher investments earmarked for in-house manufacturing, product development will continue to remain a priority for the technology company. “Later this year, we will also launch a cargo electric three-wheeler expected to be the face of the organisation,” he concluded. ACI

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access among other incentives announced for local manufacturers by the Telangana government in its EV policy. The guidelines for Environmentally Sound Facilities (ESF) for handling, processing and recycling ELVs within the purview of the larger scrappage policy is also expected to benefit the company. Etrio, confirmed Deepak, has received interest in producing 1200 eLCVs as a testimony to the product’s acceptance in the market. Despite Covid-19 setting offtargets by a quarter and softening of the near to medium-term

AUTO COMPONENTS INDIA n OCTOBER 2020

will not only reshape the e-commerce logistics space but also have a deeper impact on the EV ecosystem.” Etrio is eyeing the retro fitment of over two million Tata Aces’ plying on the intracity routes. The company will manufacture the eLCV from a 30,000 sq.ft facility in Hyderabad. Aiming to improve its localisation levels by the end of FY2021, the company is in talks with vendors and coaxing them to turn OEMs themselves in a bid to cut its import dependencies from China and Hong Kong. Etrio is also expected to benefit from the preferential market

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Trending

A SIAM Environment Series Part 1

Environmentally Sound Management of ELVs in India The first lecture of the two-part environment series provided an overview of the supplier and the OEM function, regulations and policy, and the economic impact of recycling ELVs. Story by: Deepti Thore

AUTO COMPONENTS INDIA n OCTOBER 2020

Courtesy CERO (Mahindra MSTC Recycling Pvt. Ltd.)

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Trending Key OEM and supplier considerations

With the scrappage policy announcement around the corner, OEMs and suppliers will be required to work closely and not in silos. On policy supporting the stakeholders, Shovik Banerjee, Principal at Kearney was quick to point at inefficiencies of the draft scrappage policy. “Scrap value chain is based on three key

Rahul Mishra, Principal, Kearney

Shovik Banerjee, Principal, Kearney

elements: collection and aggregation, dismantling and processing and sales and consumption. There is a need for putting in place other structural policies to support the transition,” he opined. Adding to it, Captain NS Mohan Ram, VSM, I.N (retired), FNAE, stressed on the risk factors involved around such a modernisation scale. “Shredding could be a viable option for India in the next three to four years. The need of the hour is to plan ahead for inclusions like post shredder treatment for the likely generation scale of Automotive Shredder Residue (ASR),” he explained. Notably, there are six major auto collection hubs in India with Delhi NCR region holding a 35 per cent share of contribution to recycling ELVs, as reported by Kearney. Guidelines issued by the Delhi government comply with the Central Pollution Control Board (CPCB) guidelines and provide a license to operate from Delhi. It provides a minimum 1000 sq.yard of non-residential area, CCTV cameras for surveillance, procedures for junk vehicles and covers diesel vehicles over 10 years and petrol vehicles over 15 years. Masaru Akaishi, Managing Director, Maruti Suzuki Toyotsu India (MTSI) drew attention to challenges anticipated for recycling ELVs including the ELV generation, collection, prewww.autocomponentsindia.com

AUTO COMPONENTS INDIA n OCTOBER 2020

ackling End of Life Vehicles (ELVs) in an environmentally sensitive manner is at the core of safely reintroducing waste to new production. The sound management acts to transform waste into nutrients fed to the new product. This approach popularly known as the ‘cradle-to-cradle’ although not new to the automotive industry has room for immense headway. In India, a well-oiled recycling ecosystem is the crying need of the hour. The first lecture of the two-part environment series outlined such nitty-gritty. It provided an overview of the supplier and the Original Equipment Manufacturer (OEM) function, regulations and policy, and the economic impact of recycling ELVs. Setting the tone of the proceedings, exclaimed Rahul Mishra, Principal at Kearney, “The steady shift towards ELVs in India has multiple implications for all the stakeholders in the automotive industry in particular and the economy at large.” By 2025, ELVs in India is expected to reach a market size of 2022 million at an estimated valuation of Rs.9400-12,500 crore, as per the Kearney study cited. In a further bifurcation, Shovik Banerjee, Principal at Kearney opined that the scrap generation from ELVs would touch a valuation of USD 5.6 million, by 2025. Projecting the contribution of different vehicular segments to ELVs over the next half a decade, Banerjee stated, passenger vehicles alone would be the second-largest contributor to ELVs at 10-30 per cent in a total passenger vehicle population (parc) of 12 per cent. Two-wheelers would make up for a 25-35 per cent share in a vehicle parc of about 80 per cent. Commercial vehicles would contribute the bulk of the share at 40-50 in a vehicle parc of six per cent, he pointed further.

Trending Courtesy CERO (Mahindra MSTC Recycling Pvt. Ltd.)

The scrap generation from ELVs is expected to touch a valuation of USD 5.6 million, by 2025.

AUTO COMPONENTS INDIA n OCTOBER 2020

treatments and safe dismantling all in a manner that the extracted low-value material is made useful for the future. Explained Akaishi, that ELV consists of a variety of materials oscillating between high-value aluminium and copper to low-value byproducts where the risk of dismantling or dumping low-value material is always high. In terms of environment-friendly ELV pre-treatment process, Akaishi stressed on the importance of setting aside waste oil and gasoline, freon gas and airbags ahead of the dismantling process even if it translated to an additional cost being incurred. Proper pre-treatment is mandatory for environment protection, he exclaimed. Akaishi called for the need to formulate a policy to ensure timely vehicle disposal or replacement,

Captain NS Mohan Ram, VSM, I.N (retired), FNAE

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through a cut-off year on the lines of global best practices. For instance, Japan has two annual checking systems and China is known to restrict the issuing of new number plates. China, Europe and Japan also have a robust framework for lithium battery recycling. They also have a strong framework to educate the EV owners, he added. MSTI has begun work on its first plant in Noida, expected to be commissioned in early 2021.

Scrap-based steel production

Sanjay Mehta, President of Material Recycling Association of India apprised steel producers of ELVs being a game-changer for the industry. With ferrous scrap known to be the primary raw input for steel production, the

Masaru Akaishi, Managing Director, Maruti Suzuki Toyotsu India (MTSI)

government has been working closely with steel producers to establish metal scrapping centres in India. It is quintessential to ensure the scientific processing and recycling of ferrous scrap, likely to be generated from various sources. As per the government steel scrap recycling policy, scrap-based steel-making tech is key to reduce greenhouse gas emissions intensity. Steel manufacturers must adopt the principles of reduce, reuse, recycle, recover, redesign and remanufacture, he said. As per a study one-tonne of scrap has the potential to help the industry save 1.1-tonne of iron ore, 630 kg of coking coal and an estimated 55 kg of limestone. Energy consumption savings could be to the tune of 11 MJ/ Kg (EAF/IF) which translates to an up to 17 per cent energy savings. To give a perspective, the global demand for steel scrap, a 2017 study, peggs the contribution of scrap at 475 million tonnes in the global steel production volume of 1688 million tonnes. Among key drivers is the Ministry of Road Transport and Highways (MoRTh) guideline focussed on ELV recycling, details for licensing Authorised Vehicle Scrapping Facility (AVSF), deregistration or documentation process. It covers inspection, approval and renewal of the license. AIS 129, on the other hand, covers not only ELVs, but it also deals with the design and builds of new vehicles. The three-part recyclability includes collection and dismantling of ELVs, heavy metal restriction and type

Sanjay Mehta, President, Material Recycling Association of India (MRAI)

Trending Courtesy Toyota Tsusho India Pvt. Ltd.

approval for Reusability, Recyclability and Recoverability (RRR). It follows EC regulations and also covers two-wheelers.

The EV ecosystem

Drawing attention to the need for Shared Stakeholder Responsibility (SSR) between the battery and vehicle manufacturer, Kaushik Madhavan, Vice President – Mobility at Frost & Sullivan pointed out

and service outlets besides also setting up ‘traceability’ systems. The latter is deemed to be crucial for a successful value chain. The first of the two-part lecture series also urged the policy-makers to consider subsidies, incentives, resource allocation, and the formulation of an apex body for the speedy resolution of concerns to help in decision making. Encouraging investments from OEMs and battery manufacturers in second life applications was acknowledged as a key driver of successful ELVs recycling.

Energy storage demand

Citing the global trends in recycling and reusability of next-generation batteries, Madhavan urged the industry to benchmark its standard operating procedures of recycling and reusability for India with the global best practices. “The ecosystem that we set out to build must establish a circular economic value chain for the batteries,” he emphasised. Madhavan drew attention to the consolidated demand for lithium-ion battery-based energy storage that is known to kick in the second phase of the battery lifecycle. According to Madhavan, the industry must brace itself to cater to an estimated 8400 GWh storage capacity demand by 2027 possible through environmentally sound management of ELVs. ACI

Kaushik Madhavan, Vice President – Mobility at Frost & Sullivan

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AUTO COMPONENTS INDIA n OCTOBER 2020

that advanced SSR is prevalent in China and the UK. In the UK, Kaushik mentioned, producers take back waste industrial batteries free of cost from the end-user. Awareness is generated to educate the end-users on the return process. Implementation of a shared responsibility framework where battery manufacturers invest in recycling or partner with authorised recycling facility, the nodal agency to monitor usage, OEMs to create end-user awareness and certification of logistics players involved with Hazmat transportation is also crucial. Taking China as a base case for his study, Kaushik urged EV manufacturers to consider setting up recycling channels

The government has been working closely with steel producers to establish metal scrapping centres in India.

International AUTO COMPONENTS INDIA n OCTOBER 2020

New Ingenium Engine Family

Jaguar Land Rover celebrates the Ingenium engine production milestone with a new, advanced offering. Story by: Ashish Bhatia

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International

New Ingenium

From the first Ingenium engine to go into production, the two-litre engine – AJ200D to the new addition a six-cylinder diesel engine, better fuel efficiency and lower emissions besides a greater torque for a more responsive and engaging drive have been achieved. The 48V MHEV system is said to provide torque assistance during stop/ start aimed at enhancing efficiency and offering ride smoothness. Offering a peak rated power of 300Ps and a peak torque of 650 Nm, the new Ingenium is claimed to offer a 13 per cent CO2 emissions reduction over the outgoing TDV8. The RDE2 (Euro6d) secondstep real driving emissions compliant emissions regulations compliant engine www.autocomponentsindia.com

AUTO COMPONENTS INDIA n OCTOBER 2020

aguar Land Rover hit a production milestone as it rolled out the 1.5 millionth engine of the Ingenium family since production first began in early 2015. Celebrating the milestone at the engine manufacturing centre in Wolverhampton, United Kingdom, the Original Equipment Manufacturer marked the celebrations with a new, advanced powertrain offering to add to the ultra-efficient range of clean and electrified powertrains for all Jaguar and Land Rover models. A new six-cylinder diesel engine is the latest in the family lineup of clean, refined and efficient diesel, petrol and electrified engines aimed at maximising performance. In a dual benefit, the Ingenium range is claimed to reduce the environmental impact and running costs for customers. Ken Close, Launch Director at Jaguar Land Rover Powertrain Operations mentioned, “We are experiencing an unprecedented demand for cleaner-running vehicles, so it’s more important than ever to deliver clean and efficient engines without compromising on the performance or all-terrain capabilities our customers have come to expect.” The indigenously built engines boast of an all-aluminium engine design that is modular and flexible. The scalable architecture shares core technologies.

International AUTO COMPONENTS INDIA n OCTOBER 2020

with its aluminium architecture is 80 kg lighter compared to its predecessor. The twin electric variable nozzle technology allows 90 per cent of peak torque to be delivered in a little over a second at 2000 rpm. The advanced fuel injection system, operating at 2500 bar, delivers up to five injections for every engine cycle. O.8 milligrams is delivered in 12 microseconds. In keeping with the low friction design of the Ingenium family, steel pistons and advanced Exhaust Gas Recirculation (EGR) are credited for the optimised efficiency. Claimed to offer enhanced performance, smoothness and efficiency, it will power the new Range Rover and new Range Rover Sport. The advanced in-line diesel engine is a mild hybrid and joins the range of clean and efficient six-cylinder petrol and four-cylinder petrol and diesel engines manufactured at Jaguar Land Rover’s West Midland facility. Supporting the company’s long-term commitment to reduce vehicle emissions and improve fuel economy across the vehicle range, it reaffirms the commitment to reduce emissions in line with the ‘Destination www.autocomponentsindia.com

Zero’ mission. The latest six-cylinder diesel shares its manufacturing facilities with the three-litre, six-cylinder petrol engine launched last year (2019). The shared facilities include machining of the key architecture, cylinder head, cylinder block and crankshaft. It also shares the assembly and testing infrastructure.

Evolution

The Ingenium technology will continue to evolve and better the six key features the first-generation was built upon. These included roller bearings on cam and balancer shafts over machined bearing surfaces. Computercontrolled variable oil pumps meant the availability of the optimum amount of oil at all speeds, engine loads and temperatures. The computer-controlled variable water pumps adjusted the coolant flow based on temperature, speed and driving conditions. The split circuit (two-paths) cooling system offers the benefits of lowered emissions for fast warm-ups and quicker cabin heating especially in case of lower temperatures. A simplified drive system

was designed for higher modularity. Crankshafts were designed to offset from the centre of the block. The electronically controlled piston jets were designed to improve oil pump circuit efficiency. The engine thereby reached operating temperature quicker and helped reduced emissions. Jaguar Land Rover will continue to advance the electrification of the model line-up. The OEM is also aiming to establish a concept hydrogen fuel cell powertrain solution. At the engine manufacturing centre that houses the assembly of Electric Drive Units (EDUs), the arrangement is such that there is full flexibility between the new petrol and diesel engines and EDUs. This paves the way for customers to make an easy switch from conventional to electrified vehicles. The electrification drive is expected to take advantage of the maturing electrification ecosystem in the Midlands. For instance, it will leverage the proximity to an advanced Battery Assembly Centre at nearby Hams Hall known to assemble PHEV and BEV batteries. ACI

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