April 2022 – June 2022

New Capabilities / Development

 Real-Life Fuel Economy of Commercial Vehicles (>3.5 ton)

 Understanding Lithium-ion Cell Behaviour during Abuse and its Quality Over Cycle Life

 Tyre Test Facilities as per AIS 142:2019

 Pendulum Type Bumper Test Facility


Conference/Events

 Lighting Conference “Future Trends in Automotive Lighting”

 Symposium on International Automotive Technology (SIAT), 2024

 Real-Life Fuel Economy of Commercial Vehicles (>3.5 ton)

Introduction

India’s transportation sector total sales have increased from 14.1 million in 2009-10 to 21.5 million in 2019-20,
with a compounded annual growth rate (CAGR) of 4.33% (MoRTH – Road Transport Year Book 2017-18 &
2018-19) and demand of fossil fuel is also increasing year by year. Out of total petrol and diesel consumption,
transportation sector consuming about 99.6% and 66.3% respectively (https://pib.gov.in) and as per IEA 2021
reports energy demand increased by 4.6% on 2021 as compared to 2019. This scenario leads to increase in
GHG, which alter the natural ecological cycle. To overcome this problem, more than 196 countries agreed to
2016 PARIS-Agreement to limit the global temperature increase to 1.5 0C by reducing GHG and India also taken
several initiatives to reduce GHG gases by 33-35% of 2005 level by 2030.

In this context, Worldwide auto makers are working on various technological improvements to reduce CO 2
emission by improving fuel economy, which also benefits in reducing overall fleet operational cost. Heavy
commercial vehicles have major role in the national economy, but also have significant share in CO2 emissions.
To estimate actual contribution of CO2 from HDVs segment, EUROPE, USA, CANADA, CHINA, JAPAN, S.
KOREA and BRAZIL have developed standard methodology for real life fuel consumption calculation as per
their respective geographical conditions, traffic, etc. Similar approach is required to develop for India to calculate
real life fuel consumption calculation for this segment.

ARAI is extensively working in this direction to support industry by performing vehicle energy audit and sensitivity
analysis at engine and vehicle level through field trials and simulation approach. This approach helps in
identifying the potential areas for improvement in fuel economy and parameter-wise contribution in CO2
emissions with reduced efforts.
Figure below shows the approach followed for real life fuel consumption calculation.

In this methodology, generation of input data for simulation tool, will play a very crucial role in preparing correct
vehicle model. This model will be used for assessing the vehicle fuel efficiency by field data correlation and for
identifying potential areas for improving Tank-to-Wheel efficiency. This approach is aimed to support the
decarbonisation drive in transportation sector, especially from CV segments. The significant advantage of this
methodology is assessing overall CO2 emissions across the OEMs / Fleet to set future CO2 limits with reduced
variant testing, time involved and cost.

Critical approach for real world data measurements

Vehicle preparation with Instrumentation & data Data Post-processing and

Payload & km Run data
required instrumentation measurement analysis

• Pay load • GPS

• Kilometers data • Fuel flow meter
• Req. ECU parameters
• Speed sensors
• Critical temperatures
• Fan, alternator, etc.
power consumption
• Data filtering /
smoothening
• Statistical Analysis
• Cycle condensation

Raw Data Post Processed &

condensed cycle
 Real Life Fuel Consumption Measurement Approach Advantages of Energy Audit

 Real life fuel economy of vehicle

category >3.5t, calculation of TTW
efficiency and fuel consumption
using simulation approach

 Developed model can be used for

future R&D with less time, cost
and manpower

 Approach can be extended to Life

Cycle Assessment (LCA)

ARAI Capability - Services Offering

 ARAI team fully capable to perform complete vehicle

energy audit and tank-to-wheel efficiency calculations
based on constant speed and real drive cycle basis.

 EVs, FCEV and HEV real drive performance evaluation

will be a key parameter.

 ARAI completed 6 commercial vehicle projects for

different Indian and Overseas customers to support their
future products.

 This approach will be a key assessment parameter for

Government decarbonization initiative.

 Understanding Lithium-ion Cell Behaviour during Abuse and its Quality Over Cycle Life

Latest developments of lithium-ion (Li-ion) cells based on new chemistries led to high performance, longer
lifetime and improved safety. Li-ion cells have become significant energy storage technology for electric vehicle
(EV) applications. Their performance is mainly dependent on the operating conditions such as load current,
temperature and state-of-charge (SOC). In order to evaluate the feasibility of cell for a certain application,
complete information about performance becomes necessary.
Testing Cell for its Quality
A good quality cell is one which meets all the needs of the application and has decent reliability. Internal
resistance and self-discharge greatly affect the performance. This resistance is expected to be as low as
possible while the self-discharge should be negligible. Capacity fade for a cell should also be low. Sometimes
battery specification does not meet the given datasheet values. Quality check comes handy in such a situation.
There is not a single method, which can give overall info about the battery and multiple tests required. There
are various destructive and non-destructive methods available for testing.
Main health indicator of a battery is its capacity. Galvanostatic Charge Discharge (GCD) is a technique
appropriate for determining actual capacity of a battery. A fresh cell must ideally deliver 100 per cent of the
rated capacity. A 3Ah battery should deliver 3A current for a period of 1 hr, discharge of battery before
completion of 1 hr indicates a capacity fade. Electrochemical Impedance Spectroscopy (EIS) is an efficient and
rapid technique in analyzing internal resistance and overall impedance of battery. A good quality cell has an
internal resistance of less than 100 mΩ while overall impedance is also within the specified limits. A low
resistance / impedance also leads to low heat generation during charging and discharging of a battery.
 NON DESTRUCTIVE CHARACTERISATION DESTRUCTIVE CHARACTERISATION

Cyclic Voltammetry (CV) is a technique, which can effectively state the stability and working voltage of the
battery. A good cell is expected to give similar performance with each charge-discharge. Efficient stacking, built-
in safety features with strong covering are essential for decent quality product.
Further quality check for cells requires them to be opened, internal parts to be separated and tested
independently. Scanning Electron Microscope (SEM) and Energy Dispersive X-Ray Spectroscopy (EDX) helps
in studying morphology and elemental content of electrodes. X-ray Diffraction Spectroscopy (XRD) aids in
knowing the crystalline phases and presence of any impurity within the electrodes. Strength of cell components
can be checked using the Tensile Test (TT) and Hardness Test (HT). A good electrode has uniform morphology
with no or infinitesimally small defects or impurities. Cells in the battery pack are constantly subjected to vibration
when the vehicle is in motion. Vibration is one of the important mechanical abuse tests, in which cells are
subjected to external vibrations. Modal analysis is a technique, which helps in analyzing effect of mechanical
abuse on the cell.

VIBRATION TEST FIXTURE AND SETUP

Testing Cell during and after Abuse

During actual use they are subjected to various external conditions, like change in temperature, pressure or
fluctuating input / output current. During driving, battery in an EV is subjected to varying vibration. In case of
accident batteries may be subjected to crushing force or battery may get pierced by any foreign material. To
ensure further safety, quality of a cell needs to be tested by subjecting to various abuse tests, mainly thermal,
mechanical and electrical. Non-destructive analyzing techniques, like EIS, CV, and GCD may help if outer
structure and connecter of cells is intact after the abuse test. Uneven change in the plot of EIS and CV indicates
damage inside the cell.
 VARIOUS ABUSE TESTS FOR BATTERY

MECHANICAL ABUSE TEST ELECTRICAL ABUSE TEST

 Penetration  Short Circuit
 Controlled Crush  Overcharge
 Vibration  Over Discharge

THERMAL ABUSE TEST CALENDAR LIFE OF CELL

 Thermal Stability  Cycling with constant C rate
 Elevated Temperature Storage  Cycling with current load cycle
 Thermal Shock Cycling
 Extreme Cold Storage

In-depth analysis of these cells is possible by using destructive analysis practices. Due to mechanical abuse
test mainly morphology of electrode is affected. In such cases, SEM technique helps in understanding the
damage to electrode surface. In the case of thermal or electrical abuse, internal structure of the cell may damage
completely. Chance of short-circuit or thermal runaway is high. In such cases chemistry of electrode changes.
These changes can be investigated using techniques such as XRD. While Fourier Transform Infrared
Spectroscopy (FTIR) and Ion-Chromatography (IC) are useful to analyse the electrolyte within the cell.
Analyzing battery during abuse test helps us in knowing its behaviour during abuse and understanding its effect.

ARAI team is competent enough to evaluate the cell quality by carrying out the mentioned above tests and will
be able to provide such service to OEM, Battery pack manufacturer and also the cell manufacturers.

 Tyre Testing as per AIS 142:2019

Government of India has planned to implement ‘Star Rating’ of tyres, in line with the Tyre Labelling regulation
in Europe. The objective is to ensure safety, economic and environmental efficiency of road transport by
promoting fuel-efficient and safe tyres with low noise levels.

For the same a new AIS 142 : 2019 (Automotive Industry Standard), in line with UN ECE R117 is prepared. It
comprises evaluation of tyres with regard to 'Rolling Sound emissions', 'Adhesion on Wet Surfaces' and Rolling
Resistance. Ministry of Road Transport and Highways (MoRTH) has issued a notification stating the standards
of the tyres for passenger cars, trucks and buses, vis-à-vis rolling resistance, wet grip and rolling sound
emissions. These standards will come into effect from October 2022 for tyres falling under class C1 (passenger
cars), C2 (light truck) and C3 (Truck and Buses) as defined in the Automotive Industry Standard 142: 2019.

ARAI has established test facility at its Kothrud and Chennai Centres to provide comprehensive certification
services to tyre manufacturers as per AIS 142, for C1, C2 and C3 class of automotive tyres. The facility is
accredited to NABL requirements. ARAI has already started giving test services to almost all Indian tyre
industries.

The facilities available at present are complying with the following

1) TUV Certified test tracks for Wet grip and rolling sound evaluation.
2) Dedicated Rolling Resistance test facility.
3) Standard vehicles.
4) Stock of SRTT with cold storage facility as per ASTM F 2498-18.
5) Calibrated Instruments with dedicated latest noise measurement system and instrumentation.
6) Support facilities at the workshop including tyre changing facility.
7) Tyre storage area and scrapping needs.
Tyre Testing Facility - Highlights

 Alignment - Tyre rolling resistance machine alignment with European network of reference labs
completed.
 Correlation exercise – successfully completed for Wet Grip and Rolling sound emission tests.
 ILC for Tyre RR, noise and wet grip test successfully completed.
 Tyre testing as per various international standards, e.g. Gulf, Europe, FMVSS standards is possible.
 ARAI can offer single point service support for E-certification as per UN ECE R 30, 54, 75 117 for tyres.
 ARAI can support for test reports required for BEE labelling.

This facility will not only help us test tyres for the Indian market, but also the ones that are exported after meeting
Export Homologation and Labelling requirements.

ARAI - Tyre Test Facilities

RR facility Wet Grip Facility Rolling Sound Evaluation Facility

 Pendulum Type Bumper Test Facility

Inauguration of Pendulum Type Bumper Test Facility at ARAI by Shri Pradeep Kurulkar, Outstanding Scientist and Director,
Research & Development Establishment (Engrs.), Pune on 15th January’2022

Brief introduction:

A car bumper is typically designed to absorb energy in slow speed Impacts. It mainly offers protection to the
hood, trunk, grille, parking lights, tail-lights, exhaust, tyres and cooling systems. Additionally, they are designed
to offer protection to front and rear ends of passenger vehicles. While offering protection to these devices, they
must also ensure safety of the pedestrian.
The base standards for bumper testing are FMVSS 215, UN ECE R42, IS 15901 and AIS 006. The testing was
mandated in India as per AIS 006 with effect from 01.04.2008 according to SO 1431(E) dated 20.08.2017 and
as per IS 15901 with effect from 01.10.2016 according to SO 411(E) dated 09.02.2016. The standard gives
OEMs the following options to certify their bumpers:

1. Vibration durability test as per Cl 4.1 of IS 15901

2. Four poster test as per Cl. 4.2 of IS 15901
3. Moving barrier method as per UNECE R42
4. Pendulum impact method as per UNECE R 42
Objective of the Test Rig:

The new test rig is designed to supplement the existing moving barrier bumper test rig. The new facility has the
capability to perform test on the vehicle with maximum kerb weight of 4000 kg and speed of 10 kmph. This is
done with an eye on future regulations to extend testing to commercial vehicles. The facility has features like
lifting of weights, speed reading and angle reading. There is a moving arm with a hoist motor attached to help
place the weights from the rack into the trolley. The rig has been instrumented to provide speed and angle
readings.

Intended use of the Test Rig:

The test rig is designed to perform impact tests on vehicles as per ECE R 42/AIS 006/ IS 15901. The test
consists of impacting the vehicle in longitudinal direction at two points on the front and rear bumper at a speed
of 4.0+0.25 kmph. Also, it consists to impact at both the corners of the front and rear bumper of the vehicle at
60±5° at a speed of 2.5+0.1 kmph. These impacts are carried out on the vehicle under unladen and laden
conditions.

Pendulum Type Bumper Test Facility

Features of the test rig:

The main parameters of the test rig are:

 Effective impacting pendulum mass range: 878.0 kg - 3928.0 kg.

 Pendulum radius: 3400 mm.
 Impact speed: up to 10 kmph.
 Height adjustment range: 350-650 mm
 Motorized angle movement and motorized height adjustment
Frame and pendulum

The pendulum consists of a large frame that supports swinging mass via parallelogram linkage. The frame is
constructed from welded hot rolled steel, mechanized and painted. The entire frame is screwed on to the floor.
The base weight of the pendulum trolley and arms weigh 878 kg. There are 28 steel plates weighing 100 kg
each, 6 plates of 50 kg each, 4 plates of 10 kg each and 2 plates of 5 kg each. Hence total weight of 4000 kg +
can be achieved. Height of the pendulum arm can be adjusted by means of an open looped screw jack located
on the top. The height transducer can help display the height of the pendulum arm.

Impact speeds of up to 10 kmph can be achieved by drawing the pendulum back to 28 degrees. The pendulum
is operated by an open-loop electric winch motor of which cable end is fitted with pneumatically operated quick
release mechanism. The angle transducer displays angle of the pendulum arm. There is an another motorized
arm attached on the frame to help lift the weights from the cradle to the trolley. This helps to ensure safety of
the operator.

The Pendulum Type Bumper Test Facility is a completely in-house product designed and developed by ARAI.
It is a complete Import substitute, which could save more than Rs. 75 lakh.

 Lighting Conference “Future Trends in Automotive Lighting”

ARAI, in association with SAEINDIA - Western Section, organized Lighting Conference “Future Trends in
Automotive Lighting” on 10th June 2022 on virtual platform. The aim of this conference was sharing of new
trends in automotive lighting and light signaling devices and hence it was a complimentary online webinar. The
event received overwhelming response from the industry and academia, with participation of over 450
delegates.

This conference was a congress of the best minds in the industry and participation from vehicle manufacturers
(2W, 3W, 4W, Tractors, CEV, EV, etc.), lighting manufacturers, non-automotive lighting manufacturer, test
agencies, etc.

The webinar was inaugurated by Dr. Reji Mathai, Director-ARAI, along with Mr. A. A. Badusha, Mr. S. S.
Nibandhe and Dr. B. V. Shamsundara.

In the beginning to set the form, Dr. B. V. Shamsundara presented the Journey of Automotive Lighting Standards
in India and also draft Roadmap with ARAI capabilities.

The first topic in webinar, viz. “Uniform Progress in GRE” was presented by Mr. Geoffrey R Draper (Senior
Regulatory Advisor – Driving Vision News). Mr. Draper is Ex-President of International Automotive Lighting and
Light Signalling Expert group, i.e. GTB group.
Mr. Ramashankar Pandey (CEO & MD, Hella India Lighting Ltd.) gave an excellent coverage of “New Trends
in Vehicle Rear Lights”. His message “Technology for Purpose” was inspiring to all. He elaborated the flat light
technology will be the future for signaling devices of vehicles.

The third speech in the series was on “Lighting Technology for Tomorrow’s Headlights” by Mr. Todd C. Morgan
(Chief Technology and Innovation Officer, Lumax Industries Ltd.). He touched upon the new and future
technologies in Headlamp devices, such as AFS, ADB, DMD (digital micro mirror device) and image projection
on roads using headlamps. His informative speech was well received by the participants.

Mr. Davide Puglisi (Secretary General – GTB) has presented on the topic “Intelligent lighting solutions for future
vehicles (autonomous)”. He explained the role of GTB group in WP 29, Geneva. He elaborated on the topics
such ADAS – external lighting signalization and communication, Road projections, Visual light communication
and so on considering future vehicle technologies.

Speech on “Technology roadmap for light sources” was delivered by Dr.-Ing. Wolfgang Schiene (Director
Product Manager, Lumileds). He focused on new LED technologies which will be there in the market in near
future and its various advantages.

The last speaker of the conference was Mr. R. K. Bandal (Vice President, Mobility, TUV Rheinland (India) Pvt.
Ltd.). He provided information on topic “Homologation of Automotive Lighting” and various requirements in
European Type approval process.

The number of delegates, who have registered for this webinar were 59,2 whereas total 499 delegates has
attended this webinar. The Conference received encouraging feedback in all respect. The conference
succeeded in accomplishing its purpose of knowledge sharing and providing a platform for exchange of thoughts
between the experts and the participants.
 Symposium on International Automotive Technology (SIAT), 2024

Symposium on International Automotive Technology (SIAT), a benchmark event organized by ARAI biennially,
serves as an important forum for exchange of ideas and brainstorming for the automotive industry. Over the
years, the event has grown in stature and is now considered as a prestigious automotive event by the global
automotive fraternity.

I am delighted to announce that the forthcoming edition, viz. SIAT 2024, the 18th in the series, is being organized
by ARAI, in association with SAEINDIA and SAE International (USA), at Pune (India), from 23-25 January 2024.
The theme of SIAT 2024 is “Transformation towards Progressive Mobility”.

SIAT 2024 will focus on the recent advances in various automotive areas such as Safety, Emissions, Engines,
Noise, Electric Mobility, Hydrogen and Fuel Cell, Electronics, Intelligent Transportation, Vehicle Dynamics,
Materials, Alternate Fuels like Methanol, Ethanol, CNG, LPG, Simulation and Modelling, etc. It will also bring to
fore innovative ideas and solutions in automotive technologies to meet future challenges.

SIAT provides unique common platform for national and international experts to share their thoughts in various
fields of automotive technology. Overseas experts will get chance to interact with their counterparts from the
Indian automotive OEMs and Component Industry and explore tie-up and possible business opportunities.

SIAT EXPO 2024, being organized concurrently, offers appropriate platform to the automotive and allied
industry to display / demonstrate their products / technologies / innovation / services through display booths.

PROGRAMME OF SYMPOSIUM AND EXPOSITION

SIAT 2024 SIAT EXPO 2024

23 January 2024 Tuesday Inaugural Session & Technical Sessions Inaugural Session & Exhibition

24 January 2024 Wednesday Technical Sessions Exhibition

25 January 2024 Thursday Technical Sessions & Valedictory Session Exhibition

Dr. Reji Mathai, Director - ARAI

director@araiindia.com

The Automotive Research Association of India

Survey No. 102, Vetal Hill, Off Paud Road, Kothrud, Pune 411 038 (India)
Tel.: +91-20-6762 1101, 6762 1122 Fax: +91-20-6762 1104