www.autotechreview.com June 2016 | Volume 5 | Issue 6 Now, Also available on

It’s on 16 Interview Ramashankar Pandey, Managing Director, Hella India Lighting Ltd

20 study Semiconductors in ADAS: Challenges & Opportunities

60 new Vehicle Datsun redi-GO – Best From the Brand Yet

automotive lighting ––

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Editorial

FOCUS ON QUALITY

Dear Reader,

Within a span of seven days last month, market leader Maruti Suzuki India Ltd initiated two recalls involving over 75,000 Baleno hatchbacks, close to 2,000 DZire compact sedans and an unspecified number of S-Cross crossovers. MSIL, of course, isn’t the only one. Automo- bile recalls have become very prevalent in the past few years, with India alone accounting for an estimated 2.24 mn vehicle recalls between July 2012 and May 2016, an analysis by a leading business daily stated.

Does this point towards a decline in automotive reliability and safety? Does this mean the vehicles produced today are of poor quality as against vehicles of the past? Not necessarily. While some automakers have blamed quality issues at smaller component vendors, the most significant story emerging in recent times is that of Japanese supplier, Takata. As per one estimate, nearly 78 mn defective, shrapnel-shooting Takata airbag inflators will need re- placement through 2019.

Until some time back, most of the vehicles recalled globally used to be older models with newly discovered problems. But that seems to be changing. Popular new products from Honda, Ford, Volkswagen, MSIL, HMSI and Yamaha, among others, have been recalled in recent times. Honda has been the worst affected with over 5.13 lakh recalls in the last four years, primarily due to issues with airbags sourced from Takata.

Experts point out that the increasing use of common parts, complex architectures, and heavy dependence on electronics & software, are some of the key reasons leading to a spurt in vehicle recalls. Overall, the large number of defective systems and parts getting into vehi- cles highlight one serious concern – that of inadequate quality assurance.

Many of our readers, who attended the annual ACMA convention in 2015, would recall what Osamu Suzuki, Chairman, Suzuki Motor Corporation had said – global recall of more than 1 mn vehicles has put the focus on quality. He said it is quality alone that is key to success. He urged the industry to look at the ‘Make in India’ campaign in a larger context to include ‘Quality in India’.

There couldn’t be a sounder advice to the Indian industry than that.

Deepangshu Dev Sarmah Editor-in-Chief New Delhi, June 2016

@deepangshu autotechreview.com June 2016 Volume 5 | Issue 6 1 Cover Story automotive lighting –– innovation-driven future

26, 32, 36, 42 | LED is clearly the fastest growing technology for automotive lighting in the global automotive markets. Owing to its advantages of being controllable, energy-efficient and flexible in terms of use of colour, LEDs seem to be the right technology for future mobility as well. For the time being though, it is estimated that halogen lights will continue to dominate the market, while the growth of xenon lights will remain average. In this edition of Auto Tech Review, we take an elaborate view at some of the interesting technological developments and innovations in the area of automotive lighting.

guest commentary

14 Emerging Trends in Corporate Governance Landscape Saket Mehra is a Partner at Grant Thornton India LLP

INTERVIEW

16 “Frugal Engg, Cost Innovation Helps Offer Future-Ready Solutons” Ramashankar Pandey, Managing Director, Hella India Lighting Ltd

2 contents

NEWS technology Imprint

04 Interactions 46 Audi Range Drive – Editorial

12 News Showcasing Technical Might Editor-in-Chief: Deepangshu Dev Sarmah [email protected] 50 Speed, Flexibility Through In-House @deepangshu Part Production Assistant Editor: Arpit Mahendra [email protected] study Ankur Agarwal @arpitmahendra3

Senior Correspondent: Naveen Arul (Bangalore) 20 Semiconductors in ADAS: [email protected] Challenges & Opportunities event @naveenarul Seunghyuk Choi, Florian Thalmayr, sales Dominik Wee, Florian Weig 52 CTO Roundtable 3.0 — How Electron- Manager: Sudeep Kumar ics is Changing The Way We Drive [email protected] Assistant Manager: Pramodh R (Bangalore) [email protected] Cover Story Shopfloor Sunil Deore (Pune) [email protected]

26 Modular Design for Led Glare Free 56 Technology Diversity in Engineered events

High Beam Access Hardware Manager: Vivek Tyagi Laurent Evrard, Benoît Reiss, [email protected] Joachim Ripperger, Damien Cabanne New vehicle Production 32 Evocative Lighting Design for Chief Designer/ Photographer: Bharat Bhushan Upadhyay [email protected] Premium Interiors 60 Datsun redi-GO – Video Journalist: Vasu Anantha Manfred Winklbauer, Bernhard Bayersdorfer, Best From The Brand Yet [email protected] Josef Lang

Publisher & Managing Director: Sanjiv Goswami 36 Headlamp of 2025 – Bionically DECODING TECHNOLOGY For Editorial Contribution, write to the Editor-in-Chief Inspired, Additively Manufactured at [email protected] Klaus Zander, Damir Sokolov, 64 It’s More Than Lighting For Advertisements, write to Manager – Sales at Willi Schwarz, Michael Frohnapfel Arun Jaura [email protected]

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Cover Figure © Audi follow us on @autotechreview1 INTERACTION dsm, Mathworks

DSM ENGINEERING PLASTICS | LOCAL PRESENCE TO DELIVER GLOBAL TECHNOLOGY

customising a global product for Indian needs, sensor that has to live in a given type of environ- the Indian technology centre could develop prod- ment within a vehicle, the Indian centre will ucts for global needs. Responding to the size of have access to all information pertaining to that this centre in comparison with the global ones of topic from the global centre. DSM, Polet said this isn’t one of the largest but Combining this technical knowledge with it’s surely an important one. local requirements will create products that will prove the centre’s advantage, Polet added. TECHNICAL CAPABILITY He also talked about the role this centre will play in helping the company stay ahead of In the new centre, DSM will be able to work with global standards becoming tougher and customers in supporting new product develop- helping their customers speed up the product ment using a wide variety of equipment for ma- development cycle significantly. terial and application testing, including injec- Speaking of future growth areas, Polet made tion moulding, polymer characterisation, physi- it clear that autonomous driving is not viable for cal property testing, and thermal analysis. The India in present circumstances but collision- centre is capable of providing test data for avoidance technology could have great potential. DSM’s wide portfolio of engineering plastics. Ad- DSM has been in this area for more than a DSM Engineering Plastics recently opened its ditional services include a laboratory scale twin decade and their knowledge can help their cus- new research and technology centre in Ranjan- screw extruder for new product development and tomers come up with better solutions quickly, gaon, Pune. The new facility will support new trial runs. Polet added. product and application development, and The facility has further scope to grow and Talking of challenges, Jain stated the goal deliver rapid, specific test data for its prod- add new testing equipment and capabilities, as of implementing BS VI norms by 2020 was an ucts, allowing for close collaboration with required. Adding to the scalability of the centre, opportunity for technology providers, but the DSM’s customers. Shortly after the launch of Sanjay Jain, Business Director, DSM Engineering challenge lies in the gap between the govern- the new centre, we caught up with Roeland Plastics India said, “This is our next phase in ment’s intent and the orientation of some Tier I Polet, President, DSM Engineering Plastics, India, moving from Make in India to Develop in suppliers towards the same. These suppliers who gave us an insight into the difference this India. Starting with 5,000 sq ft, we have the ca- will need to go through a sharp learning curve centre will bring to the product and business pacity to expand to 20,000 sq ft.” if the goals for 2020 are to be met and all capabilities of the company. Responding to our question on the key tech- stakeholders, including OEMs, will have to push nical areas the centre will focus on, Polet said for it, he concluded. LOCAL PRESENCE that the Indian centre is well-connected to the FOR GLOBAL SUCCESS global technical centre. Hence, if a customer needs a particular type of plastic to house a Text: Arpit Mahendra DSM today is one of the five largest engineering plastics company in the world. While this makes them a strong global player, in many cases, such companies are expected to enter local markets with global solutions, which often don’t work. Polet explained that DSM’s focus is on being a strong global player with strong local presence, testified by the presence of a large team and a development centre in India. That said, he added that products don’t need to be reinvented and hence global solutions need to be taken and cus- tomised for local requirements, which is impor- tant for any successful product. The new technology centre will play an im- portant role for the company, as apart from local development it’ll also support global business in future. Given the wide pool of skilled people in India, Polet foresees a time when instead of just

4 www.autotechreview.com MATHWORKS | DATA ANALYTICS WITHIN THE CONTEXT OF MODEL-BASED DESIGN

Model-based design has been an important part of product development across industries, including the automotive and aerospace industries, and MathWorks has been the market leader offering model-based design solutions. At the MATLAB Expo 2016, we met Richard M Rovner, Vice President, Marketing, MathWorks (L) and Kishore Rao, Man- aging Director, MathWorks India Pvt Ltd (R) to get a lowdown on the new solutions the company is bringing to the Indian market.

ENGINEERING-DRIVEN ANALYTICS

Microprocessors in vehicles generate enormous amount of data, and MathWorks sees such engi- neering data as a key driver to enhance analytics, which have become pervasive in all industries. vision technology that is critical for ADAS. TECHNOLOGY ADOPTION MathWorks continues to invest in the MATLAB and Meanwhile, Model-Based Calibration technolo- Simulink tools to enhance engineering-driven ana- gy generates optimal calibration tables that are The use of MATLAB and Simulink in model-based lytics workflows that would result in new capabili- used by automotive companies to meet fuel design of domestic OEMs and suppliers has ties of Big Data processing, new algorithms for economy requirements and emission regulations. reached a tipping point over the past couple of machine learning, and computing. This technology provides benefits in the form of years, Rao said. Companies recognise the benefits Fleet data analysis, calibration and automated reduced cost and man hours, when compared to of using model-based design and are building driving algorithms are some of the most sophisti- calibration using a dynamometer and can be used competency for use of these technologies. The level cated uses that analytics are put to. Deep learning to simulate the test bench itself. Another main ad- of awareness and need for model-based design has and predictive-models for driving algorithms are vantage of model-based calibration is that a grown and been appreciated with use in real pro- expected to have a deep impact on advancements problem can be specifically defined to see its jects. While OEMs still work with suppliers on their in automated driving, as well as in driver assis- outcome and effect on the engine. The move design front, it has changed significantly, with tance and active safety, noted Rovner. He added towards early adoption of Bharat Stage VI norms in more of a co-development approach being em- that analytics also includes computer vision and India has renewed interest within domestic OEMs ployed, which will reduce the time to market. co-generation, which can be addressed within the for such technologies, noted Rao. On the other hand, design work carried out by context of model-based design. MNCs in the country isn’t very different from their The most significant product addition to the TRENDS & CURRENT REQUIREMENTS global developments. Their development work is company’s flagship platform was Simulink Test driven by global projects, and local teams collab- that can be used to systematically verify and sim- With automotive manufacturers taking a compre- orate with their larger worldwide engineering ulate models, said Rao. The Simulink Test not only hensive approach to model-based design from be- teams, said Rao. He claimed MathWorks solutions helps model simulation in desktop simulation, but ginning to end, verification and validation (VnV) help OEMs and suppliers to reduce re-work, cut also adds to the hardware-in-loop (HIL) simula- have become important parts of the workflow. In down coding errors, and aid efficient development tion capability. addition, one of the most visible trends in the auto- of variants. Rao said MathWorks is especially focussing on motive industry at present is in the development of Rovner said MathWorks will continue to make developing four technologies that are most relevant ADAS for automated driving, where there are a strategic investments for toolboxes in its core plat- to the automotive sector. The Automatic Production number of challenges, noted Rovner. Systems in- forms of MATLAB and Simulink, in order to continu- Code Generation technology is used by OEMs to gen- cluding computer vision, learning systems, ground ously make improvements to the entire workflow. It erate codes and use the same in production pro- truthing, ground truth labelling and sensor fusion is also investing in resources to help customers grammes. MathWorks is also increasing the use of pose a range of challenges that the company works adopt its technologies, in terms of online training System-Level Simulation, where physical modelling to resolve. Other trends include model-based and examples, as well as investments in people for is used mainly for the behaviour and designing of design to address fleet data analytics and compli- application engineering, training, consulting and physical systems. ADAS is being developed, especial- ance to user and safety standards. There are a few pilot engineering. ly since automakers are incorporating this technology standards that mandate the use of model-based in developing automated and autonomous driving design, which will drive the quicker adoption of vehicles. The company is also investing in computer such technologies, he noted. Text: Naveen Arul

autotechreview June 2016 Volume 5 | Issue 6 5 INTERACTION AUTODESK INDIA

AUTODESK INDIA | DISRUPTIVE DESIGN, INNOVATION NEEDED TO LEAD MARKET

disruptions, both with conventional OEMs as well Within the future of making things, Autodesk as start-ups. has a product innovation platform called FUSION 360. This platform runs on the cloud, and hence NEW OFFERINGS does not require very heavy graphics, and can also be used on a smart device, making it One of Autodesk’s latest solutions is the VRED 3D mobile. The platform is a single tool to design, visualisation software, which enables the rendering test and fabricate with IoT on top of it, and is of the whole concept of a car without making clay also highly collaborative. models or physical prototypes. This results in a major reduction of costs and new product develop- INITIATIVES & ROUND-UP ment times, as well as in evolving creativity within the ecosystem of manufacturing. Autodesk has a very strong focus on R&D in India, Another technology that is coming into the foray and has centres in Pune and Bangalore. Gadhok of design is Internet of Things (IoT), said Gadhok. said these centres contribute significantly to the Autodesk recently acquired SeeControl, a San Fran- development of the FUSION 360 product. The cisco-based developer of an enterprise IoT cloud company invests back about $ 500 mn (approxi- service platform. Autodesk is using IoT to acquire mately ` 3,300 crore) into R&D annually. It also has The mushrooming of start-ups in the automotive fleet data and capturing it to make more refined other development centres in China and Israel. ecosystem of the country is posing a completely design. The future of all automotive design soft- Meanwhile, the company is spearheading the new set of challenges for vehicle manufacturers. ware from Autodesk will use IoT to capture data, ‘Maker Movement’ in India. Maker Movement is a Less fazed to take risks, start-ups use a wide range and this will be seen in a few months, noted space that offers various manufacturing machinery of technologies; develop varied products and solu- Gadhok. He said Autodesk may be one of the first to enthusiasts to come and make products at their tions that conventional companies don’t even think companies to use IoT for design and automotive in own time, in order to further develop their skills. about. Additionally, various analyses say that the the market currently. Autodesk allows subscribing members of Maker rise of taxi and cab aggregators across the globe The traditional process of Product Lifecycle Movement to use their software to design and make may see car buyers reducing drastically by 2025. Management (PLM) has been rather fixed – concept virtual prototypes, and finally build their final This requires car makers to develop innovative and design, to full production design, to simulation, and product. Such initiatives help boost creativity of de- technology-rich products that will continue to finally manufacturing and launch. The future of signers from OEMs, suppliers and the complete attract buyers to purchase vehicles. manufacturing though involves varied steps in the ecosystem to innovate at a leisure pace, said We recently caught up with Varun Gadhok, process of designing, developing and making prod- Gadhok. Autodesk is also working on technologies Country Manager – Manufacturing Solutions – ucts. One step is to collaborate with the top innova- like robotics for the future of manufacturing. The India and SAARC, Autodesk India Pvt Ltd to under- tors at every step of the manufacturing process, challenge up until now was in the low awareness stand how the company is helping OEMs and sup- from concept to final production. In manufacturing, level of the company’s offerings, which is now pliers innovate and offer disruptive solutions to the IoT plays an important role in realising connected changing, noted Gadhok. market. From being viewed as an AutoCAD solution manufacturing with less or complete absence of provider, Autodesk has taken a stance to lead these human intervention. Text: Naveen Arul

6 www.autotechreview.com

INTERACTION BORGWARNER, NI

BORGWARNER THERMAL SYSTEMS | BS VI OFFERS EXCITING PROSPECTS

In search of increased efficiency and reduced incidentally, have already replaced emissions, the automotive industry has been in- all other technologies in favour of creasingly looking at electric and hybrid solu- the electronic fan drive. tions to drive their future businesses. And the The second product that could component and system suppliers aren’t differ- potentially drive in good business for ent. BorgWarner, the global product leader in the company in the long-term in powertrain solutions, is developing products and India is the control coolant pump for solutions to meet similar demands in the future heavy trucks. In passenger vehicles, across all its product areas. the company is pursuing electrifica- We had caught up with Karl Wagner, Vice tion of thermal management President Global Sales & Engineering for systems, and has a few products in Thermal Systems, BorgWarner some time back its portfolio. It is currently working to understand how the division he represents – on a 48 V fan solution, as well as a thermal systems – is gearing up to meet future dual-mode coolant pump, based on challenges. Wagner’s division is focussed on the same product it has for CV ap- meeting the thermal management needs of plications. Wagner is confident this OEMs, while also improving fuel economy and re- product would have a huge opportu- ducing emissions. nity in global markets. We began by talking about the most-dis- cussed subject in India currently – the move to PROSPECTS IN INDIA BS VI norms. Wagner’s excitement is visible, and value of a system. That is a welcome sign since he says the company had been waiting to In general, Wagner said, the Indian market is for Wagner. see technology migration really take off in India. very receptive to the idea of technologies. While “India is a slow growing, but steadily growing Calling it a “great idea” to skip one level and growth was slower than anticipated, volumes huge market opportunity for BorgWarner and for move to BS VI regulations, Wagner said it would currently do not allow big jumps in terms of the thermal business in particular. The India oper- clearly drive in a lot of emission reduction, effi- technology migration. There are specific chal- ation is one of our smaller plants today, but we ciency, performance and consumer comfort lenges in a market like India, and that will drive see steady growth. From a thermal systems per- through newer technology introductions. product development at BorgWarner. spective, India is the third biggest market in Talking of product development, the company Asia,” he said. Once the domestic market is FOLLOWING TRENDS continues to invest into its application and catered to, there would be opportunities in the testing capabilities in India. In the long-term, future for the Indian unit to even export products The major trends seen in thermal management, the Indian unit could likely provide services to other India-like markets,” he said. both globally and in India, are in the areas of air around the world, especially in the area of flow, coolant flow and electrification, said design. Work in that area has already started, CONCLUSION Wagner. Predominantly focussed on the commer- and is being expanded currently. That could lead cial vehicle sector, Wagner’s division also has to the next steps of product R&D and product de- BorgWarner’s focus on developing products and opportunities in passenger vehicles business in velopment, viewed Wagner. However, for India to solutions that cater to the market-related objec- sight. The company is looking at launching in become a strategic hub for the thermal system tives of fuel economy, reduced emissions, noise India a localised electronic fan drive for CVs. business globally would depend a lot on the reduction, performance and durability augurs well This is the first time that this product is being speed of technology migration in India. for the Indian market. There sure is enough oppor- manufactured in India. “When technologies start migrating to India, tunity for the company to grow its business in the “That’s a big breakthrough for us with a I see more specific products being developed for market, especially in the commercial vehicle leading customer in India, and we see that India. And when the market is big and mature segment that is increasingly adopting newer tech- product making inroads into other OEMs as well,” enough that would be the right time to look into nologies not just from a regulatory perspective but he said. Investments made on the electronic fan investing into a larger R&D set-up in the also because of increased competition. drive production capability in India have now been country,” said Wagner. completed, Wagner informed. As of now, the op- Critically, he feels the Indian industry is ma- portunity is clearly big in the higher CV market, turing even in terms of its earlier rigidity with like in Europe, but Wagner is confident of the cost. Although the market continues to be price- product finding acceptance in the entire CV sensitive, it clearly shifting from focussing on market in real quick time. European CV makers, the cost and value of components, to the cost Text: Deepangshu Dev Sarmah

8 www.autotechreview.com NATIONAL INSTRUMENTS | HIL TESTING SOLUTIONS FOR PRODUCT DEVELOPMENT

This would result in high cost and increased con- using this product. This enhances LabVIEW into sumption of time. As a result, most of the embed- an ecosystem, in the sense that it is software on ded software development is carried out with a which customers can develop toolkits and add- simulated system, which emulates the engine, ons, especially in domain-specific areas. This is and is called HIL simulation. further made easy by the open-architecture of In electric vehicles (EV), engines are replaced LabVIEW, which allows the development of add-on by motors, and ECUs by Electric Motor Control toolkits that can be uploaded to the LabVIEW Tools Unit, with some additional challenges in terms of Network. The IPs for these customer-developed the speed at which the control loops work. There- add-ons are held by them, and are available for fore, the company has developed specific tools download from the LabVIEW Tools Network, either that would be focussed on the HIL testing require- free or at a cost. ments of EV motor and component manufacturers, noted Chivukula. He added that this software has INDUSTRY TRENDS been developed and merged with the existing hardware, which is possible due to the company’s A major trend in the industry is the growing so- platform-based product approach. phistication in vehicles due to the increased level The automotive industry, encompassing OEMs and of electronics. An average passenger vehicle has suppliers, has been one of the largest users of NEW SOLUTIONS anywhere between 15 and 20 ECUs, which is in- test and validation equipment for development of creasing the focus on HIL testing, since develop- new products and variants. These testing solu- The company has made enhancements to its hard- ment for these ECUs need to be done in parallel, tions are becoming even more important for man- ware and software in the recent updates released. said Chivukula. Most of these ECUs are of low ufacturers with requirements of reduced develop- In terms of hardware, NI has developed data, or functionality, which brings up the requirement for ment times, first-time correctness, and increased signal acquisition modules for +/- 50 V signals tear-down versions of HIL testing systems. These product robustness and reliability. National In- that are mainly suited for automotive Input/ Output. test solutions need to be low-cost, with low-func- struments (NI) has been a company offering hard- It has also released hardware packaged version for tionality, and enough to test small electronic ware and software test solutions to various manu- low-cost desktop-based HIL systems, which include modules, he explained. There is also the require- facturing industries, with a number of tools spe- additional signal conditioning. Another enhance- ment that these HIL test systems are mobile, in cifically focussed on automotive. ment is the development of low-cost, standalone order to be shifted between users easily. On the side-lines of the fourth National Instru- data acquisition systems that are capable of meas- Additionally, development of hybrid and full ments Automotive Seminar, we met Raviteja Chi- uring various engine signals for on-board in-vehi- EVs add high requirements for HIL and physical vukula, Staff Technical Marketing Engineer, NI cle data logging. The company has also developed testing systems, even though standard test & Systems (India) Pvt Ltd, to understand the direc- multiple radio frequency signal generators and an- measurement and data logging solutions can be tion of testing within the automotive industry. He alysers that can be used to implement current applied to them. However, certain specific tools provided details on the test methodologies being testing protocols for infotainment systems. for the development of particular systems within employed in the automotive sector, by both OEMs In terms of recently released software en- EVs are generally developed by customers manu- and suppliers, especially with regards to Hard- hancements, Chivukula highlighted two updates facturing such products. ware-in-the-Loop (HIL) testing solutions that are that mainly pertain to HIL testing. First, NI has re- Chivukula said that component testing require- gaining strong demand. leased a new version of the VeriStand software ments are also increasing, since manufacturers are The NI seminar touched upon the area of end- based on the latest LabVIEW technology that increasingly carrying out extensive testing and vali- of-line component testing, which includes infotain- eases the process of HIL testing. The other is the dation of their products to enhance reliability before ment system testing, as well as cluster inspection release of add-ons that can perform HIL testing launching. There has been an increase in the incor- testing. Additionally, the company showcased its on electric motors. Chivukula said these enhance- poration of RF-based systems, beyond infotainment traditional offerings of data acquisition and control ments work in developing both the hardware and into vehicles. Systems like tyre pressure monitoring to show how they can be used in test cell automa- software provided by NI, and in turn prepares the systems (TPMS) and in-vehicle wireless networks tion and control in vehicle data logging. complete platform for future technologies. are also finding more acceptance. These wireless We were told NI has been making improve- systems in particular are finding increased use due HARDWARE-IN-LOOP (HIL) TESTING ments to LabVIEW, in terms of core enhancement to their benefits of weight saving, lower cost and to the platform’s productivity and increasing lesser chances of failure. Engines these days are mostly controlled by ECUs, speed of its programme execution. The more im- and development of this system cannot always be portant enhancement, according to him, is in the done on a physical prototype, noted Chivukula. development of LabVIEW add-ons by customers Text: Naveen Arul

autotechreview June 2016 Volume 5 | Issue 6 9 INTERACTION JD POWER

JD POWER ASIA PACIFIC | quality in TWO-WHEELERs on the rise

competitive pressure from independent workshops that people who have a pillion rider tend to providing similar service as OE workshops. The report more problems. This is not due to the extra IQS more specifically refers to the problems faced weight of the pillion rider but due to different by consumers in the initial period of buying the people judging the same product, and also the vehicle. The highlight in the Initial Quality Study pillion not having to focus entirely on the road (IQS) study, when reviewing the changes in a year, and traffic. turned out to be the overall quality improvement When asked about influx of features in two- by OEMs in the country. wheelers in recent times, Roy said that the study Speaking about the key problems reported points out that more features in general lead to by consumers, Roy highlighted fuel-efficiency, reporting of more problems. Clarifying the state- which is an issue even for four-wheelers in ment further, he added that customers do not India. Kick start too has been reported by many dislike the features but desire better execution of for requiring more number of operations than those features. In addition, dealerships need to desired to get the engine started, especially on explain these features in a better manner to cus- the first start of the day. Thereafter, there are tomers at the time of purchase so that they can minor issues such as fit & finish and noise optimally use such features. Indian two-wheeler OEMs have made significant from the chain. For scooters as well, starting improvements in quality in the last year or so problems, paint peel-offs and fit & finish 2-WHEELER CUSTOMER SERVICE INDEX and problems reported by consumers have de- issues were reported. clined. This was one of the key takeaways from Segments covered in the study involve motor- The inaugural study measures customer satis- our SPOTLIGHTconversation with Kaustav | Roy,Quality Director, ofJD Two-Wheelerscycles for entry-level commuters in to the segment faction with the after-sales service experience at Power Asia Pacific, who talked about some in- where Royal Enfield operates. The company original equipment (OE) authorised service teresting trends reflected in theIndia two-wheeler Improves hasn’t Significantly forayed into the high-end of the market centres between the first 12 to 24 months of study carried out by the marketing information involving foreign makers as the required mass of ownership. The study focuses on what matters servicesNumber company. of initial quality problems reportedbuyers for by the two-wheelerstudy isn’t easy to owners find yet. most to customers, when they take their two- has declined by 14 problems per 100 vehiclesThe appealing factors for consumers, or the wheeler in for service and also analyses the pro- STUDY FINDINGS drivers of satisfaction for scooters, were mainly cesses that define the service experience. seats and engine & transmission, while for mo- The study measures overall satisfaction in -14 What is PP100? This is second version of the study, after havingJ.D. Power evaluatestorcycles initial it qualitywas fuel-efficiency based on the number and ride of & han- five factors, listed in order of importance: introduced thePP100 inaugural version of the two-problems experienceddling. As per the 100 motorcycle vehicles (PP100). segments grow, engine vehicle pick-up (22 %); service advisor (21 %); wheeler quality and appeal study in 2015. The & transmission starts becoming more important service quality (20 %); service facility (19 %); The lower the better company also launched its inaugural 2-WheelerA lower score representsas customers higher prioritise quality. This acceleration year, the industry and power. and service initiation (18 %). Overall, TVS Customer Service Study (2WCSI), signifyingexperiences the a 9%An year-over-yearinteresting observation improvement from in initial the studyquality. was Motors ranked highest in customer satisfaction with after-sales service with a score of 773, per- Greatest contributor to the improvement forming particularly well in all five factors. What does Greatest year-over-year improvement is in the engine category. this number mean? Suzuki (764) ranked second and Royal Enfield ranked third (758). The 2016 India 2WCSI Study is based on Three major factors influencing perceived quality evaluations from 7,270 two-wheeler owners in of two-wheelers 45 cities across India. These owners purchased a new two-wheeler between November 2013 and Pillion Kilometers First-Time March 2015 and had a service experience within 1 Driving 23Driven Buyers three months of evaluation. The study includes 10 two-wheeler makers and over 75 two-wheeler

Two-wheeler owners who Owners who ride their More than three-fourths of models, and was fielded from November 2015 to ride with a pillion report two-wheeler 41 kilometres two-wheeler owners are March 2016. 7% more problems than or more per day report first-time buyers, and they those who ride solo. The 12% more problems than report fewer problems than increase in reported problems those who ride up to those with previous is particularly notable in the 40 kilometres. ownership experience engine, brakes and ride and (138 PP100 vs. 199 PP100, handling categories. respectively).

Text: Arpit Mahendra

Brand Performance 10 www.autotechreview.com Power Circle Ratings

J.D. Power 2016 India Two-Wheeler Initial Quality Study (2WIQS) StudySM Motorcycle—Economy Economy AWARD RECIPIENT: Honda Dream Neo

RATINGS FACTORS

Overall Fit and Ride and Electrical Gauges Satisfaction Finish Engine Transmission Brake Handling and Light and Controls

AWARD RECIPIENT: Honda Dream Neo TVS Star City Plus

TVS Sport

Bajaj CT

Honda Dream Yuga

Bajaj Platina

Hero HF Deluxe/ Deluxe Eco

Hero Splendor Pro

Mahindra Centuro

Hero Splendor iSmart

Bajaj Discover 100

Hero Splendor+

Hero Passion Pro/ Pro TR/Xpro

J.D. Power 2016 India Two-Wheeler Initial Quality Study (2WIQS) StudySM Motorcycle—Executive Executive AWARD RECIPIENT: Hero Super Splendor

RATINGS FACTORS

Overall Fit and Ride and Electrical Gauges Satisfaction Finish Engine Transmission Brake Handling and Light and Controls

AWARD RECIPIENT: Hero Super Splendor

Hero Glamour

Honda CB Shine

Bajaj Discover 125

J.D. Power 2016 India Two-Wheeler Initial Quality Study (2WIQS) StudySM Motorcycle—Premium Premium AWARD RECIPIENT: TVS Apache RTR 180

RATINGS FACTORS

Overall Fit and Ride and Electrical Gauges Satisfaction Finish Engine Transmission Brake Handling and Light and Controls

AWARD RECIPIENT: TVS Apache RTR 180

TVS Apache RTR 160

Bajaj Avenger

Honda CB Unicorn 160

Bajaj Pulsar 180

Bajaj Pulsar 220

J.D. Power 2016 India Two-Wheeler Initial Quality Study (2WIQS) StudySM Motorcycle—Upper Executive Upper Executive AWARD RECIPIENT: Suzuki Gixxer

RATINGS FACTORS

Overall Fit and Ride and Electrical Gauges Satisfaction Finish Engine Transmission Brake Handling and Light and Controls

AWARD RECIPIENT: Suzuki Gixxer

Yamaha FZ

Honda CB Unicorn

Bajaj Pulsar 150

Bajaj Discover 150

J.D. Power 2016 India Two-Wheeler Initial Quality Study (2WIQS) StudySM Scooters—Executive Executive AWARD RECIPIENTS: TVS Wego/Yamaha Alpha

RATINGS FACTORS

Overall Fit and Ride and Electrical Gauges Satisfaction Finish Engine Transmission Brake Handling and Light and Controls AWARD RECIPIENTS:

TVS Wego

Yamaha Alpha

Honda Activa I

Yamaha Ray/Ray Z

Mahindra Gusto

TVS Jupiter

TVS Zest 110

Hero Pleasure

Suzuki Access

Honda Activa 125

Honda Aviator

Honda Dio

Honda Activa/ Activa 3G

Hero Maestro

Among the best Better than most About average The rest

Please note that JDPower.com Power Circle Ratings may not include all information used to determine J.D. Power awards. See more: http://www.jdpower.com/about-us/jdpower-ratings

© 2016 J.D. Power, McGraw Hill Financial. All Rights Reserved.

Charts and graphs extracted from this publication must be accompanied by a statement identifying J.D. Power as the publisher and the J.D. Power 2016 India Two-Wheeler Initial SM Quality Study (2WIQS) Study as the source. Rankings are based on numerical scores and not necessarily on statistical significance. No advertising or other promotional use can be made of the information in this publication or J.D. Power study results without the express prior written consent of J.D. Power. Good for the environment and good for you

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Global NCAP | Zero Stars For Five Indian Passenger Vehicles

Global NCAP, new car safety certifying agency, re- reasons for the poor performance. The Mahindra forward to testing another improved version of the cently awarded zero stars in adult occupant pro- Scorpio, Maruti Suzuki Eeco and Hyundai Eon also Kwid with airbags, he said. tection to five models of vehicles from India. The faced similar issues with the structure, in addi- Ward observed that the results highlight the models tested included the Renault Kwid, Maruti tion to the exclusion of airbags as reason for their importance of the Indian Government’s decision to Suzuki Celerio, Maruti Suzuki Eeco, Mahindra low scores, noted Global NCAP. However, Maruti mandate front and side impact crash tests from Scorpio and Hyundai Eon, and all models showed Suzuki Celerio scored lowest, with zero stars in October, 2017. Legislative action is needed to low levels of adult occupant protection. However, adult occupant protection and one star in child ensure that the minimum levels of occupant pro- all vehicles, except the Maruti Suzuki Celerio occupant protection. The Celerio’s low child occu- tection recommended by the United Nations are achieved two stars in child occupant protection, pant protection score was explained by high guaranteed for Indian consumers, he said. Ward with the Celerio scoring just one star. values recorded in the child dummy, along with noted that Global NCAP also welcomes the forth- Global NCAP tested three versions of the Kwid, the extensive forward excursion. coming launch of a Bharat New Car Assessment all scoring zero stars in adult occupant protection David Ward, Secretary General, Global NCAP, Programme (NCAP) that can help build a market and two stars in child occupant protection. Col- said the latest SaferCarsforIndia results show for safer cars in India. lapse of structure in the passenger compartment, how important it is for cars to have a body shell Renault India And Mahindra & Mahindra Ltd lack of airbags and unstable structure were the that can remain stable in a crash. He added that issued statements after the results were an- this is a crucial pre-requisite nounced, saying all their products meet and exceed for occupant safety, together requisite safety standards set by Indian Regulatory with fitment at least for front Authorities. Renault said India is gradually moving air bags. It is very surprising towards international safety norms by including that a manufacturer like more robust safety regulations and the assurance Renault introduced the Kwid in- of the Bharat NCAP is a positive step in this direc- itially lacking this essential tion. It added that the Indian Government has an- feature, Ward noted. Global nounced crash test regulation for existing cars to NCAP welcomes Renault’s come into effect in 2019 and for new cars in 2017, efforts to correct this and looks timelines with which it will comply.

Axalta | Developing Future lightweight Coating Technologies

Axalta Coating Systems showcased coating tech- The company currently has low-bake systems from its 150 years of experience in coatings, espe- nologies that would assist in lightweight automo- that cure faster and at lower oven temperatures cially from its refinish paints. He added that tive design, at the European Automotive Coating than traditional systems to help car manufactur- Axalta can work to transfer this knowledge into Conference held in Germany. The company exam- ers reduce energy costs and enable them to use workable and successful solutions for the OEM ined the challenges and opportunities that light- new materials. Axalta said its new systems share market. The next decisive step is the integration weight automotive design brings to coatings the ability to reduce the number of bake steps of individual low-temperature solutions and their systems used by car manufacturers. while aiming to deliver the same full layer perfor- transfer to pilot production, he noted. Axalta said that over the next 15 years, auto- mance as traditional coating motive manufacturers will be replacing standard processes. A possible option steel with high-performance steel, aluminium, from Axalta is UV drying on the plastics and composites, and will also be cutting paint line, which replaces weight from safety, communication and electrical drying ovens with UV curing. components. These changes will have a signifi- Additionally, new robotic appli- cant impact on coating systems, as many of the cations could open up the pos- new, lighter materials cannot withstand high- sibility of reaching shadow bake temperatures. As a result, lightweight zones, which are very hard to vehicle construction is said to be driving innova- reach during the coating tion in low-bake coatings. Axalta is using new process. technologies to develop solutions that integrate Sven Radek, Group Leader, existing low-temperature paint system solutions, Process and Application, Axalta but hasn’t found a comprehensive, integrated so- Coating Systems EMEA region, lution that suits all application situations. said the company is benefiting

12 www.autotechreview.com Daimler | Opens Regional CV Centre in chennai Volvo Penta | To make

Daimler AG has inaugurated its commercial vehicle sees sales and service of a wide range of brands Industrial Engines Regional Centre Southern Asia in Chennai, marking and products, with market responsibility extending In India the completion of the launch of the sixth regional to Nepal, Bhutan, Bangladesh, Myanmar, Sri Lanka centre for the company. These regional centres have and Maldives. These include BharatBenz trucks, been set up by Daimler to carry out activities dedi- FUSO trucks and buses, and Mercedes-Benz trucks, cated to markets in Africa, South East Asia and buses, and vans. Amit Bisht, Head, Regional Centre Latin America. This inauguration comes after seven Southern Asia, said the company is very positive months of Daimler opening its first Regional Centre about this region, with demand across brands and for Commercial Vehicles in Dubai. product lines already being favourable. The new Regional Centre Southern Asia over- Dr Wolfgang Bernhard, Member, Board of Man- agement, Daimler AG, responsible for Daimler Trucks and Buses, said the company has launched the last of a total of six new regional centres. He Volvo Penta has announced the start of production added that this will enable Daimler to offer tai- of its 5 and 8 l industrial engines in India, at the VE lored products and services from a single source Powertrain (VEPT) plant in Pithampur, from the to customers in markets such as Sri Lanka, second quarter of 2017. The company said it will Myanmar or Nepal. add a new line at the plant exclusively to manufac- The Regional Centres are an example of how ture the 5 l and 8 l Volvo Penta engines. This move Daimler Trucks Asia directly benefits from the is also said to reconfirm Volvo Group’s commitment global reach of Daimler, noted Marc Llistosella, towards the ‘Make in India’ initiative by investing in President and CEO, MFTBC, and Head, Daimler local production. Trucks Asia. He said Daimler expects these Re- Volvo Penta’s range of 5 l and 8 l engines are gional Centres across the globe to provide sub- certified for Indian Bharat (CEV) Stage III emission stantial further momentum for exports both from standards, equivalent to EU stage IIIA/ Tier III. The Japan and India. engines, having a power range from 105-235 kW are already in the field, powering a variety of appli- cations including construction, material handling, raw material exploration and agriculture. The new Renault | enters Pre-Owned Car business production and assembly lines will enable various solutions tailored to the local market needs, Volvo Renault India has inaugurated its first ‘Renault Se- The pre-owned vehicles sold at Renault Selection Penta said. lection’ multi-brand pre-owned car showroom in get covered with a one year/20,000 km warranty, Jonas Nilsson, Head, Volvo Penta India, said the the country, in Bangalore. Renault Selection will with cashless claims available at over 1,000 au- company sees great opportunity in infrastructure provide customers a platform to buy, sell and ex- thorised workshops in India. The warranty also development in the country. Demand from custom- changing certified pre-owned cars of all brands, comes with 24X7 RSA for the same period. ers is increasing constantly, since there is pressure with offers on finance, insurance, warranty and Sumit Sawhney, Country CEO and Managing Di- on contractors to complete projects within the spec- Road Side Assistance (RSA). The company said it rector, Renault India, said the company is pursuing ified time with the cost levels calculated, he added. will use this business vertical to cater to customers an aggressive growth strategy in India and is en- The plant in Pithampur is not only one of the looking at selling multi-brand used cars in ex- tering new businesses in the automotive space. He most modern engine production facilities in India, change for a new Renault car. added that the pre-owned car market in India has but by any global standard, noted Peter Hertinge, The Renault Selection facility in Bangalore is steadily gained momentum over the past decade, Senior Vice President, Global Operations and spread over 21,000-sq ft, and can accommodate spurred by new model launches, quicker upgrada- Quality, Volvo Penta. Hertinge said the plant is 100 cars at any given point in time, giving cus- tion cycles by customers and rising income levels. highly automated with integrated testing facilities, tomers a large range to choose from. The Banga- and has quality standards in place to consistently lore facility is the first of four Renault Selection manufacture engines suitable for customer require- showrooms that are currently being set up, with ments and fulfil latest emission regulations. the others being set up in Nagpur, Jaipur and The VEPT plant in Pithampur is part of the VE Chandigarh. Commercial Vehicles’ joint venture between the Volvo The company said it puts each car that comes Group and Eicher Motors. It is one of six manufactur- into Renault Selection through 199 quality checks, ing plants that the Volvo Group has invested in, in which authenticate the vehicles’ condition, along India, including several in Bangalore for the Trucks, with accompanying documents to offer customers. Buses and Construction Equipment divisions.

autotechreview June 2016 Volume 5 | Issue 6 13 Guest commentary

SAKET MEHRA is a Partner at Grant Thornton India LLP

EMERGING TRENDS IN CORPORATE GOVERNANCE LANDSCAPE

Over the years, companies across the globe have understood the THE EVOLVING REGULATORY FRAMEWORK AND CHALLENGES need and importance of an effective Enterprise Risk Management (ERM) function, especially after catastrophic events such as the As a step towards bringing transparency and sustainability of do- Dotcom bust, subprime mortgage crisis, European sovereign debt ing business, the Companies Act, 2013 provides for a major over- crisis to the latest Chinese stock market crash. However, the nature haul in the corporate governance norms for all companies regis- of risks continues to change and evolve with the passage of time. tered in India. The requirements under the Companies Act, 2013 In 2015, geopolitical risks, social risks, vendor risks, regulato- and the rules notified thereunder are applicable to every compa- ry compliance risks and cyber security risks were the major ones ny or a class of companies (both listed and unlisted) as may be that kept the CXOs on guard. From Europe’s mass refugee crisis provided therein. For example, while listed companies already to economic slowdowns in emerging markets, from ever rising maintained internal audit departments (as per requirement of numbers of terrorist’s attacks and cyber-attacks to water shortag- Clause 41 of the Listing Agreement), the Companies Act, 2013 es, risks have been making headlines over the last few years. has extended the coverage to unlisted public companies and pri- Over the years, both external and internal risk events such as vate companies meeting specified criteria. The Act also requires business interruptions, market and technology developments – the Audit Committee or Board to formulate the scope, function- volatility or stagnation, cyber incidents, natural disasters, chang- ing, periodicity and methodology for conducting internal audit. es in legislations and regulations, employee frauds, etc. have led Under the revised regulatory environment, responsibility and to enterprises realign and re-strategise their business models. liability of Directors have also been elevated to an unprecedented Managing these risks requires organisations to build more robust level. For example, section 134 (5) requires the directors of a list- and mature risk management framework, stronger controls, bet- ed entity to state in the Director’s Responsibility Statement about ter risk cautioning mechanism and smoother processes for risk the adequacy and effectiveness of internal financial controls. The analysis and mitigation. term internal financial controls has been further explained to in-

14 www.autotechreview.com clude policies and procedures, safeguarding of assets, prevention and responding to mergers, acquisitions, and changes in man- and detection of frauds, accuracy and completeness of account- agement teams, business structure, products, services and dis- ing records, and timely preparation of reliable financial informa- tribution channels. tion. The auditors are also required to provide their opinion on Companies Act, 2013 aims to improve the governance stand- internal financial controls as part of their reporting requirements ards, establish accountability on auditors and management, pro- under section 143 of the said Act. The Act also requires the Di- tect shareholders rights and bring transparency in financial re- rectors to comment upon the compliance with the provisions of porting and disclosures. The 2013 Act has been developed with a applicable laws and regulations. view to enhance self-regulation and encourage corporate democ- Further, section 134(3) (n) requires a statement indicating de- racy. The act aligns itself to the need of reducing the number of velopment and implementation of a risk management policy for government approvals required for ease of doing business in In- the company including identification therein of the risk elements, dia. The act requires companies to adopt good governance norms if any, which in the opinion of the Board may threaten the exist- by embedding a control culture, which flows from the top and ence of the company. forces entities to revisit their risk mitigation strategies in light of In light of the above regulatory amendments, it is evident global warning on corruption and malpractices. that the continued focus on taking an enterprise view of risks will challenge organisations to break down barriers and promote greater information, transparency and collaboration. Functions WHAT SHOULD BE DONE? and processes that do not consider the broader risk environment of the organisation are subject to increased scrutiny by regula- Thus, it is imperative to have an ERM policy and framework to tors, auditors and key stakeholders. identify these new and emerging risks and also devise an effective Another major challenge in establishing good governance mitigation strategy for effective and efficient management of risks. norms is around multinationals not paying their fair share of tax Such a risk management framework needs to be supported by a and taking advantage of the arbitrage opportunities afforded by risk management structure, defining the entity’s alignment of the outmoded principles of international taxation. As an effort to en- risk management function to its vision and mission statement. hance transparency, G20 countries and Organisation for Economic The framework should also include the risk appetite of the entity, Co-operation and Development (OECD) joined hands in order to risk rating criteria, evaluation and prioritisation criteria, roles and tackle Base Erosion and Profit Shifting (BEPS) and close gaps in responsibilities and a formal reporting structure to the Board of international taxation. OECD came out with detailed reports on 15 Directors. As part of the framework, an emerging risks log should point Action Plan to revamp international taxation. BEPS Action be created to enable decisions around which risks should be miti- Item 13, in particular, aims to transform the way in which related gated on a priority, which risks can be transformed into opportu- entities transact with each other requiring them to reconsider the nities and which risks needs to be avoided completely. transfer pricing documentation and reporting to the tax authori- Good governance practices can provide an answer and influ- ties through country-by-country reporting (CbCR) (applicable to ence the ways in which companies are able to attract capital and companies beyond a certain threshold) and suggesting a three tier increase their valuation. Focused corporate governance issues in documentation structure: master file, local file and CbCR. emerging markets can improve access to globally present financ- ing sources. Investors need to feel secure in the process that their rights are being properly protected by controlling owners and the AUTOMOBILE SEGMENT IS NOT ISOLATED! management. They also need to know if the company has set up minimum governance standards to reduce the risk in case the Governance standards play a significant role in an entity’s per- controlling group abuses their rights. Good governance, by its na- ception value and enterprise value. Uncertainties in today’s envi- ture, demands effective system of internal control. ronment present both risk and opportunities to erode or enhance The business environment is changing. This includes chang- value. However, the challenge for the management is to deter- es in customer preferences, technology and environmental mine how much uncertainty to accept as it strives to grow stake- norms. This has forced all components of the automobile indus- holder’s value. In recent past, fuel economy test procedures and try value chain to re-assess the impact of such changes and in- methods by major players have resulted in huge penalties, dip in clude adoption of a formal risk management framework as part share price, tarnishing the brand image and impacting the overall of their overall governance structure. The Board of Directors enterprise value. would also play a significant role in discharging their duties to- Regulatory requirements continue to increase the expecta- wards developing and maintaining an effective governance tion of risk and capital management. The enhanced techniques framework. require deep technical skills in market, liquidity, credit and The entire industry needs to collaborate and devise counterparty, and operational risk management coupled with mitigation strategies to protect and safeguard the interests compliance, finance and treasury expertise. Traditionally, these of all stakeholders. verticals have operated in silos and now must be closely coordi- nated to report and act in a consolidated, enterprise-wide view. Business models, structures and change in target goals requires an ERM framework that is robust yet adaptable; incorporating Read this article on www.autotechreview.com autotechreview June 2016 Volume 5 | Issue 6 15 interview HELLA INDIA LIGHTING

“FRUGAL ENGg, COST INNOVATION HELPS OFFER FUTURE-READY SOLUTONS”

A change in its business strategy in 2011 saw Hella India Lighting Ltd push for the “technology of tomorrow, for the life of today on Indian roads.” That strategy has allowed the company not just to stay ahead of its competitors, but also build strengths that would hold it in good stead for a long time to come. In a recent interaction, Ramashankar Pandey, Managing Director, Hella India Lighting Ltd gave us deep insights into this strategy, and more.

Managing Director of Hella India Lighting Ltd since 2010, His professional journey started in 1997, when he joined BOSCH Ramashankar Pandey has over 18 years of experience in the as a Technical Graduate Trainee, quickly rising to the position of auto component industry. A university rank holder in Mechanical a Business Manager/ Profit Centre Head by 2003. In 2004, he Engineering, Ramashankar Pandey passed out of the National joined Timken as a Business Manager, responsible for its after- Institute of Technology, Calicut in 1997. He then completed a market business. In 2006, Pandey joined Hella Asia Singapore to diploma in Business Finance from the Institute of Chartered lead its Indian aftermarket start-up, and joined Hella India Light- Financial Analysts of India (ICFAI) and has also done a course on ing Ltd board in 2009. Executive General Management from IIM, Bangalore. He also has a Six Sigma green belt certification.

16 www.autotechreview.com ATR _ We have seen rapid development of development and technology of LEDs, in an accident situation. What also helped lighting technology in the last few years, even when the market had no such us was upcoming competition in the CV especially in the area of LEDs. What do demand, at that point of time. The initial market after the entrance of multinational you attribute this to? purchase cost was high and this created CV makers in India. Even the local players RAMASHANKAR PANDEY _ The general initial resistance in adoption among fleet have upped the ante in terms of product awareness about LEDs in the Indian con- owners and OEMs alike, but as it was a introductions. That has helped. text has been driven by the penetration maintenance free option, fortunately by of this technology in home lighting. In 2014-15 we started getting some green LEDs also offer the industry flexibility in that segment, you have educated con- shoots. We partnered with most of the terms of design and styling. How do you sumers, who dictate the technology they OEMs in these years, and in the last one see that developing over years? want and the Indian Government part- year, we have clearly seen the acceptance There is a very high need for differentia- nered the penetration. In the automotive of LEDs for tail lamps among all CV man- tion among OEMs in the current tough industry, OEMs have a bigger role in the ufacturers in the country. On the signal/ and competitive market, as customers adoption of LED technology, be it for sig- rear lighting at least, especially in the CV have more and more choice. LEDs offer nal lighting and front/ rear lighting. segment, LEDs would become a norm. immense possibility of design and styling There is awareness today about daytime options due to its flexibility of application. running lights (DRL), initially fitted in Talk to us about the full LED tail lamps To bring differentiation in front lighting is luxury cars and slowly becoming a nor- that Hella developed and produced locally still an expensive proposition. However, mal trend. Full LED headlamps like for trucks. signal lighting cost is moderate, and that’s Matrix LEDs still remain in luxury cars, We were the first company in India to the reason why most of the signal lighting but they’ve been able to drive some curi- make a fully-sealed LED stop/tail lamp for is getting converted to LEDs. That leads osity among consumers. CVs with 5 Years warranty, high impact me to another important point. In front Overall, LED technology is still fairly lens material and extremely robust against lighting, even if you don’t convert the full expensive. The transition cost from Halo- vibration to withstand tough operating headlamp into LED, adoption of add-on gen to Xenon to LED is still very high. condition. And regulation was not the features such as DRLs or even signatures The industry knows that LEDs offer a lot prime motivation. It was driven by the will pick up speed. Styling and signature of safety and styling in vehicles, but the partnership between us and the OEMs is a very strong trend, and we ride that cost continues to be prohibitive for mass towards better road safety by ensuring wave as well with our products. adoption. In India, from a signal/ rear visibility. It offers roughly 3-4 m of extra OEMs can change the look and feel of lighting perspective, we have seen good braking distance as compared to a bulb the vehicle by using lights as a signature progress across all segments, although lamp, which becomes lifesaving distance or differentiator. This is a great opportu- two-wheelers were one of the early adop- ters. Unfortunately, we haven’t seen much movement in front lighting because of the cost factor. Secondly, from a Hella India perspec- tive, in 2011 we found that almost 90 % of trucks on the roads were either fitted with Hella’s bulb-based chamber lamps, or a similar design with similar old technology of stop/tail lamps. This technology being old needs heavy maintenance and has very high rate of failures. While studying road accidents in night time, we found that tailgating was one of the major rea- sons for road fatalities in India involving trucks, because of dysfunctional or una- vailable tail lamps. The filament technol- ogy used in the past didn’t last long enough for even a single trip. Even today, you would see 80 % of the trucks without a working tail lamp. We took this as a new strategy to drive the market. The whole DNA of the organi- sation changed, when we decided to stop developing and advocating bulb-based tail lamps for Commercial Vehicle in India. It was decided to invest only on the design, Pandey expects LED signal/ rear lighting to become a norm in the CV segment autotechreview June 2016 Volume 5 | Issue 6 17 interview HELLA INDIA LIGHTING

nity for us to push technology as a differ- live on future forecasting of technology, choose from. This approach offers high entiator. But in doing this, it is important our business model is different. Our busi- degree of innovation possibilities to the to understand that we won’t be able to ness – part of the Special Original Equip- engineering department of these OEMs. push technology till the time it is afforda- ment (CVs) category with Hella – has ble. Frugal engineering, cost innovation or high variety, low quantity and mass cus- What about xenon lights? Do you see reverse innovation will be fundamental, tomisation. Unlike passenger cars, which LEDs completely replace xenon as a light- and that’s what we are working on. in the Hella world fall under the automo- ing technology? tive category, the volumes for specific I’m very confident that India’s transition Clearly, LEDs offer a lot of benefits in the models of CVs are relatively smaller and is from halogen to LED. I don’t see any sense that they are controllable, are thus offering product differentiation is a of our customers getting excited with energy-efficiency and offer flexibility in challenging task, hence Special OE at anything in between. I see the same the use of colour. These seem to all work Hella takes care of this business. trend in two-wheelers and tractors as Apply a fine mist of lubricant, exactly where needed. in favour of future mobility. We are probably the only company in well. Today, with costs coming down, it Let’s Talk LEDs indeed are a boon for future mobil- India who build the core of the product makes more business sense to get into In your products, and how you can use less of it in ity, especially electric and hybrid vehicles. ourselves, based on our technology and LEDs. At this year’s Auto Expo, for exam- ® The LED product we introduced for trucks market forecasts. To some extent, we are ple, one of our full LED headlamps was your metal stamping operation. The MicroCoat reduces almost 80-90 % of energy con- already doing advanced application engi- on display on an e-bus. I couldn’t have about Oil Lubrication System from Nordson EFD applies a thin, sumption, as compared to bulbs. In EVs, neering. When customers have a require- expected this two years back. From a precise film of lubricant exactly where it’s needed, LEDs can help batteries retain charge for a ment, we are able to pick from our library technology upgrade point of view, you reducing oil consumption by up to 85%. But that’s lot longer – a pain point for the industry of solutions. For instance, we have made have no barriers moving to LEDs. This is just the beginning. until now. different types of projector modules, and possible because of the standardisation, depending on the customer need, we are modularisation and flexibility that LEDs Cuts manufacturing costs Talk to us about Hella India’s approach to able to offer the right product. For that, offer, leading to mass customisation. • Can double tool life design, development and technology. we do need to tap the outcome of our • Virtually eliminates disposal of wasted oil We have offered the industry a lot of inno- core research at Hella Germany. Today, we The other critical global trend is that of vation in the past few years, and OEMs already have a roadmap of products ready light-based driver assistance systems. Increases productivity today only look at us for solutions. The for the next four to five years. How do you see that developing in the • Presses run up to 40% faster change in strategy, as I said earlier, hap- That is where we are unique. We are Indian context? • Reduce VOCs for a cleaner, fog-free pened in 2011, when we proposed the fol- capable to make an offer of fully homolo- There is already a discussion in this environment lowing punch line: “Technology of tomor- gated headlamp in three to four weeks’ regard in some segments of the indus- row, for the life of today on Indian roads.” time as these modules are homologated try, but it won’t be adopted entirely for Improves your end product We decided to jump technologies to bring for all light functions beforehand by Hella the Indian volumes. We showcased • Stops slug pulling and part deformation products that are futuristic. We focus not India Lighting as standard product, and dynamic bend lighting with one of the just on the product specifications, but also then depending on customer need, we top two manufacturers at the last Auto • Makes higher-quality evaporating lubricants a on manufacturing technology, design and mass customise the styling element. Our Expo. Many of these companies also more viable, cost-effective option development. And all of that is based on time-to-market is much faster compared have a strong export focus, and it makes Better product quality, with lower cost and benefits that are acceptable to to our competitors. Also, our customers sense for them to look at light-based our customers. don’t have to always bear the total cost of DAS. I clearly see a lot of interest in manufacturing costs. That sounds like a Our approach is unique in the sense tooling if they choose one of our standard dynamic bend lighting or a cluster that pretty slick operation. Let’s get together that our product development is not products. In our frugal approach, we has DRL and fog lights together. I don’t and talk about how Nordson EFD’s dependant on customer’s current demand aggregate the investment of many OEM expect technologies like camera-assisted technology and expertise can help. alone but mostly depends on their future projects into our investment, and then Matrix beam to be mainstream in India or latent demand of differentiating their spread the cost across the combined vol- in a year or two due to high cost, but product. We believe in the future trend ume. For any single low volume project to there are enquiries about solutions such See it in action and have invested a lot on building capa- bear the tooling cost may be difficult, but as auto-levelling, auto-dippers and no- bility in-house, and in our D&D, and man- this way we are able to bring down cost glare lamps. nordsonefd.com/precision-dispensing ufacturing technology. Then, we also for everyone. This leads to technology needed to ensure there was a business jumps. This also offers each OEM the flex- case for this. So, we had to do enormous ibility to opt for their own signature styl- amount of value engineering in India to ing, but the heart remains the same. make sure we met the target specs and standards for the product. So, being future ready is a way of life at Text: Deepangshu Dev Sarmah Hella India? Photo: Hella India Lighting Do we see Hella India getting into core Indeed. Today, we are ready with the R&D or advanced development at some complete signal lighting package in LED stage? at different levels, and for different appli- Nordson India Pvt Ltd, 143A, Bommasandra Industrial Area, We weren’t into advanced development or cations. We have offered our customers a Read this article on core research in the past. But since we library of products that they can pick and www.autotechreview.com Bangalore – 560099, India. [email protected] +91 80 4021 3600 18 www.autotechreview.com

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Auto Tech Review-0316.indd 1 2/28/16 11:33 AM study SEMICONDUCTORS semiconductors in ADAS: CHALLENGES & OPPORTUNITIES

In a new study, McKinsey & Company says semiconductor companies can help take Advanced Driver Assis- tance Systems (ADAS) applications to a new level — provided that they are ready to embrace change.

Authors

SEUNGHYUK CHOI FLORIAN THALMAYR DOMINIK WEE FLORIAN WEIG is an Associate Principal in is a Consultant in McKinsey is a Principal in McKinsey is a Director in McKinsey McKinsey in Seoul (South Korea). in Munich (Germany). in Munich (Germany). in Munich (Germany)

Demand for advanced driver assistance automotive brands, as well as one of THE OPPORTUNITIES AND systems (ADAS) — those that help with their most important revenue sources. CHALLENGES AHEAD monitoring, warning, braking, and steer- And the same technologies that enable ing tasks — is expected to increase over today’s ADAS offerings could also be Although ADAS technology has the poten- the next decade, fuelled largely by regula- used to create fully autonomous vehi- tial to transform the automotive sector, its tory and consumer interest in safety appli- cles, which are now a major focus of current annual revenues — which range cations that protect drivers and reduce research and development, both at from about $ 5-8 bn, according to most accidents. For instance, both the Euro- OEMs and at high-tech players that have sources — are modest compared with pean Union and the United States are recently entered the automotive sector, those for other automotive systems. For mandating that all vehicles be equipped including Google. Any ADAS technology instance, 2015 revenues were about $ 30 with autonomous emergency-braking sys- that gains early support could therefore bn for audio and telematics and about $ tems and forward-collision warning sys- have an advantage if self-driving cars 60 bn for climate control. Part of the prob- tems by 2020. A recent McKinsey survey reach the market. lem is that many of the most promising also suggests that car buyers are becom- Many semiconductor companies now ADAS applications are still being refined ing even more interested in ADAS applica- offer ADAS products, or are developing or have not yet hit the market; still others tions that promote comfort and economy, them. As with any new technology, are expensive and mostly available in pre- such as those that assist with parking or however, much uncertainty persists mium cars. But one of the most important monitoring blind spots. about the market, including how con- factors inhibiting demand may be a lack Although ADAS applications are still sumers will respond to more advanced of consumer awareness. in their early days, OEMs and their sup- applications in which a computer con- In a recent online survey of more than pliers realise that they could eventually trols or assists with steering and other 4,500 car buyers in five countries con- become the main feature differentiating critical driving functions. ducted by McKinsey, many respondents

20 www.autotechreview.com Semiconductors 2015 Advanced driver system Exhibit 1 of 5

were unfamiliar with ADAS applications,Exhibit 1 Many car buyers are still unaware of the technology for advanced driver- and few purchased cars with this technol- assistance systems. ogy, 1. The survey offered reason for Transfer rates and process-step values in the consumer decision journey for advanced driver-assistance 1 optimism; however, since it revealed that systems in selected countries, % the repurchase rate for those who did buy XX Transfer rates2 Process-step values3 a vehicle with ADAS was quite high, rang- All recent Intent to Awareness Trial Purchase ing from 87 to 89 %. This finding sug- vehicle buyers repurchase4 gests that once consumers become famil- iar with ADAS, they will prefer cars with Germany 77 44 29 87 these features. 100 77 34 10 8 Even though industry experts hold dif- ferent opinions about 2015 revenues and Japan 49 26 42 87 growth prospects for ADAS, most expect 100 49 12 5 4 to see an annual increase of more than 10 South Korea 72 39 32 88

% from 2015 to 2020. For instance, one 100 72 28 9 8 leading analyst predicts 16 % growth dur- United States 63 27 47 89 ing this period, and a second predicts 29 % growth, 2. This could give the seg- Semiconductors 2015 100 63 17 8 7 Advanced driver system ment one of the highest growth rates in 1 The online survey included 4,500 car buyers in China, Germany, Japan, South Korea, and the United States. 2 %Exhibit of buyers moving2 of 5from one stage of the consumer decision journey to the next. 3 % of all recent vehicle buyers that reach a given step of the consumer decision journey. Figures may not sum, because of rounding. the automotive sector and related indus- 4 Includes consumers who said they would definitely or probably purchase cars with ADAS features. tries. However, with the base price for Source: McKinsey survey on connected cars, 2015 cars remaining relatively stable (CAGR ~ 1 1 %), semiconductor companies and Exhibit 2 The market for advanced driver-assistance systems is expected to show strong other suppliers may face pressure from architectures and higher frequencies, as well as during less-than-ideal environmental conditions, momentum through 2020. lower power-consumption requirements. such as rain and fog. OEMs and customers to keep ADAS costs Compound Global revenue projections for advanced driver-assistance systems, $ billion annual growth low, even as the technology becomes Sensors. These devices gather information on their Many industry players are trying to improverate, individual2016–20, 1 2 standard. In consequence, we predict that immediateStrategy Analytics environment,TechNavio such as pedestrians and sensors. They are also attempting to optimize%5 system growth in ADAS value may proceed at a oncoming30 cars. Most have a limited measurement performance through better sensor fusion—the29 range and signal bandwidth, which makes it diffi- coherent combination of data from multiple sensors. 30.0 slower rate than growth in unit volume. cult to distinguish between “signal” (for example, On the hardware side, intersensor communication is 25 obstacles in the road) and system “noise.” It is a major challenge because it requires high bandwidth especially difficult for sensors to track moving objects and solutions for preventing network overloads.

20 17.6 ADAS TECHNOLOGY: OVERCOMING 18.2 16 LIMITATIONS TO ENSURE ACTIVE, 15

AUTONOMOUS SAFETY 11.1 3 14.5

10 8.73 One factor that could influence ADAS 10.5 8.43 uptake is the rate at which the technology 5 advances. Although semiconductor com- panies and other players have made 0 4 important enhancements in recent years, 2015 2016E 2018E 2020E there is much room for improvement. For 1Includes autonomous emergency-braking system, adaptive cruise control, forward-collision warning, lane-departure warning, parking assistance, back-side monitoring, night vision, driver monitoring (eg, for fatigue), and traffic-signal recognition. instance, forward-collision warning sys- 2Also includes adaptive front lighting and heads-up display. 3Most sources estimate 2015 revenues between $5 billion and $8 billion. 42018–19 compound annual growth rate used to derive 2020 market size for Strategy Analytics and TechNavio forecast. tems still have difficulty identifying 5Figures may not sum, because of rounding. objects, when a vehicle is traveling at Source: IHS; SBD; Strategy Analytics; TechNavio; McKinsey analysis high speeds. A typical ADAS application 2 3 incorporates many technologies, , but Players are currently optimizing the partitioning progress on both fronts, however. As one example, four stand out with regard to the chal- and distribution of system architecture to address Mobileye and various start-ups are trying to improve lenges they present: processors, sensors, Sensors:this issue. OnMany the software industry side, theplayers fusion of are image try - the functionalityis particularly of camera-based challenging. solutions, which Some OEMs and nonimage data is particularly challenging. Some typically have difficulty detecting obstacles during software algorithms, and mapping. ingOEMs to improve and tier-one individual suppliers are working sensors. together They rainstormsand or Tierin other I situationssuppliers when are visibility working together Processors: Electronic control units arewith also academia attempting to address to this optimise challenge, assystem can be is limited.with If camera-based academia solutions to address catch up to this radar challenge, (ECUs) and microcontroller units (MCUs) performanceseen in Daimler’s through collaboration better with the sensor Karlsruhe fusion and lidaras in canfunctionality, be seen they in could Daimler’s eventually collaboration Institute of Technology and the University of Ulm. dominate the ADAS market because of their lower are essential for most ADAS applications, — the coherent combination of data fromcost. “Onewith box” the solutions Karlsruhe that combine Institute lasers and of Technol- including autonomous driving. For ADAS multipleThe limited sensors. functionality On of today’sthe hardware sensors, combined side, camerasogy may alsoand become the University popular because of they Ulm. are The lim- to advance, processors need better per- inter-sensorwith their high communication cost, may be the greatest is constraint a major less expensiveited functionality than radar or lidar ofalone. today’s This is an sensors, to ADAS uptake. Many companies are making important development, since experts believe that formance, which could be enabled by challenge because it requires high band- combined with their high cost, may be multicore architectures and higher fre- width and solutions for preventing net- the greatest constraint to ADAS uptake. 4 quencies, as well as lower power-con- work overloads. On the software side, Many companies are making progress on sumption requirements. the fusion of image and non-image data both fronts, however. autotechreview June 2016 Volume 5 | Issue 6 21 study SEMICONDUCTORS

Software algorithms: In response to FedEx, as well as GPS data from drivers. ing out into software will offer more developments in sensor fusion, the indus- opportunities, and developing new strat- try is about to transition from embedded egies for collaborating with OEMs. Com- software running on a single ADAS-spe- AN EVOLVING panies that move quickly and establish cific ECU to software platforms running COMPETITIVE ENVIRONMENT themselves as ADAS players may gain on centralised ECUs or MCUs. These soft- the most when the market moves into a ware platforms have a higher level of Many players are aware that regulators phase of even higher growth. abstraction to allow flexible integration of will require vehicles to be equipped with sensor-fusion algorithms. Industry players certain ADAS applications over the next are now focusing on creating such algo- five years, and they are already preparing OPPORTUNITIES IN rithms, which allow for more accurate to capture growth. This activity is trigger- HARDWARE AND BEYOND synthesis of sensor data and more effi- ing unprecedented changes in the auto- cient processing, because they will help motive industry. First, more established We investigated ADAS hardware oppor- prevent data overload or slowdowns. high-tech companies, including semicon- tunities for semiconductor companies Another priority is creating algorithms ductor players, are actively pursuing through 2025 using a model that consid- that allow for safer car navigation and ADAS opportunities, even if they did not ered various factors, including expected more accurately predict all possible previously have a presence in the automo- end-market adoption and price erosion human behaviour — including potentially tive sector. In another active shift, OEMs for systems and components. We found irrational responses — in various situa- — once the primary drivers of automotive that overall revenues could increase tions, such as when a collision between innovation — may now be more willing steadily, reaching about $ 4.6 bn to $ 5.3 two cars appears imminent. to collaborate with semiconductor compa- bn in 2025. Parking-assistance systems Mapping: When GPS coverage fails, nies and other Tier II suppliers, whose may generate the most revenue for semi- such as during tunnel travel, detailed technologies facilitate their development conductor players, followed by auto- and accurate mapping systems can help of ADAS. Similarly, both Tier I and Tier II mated emergency braking, adaptive prevent accidents. These systems also suppliers are aggressively pursuing merg- cruise control, and forward-collision store geographical and infrastructure ers and acquisitions to ensure they have warning. For system components, the information, making updates as needed, all the capabilities needed for ADAS, best opportunities appear to be in pro- semiautonomous driving will not become a reality In response to developments in sensor fusion, the anduntil communicate the industry has a withcost-effective on-board lidar system sensors industry including is about to transition software from capabilities.embedded soft- cessors (generating an anticipated 37 % to thatdetermine is fully integrated a car’s with exact other sensors. location. OEMsware runningSemiconductor on a single ADAS-specific companies ECU to now of total revenue) and optical semicon- and other players in the automotive softwarereceive platforms moderate running on centralized revenue ECUs from or ADAS — ductors (28 %), as 4 suggests. Software algorithms. Running on ECUs and MCUs, MCUs. These software platforms have a higher industryalgorithms are use thelooking input from for sensors lower-cost to synthesize meth level- of abstractionless than to allow$ 2 bnflexible in integration2015, compared of with With processors and sensors expected odsthe to environment construct surrounding and maintain a vehicle inmaps. real sensor-fusion$ 29 algorithms.bn for automotive Industry players electronic are sys- to account for most revenues, it makes time (going above and beyond the processing that now focusing on creating such algorithms, which Somesensors of have the already most completed). recent Thesolutions algorithms allow fortems more accurate— but synthesis this is of expected sensor data to grow rap- sense for semiconductor companies to includethen provide deploying output to the “mapping driver or specify cars” how the and moreidly. efficient To processing,ensure that because they they willcapture help full consider competing in these segments by equippedsystem should with actively 3D intervene lasers in and vehicle 360° control. high- preventvalue, data overload semiconductor or slowdowns. Another companies must creating differentiated offerings. In addi- SemiconductorsThis could require some 2015 of the most complex in-car- priority is creating algorithms that allow for safer car definitionAdvancedsoftware integration cameras.driver system ever created,Map developers since any decisions are navigationdecide and more where, accurately how, predict and all possible when to com- tion to hardware, which still accounts for alsoExhibitthat leveraging the algorithms 3 of 5 specify,data fromsuch as thesensors application human pete.behavior—including This could potentially involve irrational rethinking their most of their revenues, semiconductor installedof emergency on brakes, commercial are critical tofleets, ensuring such safety. as responses—inproduct various focus situations, on suchhardware, as when since branch- companies could capture value by a collision between two cars appears imminent. expanding their offering into software and algorithms.

Exhibit 3 Four control points in advanced driver-assistance systems are key for autonomous Processor enhancements: Those players driving and product differentiation. with experience in adjacent industries,

Key control point such as consumer, mobile, or data pro- cessing, could be best positioned to Connectivity Actuator Mapping Processors Internet between Takes prompt Stores and updates (ECUs/MCUs)1 improve processor performance — the vehicle-to-vehicle Data cloud actions based on geological Process data most important selling point. Since fast and vehicle-to- computed results and infrastructure needed to make infrastructure systems information decisions processors are found on the smallest nodes, they require huge investments in Sensors R&D and manufacturing. Sales in the Perceive external Middleware data automotive market alone will not justify

Software these investments, so semiconductor com- algorithms panies may need revenue from other sec- tors to receive a decent return on invest- ment. In addition, players with experience in adjacent industries may be able to

1 Electronic control units/microcontroller units. adapt some of their products for ADAS Source: McKinsey analysis applications, reducing development time. 3 For instance, NVIDIA adapted its Tegra

22 www.autotechreview.com 5 to hardware, which still accounts for most of their investments in R&D and manufacturing. Sales in revenues, semiconductor companies could capture the automotive market alone will not justify these value by expanding their offering into software and investments, so semiconductor companies may need algorithms. revenue from other sectors to receive a decent return on investment. In addition, players with experience Processor enhancements. Those players with experi- in adjacent industries may be able to adapt some Semiconductorsence in adjacent industries, 2015 such as consumer, of their products for ADAS applications, reducing Advancedmobile, or data driver processing, system could be best positioned development time. For instance, NVIDIA adapted its Exhibitto improve 4 ofprocessor 5 performance—the most Tegra platform, which was originally developed for important selling point. Since fast processors are gaming devices, smartphones, and tablets, for use in found on the smallest nodes, they require huge automotive systems.

platform, which was originally developedExhibit 4 For semiconductor companies, processors and optical semiconductors are expected to for gaming devices, smartphones, and account for most hardware revenues for advanced driver-assistance systems in 2025. tablets, for use in automotive systems. Semiconductor revenue in advanced driver- Semiconductor revenue distribution on device Sensor enhancements: Many different assistance systems per application, %1 types in 2025, %1 Most important components types of sensors exist, but three are most 100% = $1.8 $3.4 $4.6 billion– billion– billion– Processors Microprocessing units, important for ADAS. The first and most $2.0 $4.2 $5.3 37 electronic control units, billion microcontroller units, digital billion billion signal processors, and cost-efficient option involves optical systems on a chip for signal processing sensors and camera-based solutions. 30 Parking assistance 38 32 Optical Complementary-metal- semiconductors 28 oxide-semiconductor These sensors are versatile and can assist imaging sensors, LEDs, laser diodes, and photodetectors with a wide range of ADAS functions, but AEB, ACC, and 19 21 2 they are easily affected by poor weather 12 FCW Radio- Radio-frequency frequency 13 transceivers and radar Lane-departure preprocessing 12 semiconductors conditions and other environmental 13 14 warning Memory System memory hazards. Optical sensors and camera- 13 13 13 Blind spot 12 4 based solutions also require complex 5 6 Driver monitoring 10 6 4 Adaptive front lights Mixed signal Power-management 2 3 software algorithms to recognise objects, 2 Night vision 8 integrated circuits, bus 8 10 10 transceivers such as pedestrians and other vehicles. Other3 2015 2020E 2025E Other Discretes, other types The second category involves lidar 3 of sensors systems, which use a scanning laser to generate a complete 3D image of the 1Figures may not sum to 100%, because of rounding. 2Autonomous emergency braking, adaptive cruise control, and forward-collision warning. environment. Unlike optical sensors, lidar 3Includes, among other categories, back-side monitoring and traffic-signal recognition. Source: McKinsey analysis is less sensitive to weather conditions and directly provides the location of objects 4 around the vehicle. Although prices have fallen in the past decade, dropping from 7 many tens of thousands of dollars to less codecs) and algorithms, including those would also ensure that OEMs have a bet- than $ 10,000, they are still too expensive used for real-time processing of sensor ter chance of differentiating themselves for deployment. data. Bundling may generate more value from competitors for both driver-support Finally, ADAS often incorporates than simple hardware enhancements, and autonomous-driving functions. short- and long-range radar using electro- such as improved memory or central-pro- The need to develop innovative ADAS magnetic waves in the range of 20 to 80 cessing-unit performance. In addition, technologies is prompting OEMs to collab- GHz for determining the distance, speed, semi-conductor companies could attempt orate more closely with Tier II suppliers, and direction of objects. These sensors to provide more modules or integrated thereby giving these suppliers a more crit- function better than others during solutions, such as systems on a chip. ical role in vehicle design and manufac- adverse weather conditions, but they typ- ture. The exact assistance that an OEM ically involve compromises in measure- requests will vary by company and appli- ment range and angle. For instance, long- STRATEGIES FOR STANDING OUT cation, so semiconductor companies range radar can detect obstacles up to FROM THE CROWD should be prepared to provide different 250 m away, but the measurement angle types of support. For instance, they might is quite narrow. In consequence, adap- The changing automotive market offers actively help OEMs with integration, tive cruise control often combines long- new opportunities for semiconductor assist with the development of customised range radar with short-range radar, companies, but it will also be intensely integrated systems, or support the optimi- which has a wider measurement angle. competitive. The following three factors sation of system performance. Although sensors generate less revenue may be crucial to winning market share. Multiple collaborations across the value than processors, semiconductor compa- Strong relationships with chain: Numerous non-traditional auto- nies may prefer to work in this area OEMs: Although OEMs have long relied motive players and small to midsize busi- because scale is of lesser importance, on Tier I suppliers to provide innovative nesses are now trying to capture value and it is easier to differentiate products. components, they are willing to take a from ADAS. Semiconductor companies Software: Moving into the software space much more active role in ADAS develop- could pursue multiple collaborations may be difficult, since semiconductor ment. In fact, OEMs may eventually with these players — even those that companies often lack advanced software assume the lead because the systems may be competitors or customers. For skills. To compete, they may need to build found in fully autonomous vehicles must instance, they may seek to complement their software skills internally or under- work together closely. If they drive ADAS their hardware knowledge through part- take mergers and acquisitions with play- development, OEMs will have the free- nerships with competent software play- ers that have the necessary capabilities. dom to select the best sub-systems — ers that have strong automotive track Semiconductor companies should con- including sensors and general control sys- records. In some cases, two or more sem- sider bundling hardware with non-silicon tems — from a variety of Tier I suppliers, iconductor companies may work offerings — both software (for instance, rather than relying on a single source. together. For example, Renesas Electron- drivers, operating-system adoption, and Taking charge of ADAS development ics collaborates with more than 150 com- autotechreview June 2016 Volume 5 | Issue 6 23 of respondents said they would be willing to use an the safety of the ADAS component and the autonomous vehicle if their concerns were addressed entire system under different environmental and (Exhibit 5). operational conditions.

Since safety and security issues could derail the Autonomous driving is supported by cloud data, car- ADAS market, it would be helpful for semiconductor to-car communication, and car-to-infrastructure companies to become familiar with Automotive communication. In consequence, ADAS systems must Safety Integrity Level risk-analysis methods and per- link to a vehicle’s communication module directly Semiconductorsform them during the 20 earliest15 stages of product to enable fully autonomous driving. Although these Advanceddevelopment, driver thereby system eliminating any potential for modules have intrinsically secure connections, studyExhibitcomponent 5 of or SEMICONDUCTORS5 system-level failures. As products additional protections will be needed. Advanced advance in development, semiconductor companies hardware firewalls, incorporated network-level may need to conduct extensive testing that evaluates security elements (for instance, crypto chips), and

Exhibit 5 Despite reservations about autonomous driving, more than half of surveyed drivers Although their caution is understandable, would use this technology if their concerns are addressed. our research suggests that early entry may

Main sources of concern, % of respondents1 Share willing to use autonomous provide long-term benefits. First movers vehicles if concerns are addressed, Distrust in a computer % of respondents may have a chance to shape the industry driving the vehicle 48 — for instance, by helping to establish Fear of vehicle systems being hacked 38 technical standards or defining fundamen-

Extra cost of autonomous Yes tal system-design architecture. And com- vehicles 33 45 55 panies that secure intellectual property for Distrust of other human drivers 28 their ADAS technology early could poten- No or Loss of the pleasure tially collect royalties over a longer period, uncertain of driving 20 as Bosch did when it created the control- Lack of willingness to share ler-area-network bus system that became data with public authorities 19

Possibility that the vehicle an automotive standard for many years. will travel slower than one 17 operated by a human driver Early entry may also make sense when Lack of comfort when a considering the customer base and the computer is driving 10 industry. OEMs need to screen and priori- Other 1 tise their ADAS suppliers now, since auto- motive design cycles are long, so first 1Based on responses from car buyers in China, Germany, Japan, and South Korea (n = 3,500); data from US respondents were not available for this question at the time of publication. movers may be best positioned to capture Source: McKinsey survey on connected cars, 2015 value when sales volumes increase. They 5 could also gain a long-term advantage

10 because OEMs and Tier I suppliers may want to stick with trusted, well-known panies, including other semiconductor respondents said they would be willing to suppliers as they develop next-generation players, on infotainment and ADAS capa- use an autonomous vehicle if their con- technologies to create fully autonomous bilities. By collaborating with multiple cerns were addressed, 5. vehicles, which are expected to reach the players, semiconductor companies may Since safety and security issues could broad market between 2025 and 2030. develop high-quality solutions that differ- derail the ADAS market, it would be entiate them from competitors. They may helpful for semiconductor companies to also reduce costs, optimise resource use, become familiar with Automotive Safety CONCLUSION and decrease time to market. While Integrity Level risk-analysis methods and many semiconductor companies may perform them during the earliest stages ADAS applications may represent the form partnerships with existing players, of product development, thereby elimi- next critical business opportunity in the they could also consider collaborating nating any potential for component or automotive sector, and semiconductor with start-ups that offer strong solutions. system-level failures. As products companies are well positioned to capture Differentiation through safety and secu- advance in development, semiconductor it. Their technological expertise — rity: ADAS technologies already have companies may need to conduct exten- always valued by OEMs — is now more high safety requirements, and these will sive testing that evaluates the safety of important than ever, especially if they increase as applications take more active the ADAS component and the entire sys- can provide components and solutions control of cars. In fact, many future ADAS tem under different environmental and that improve system-level capabilities. technologies will be rated at Automotive operational conditions. But it may be equally vital for semicon- Safety Integrity Level D, the classification Autonomous driving is supported by ductor companies to adapt their tradi- reserved for components or systems, cloud data, car-to-car communication, tional business model by expanding into where a malfunction poses the risk of and car-to-infrastructure communication. software and integration capabilities and injury or death. ADAS security require- In consequence, ADAS systems must link by developing new strategies for working ments are also among the highest because to a vehicle’s communication module with OEMs and various players through- the consequences of a hacker’s interfer- directly to enable fully autonomous driv- out the value chain. Those companies ence with steering, braking, or other vehi- ing. Although these modules have intrin- that take action now, while the ADAS cle functions could be catastrophic. sically secure connections, additional pro- market is still in its early days, may A recent McKinsey survey on con- tections will be needed. emerge as the winners. nected cars confirmed that consumers are concerned about the safety of ADAS autonomous-vehicle offerings. When WHEN TO PLAY: THE ADVANTAGES asked about autonomous driving, almost OF EARLY ENTRY half of respondents expressed distrust about the computers that control the vehi- Some semiconductor companies are hesi- cle, and 38 % stated that they feared tant to enter the ADAS market because Read this article on hacking. However, more than half of the technology is not yet mainstream. www.autotechreview.com

24 www.autotechreview.com

Cover Story AUTOMOTIVE LIGHTING MODULAR DESIGN FOR LED GLARE FREE HIGH BEAM

Headlamps and their lighting technology shall give a sense of safety but also have to face demands for high per- formance, low energy consumption and a great styling potential. Until now, the functionality of safety and assis- tance glare free high beam was only possible with xenon (HID) technology. In cooperation with Volkswagen, Valeo developed a new headlamp for the VW Passat (B8) which now fulfils the requirements in LED technology. It is built-up on a modular basis with use of two modules: one which integrates the glare free high beam func- tion (multi-functional module) and an additional one (complementary module) for styling and performance.

26 www.autotechreview.com Authors CONSIDERABLE EVOLUTION Since introducing LED front lighting systems, several technical solutions have Over the last two decades, there has been been developed by lighting engineers to considerable evolution in the field of exte- provide a similar functionality with all the rior lighting for automobiles. After the benefits of LED technology [1]. This counts first complex headlamp shapes which now also for the multi-functional module made new stylings possible for the front from Valeo which has been chosen from LAURENT EVRARD is Director Research & Development end of vehicles, the development of xenon among these solutions to equip the glare at Valeo Lighting Systems in bulbs opened the door to highper- free high beam function on the recently Bobigny (France). formance lamps in compact designs. They launched VW Passat (model year 2014, B8 were then followed by white LEDs which [2]). This solution is very close to the one offered new headlamp solutions for high used up till now with xenon lamps, and performance, low energy and a great styl- as a result, both the vehicle architecture ing potential for each automobile brand. and the control parameters can remain At the same time, multi-functional almost the same. front cameras have appeared on vehicles, BENOÎT REISS making it possible to detect the position is Advanced Engineering Research & Development Manager at Valeo of other vehicles on the road, especially at HEADLAMP STYLING AND Lighting Systems in Bobigny (France). night. Combined with adapted xenon E/E ARCHITECTURE headlamps, this technology has led to the development of the glare free high beam For the past two years, Volkswagen has or Adaptive Driving Beam (ADB). The defined common styling elements in its concept of glare free high beam allows to headlamp designs, in order to create a drive on high beam without glaring other common signature for all the vehicles in road users. Its first application of this the range. On the new VW Passat, this DR JOACHIM RIPPERGER function came in 2010, in the market by has been translated into the following key is Director German Customer Office, Valeo for the VW Phaeton. characteristics: Research & Development at Valeo Lighting Systems in Munich Based on a compact xenon headlamp :: two lighting modules, with a lens (Germany). module the ADB system provides five dif- appearance ferent light functions: :: Day-time Running Lamps (DRL) :: country light around each module for day time and :: city light night time signatures :: motorway light :: reduced height. :: high beam In 1, the styling elements of the VW :: glare free high beam with the same Passat headlamp are shown. Regarding DAMIEN CABANNE visibility as the normal high beam for the sharing of functions between the two is Research & Development the driver as a new ADB function. lighting modules, the exterior one (multi- Manager for Southern Europe Regional Operation at Valeo Lighting This new glare free function has rapidly functional module) manages the main Systems in Martos (Spain). became popular, as it really has part of the light beam and also includes enhanced visibility at night drives signifi- the high beam, while the interior one has cantly, while also improving the percep- the complementary role of spreading tion of other drivers (less glare because light when on low beam. The global E/E of the automation). architecture of such a headlamp for auto- mobile technology is based on three main elements: :: on the camera, to detect and character- ise the position of other vehicles in the field of view :: on the light control: this ECU which interprets the data from the camera sensors and other vehicle sensors (for example speed, steering wheel angle, inclination sensors etc.) and sends orders to the headlamp control units about which adequate light source should be lit, and which position the various motors should be in 1 LED headlamp with special styling elements for the VW Passat :: the headlamps (left and right). autotechreview June 2016 Volume 5 | Issue 6 27 Cover Story AUTOMOTIVE LIGHTING

Communication between these differ- beam) is in line with high range xenon driven by the light control unit which ent elements is established through data performances, the total quantity of light is contains all the data and parameters, buses, such as LIN or CAN depending on well below. linked to information from the camera requirements, operating in both directions and other vehicle sensors. in order to carry out diagnostics as well. As well as these three stepper motors, COMPLEMENTARY MODULE FOR the system also contains one fan which MORE LUMINOUS FLUX is necessary to cool down the LEDs CHARACTERISTICS OF (35W) used on the multi-functional mod- MULTIFUNCTIONAL MODULE That – along with the need to comply ule. All of them are located on the same with styling requirements – is the reason compact heat sink and interconnected The technical principles used for the why a complementary module has been through a combination of flat circuit multi-functional module are close to these integrated in this headlamp. This module boards and flexible connections. The solutions used on the xenon ADB systems is also 40 mm high and is designed to add compact fan has been specifically devel- (for example in VW Passat 2010, Phaeton about 600 lm of luminous flux in the oped for automotive applications in order 2010 or Volvo XC60 2013). A projector beam pattern of each function. This addi- to take all the thermal, environmental module, composed of several LEDs in a tional light is mostly “balanced spread and reliability constraints into account. It multi-cavity elliptic reflector, is optically light” which enhances driver’s visibility has already been used on several head- combined with a lens to project the light comfort and visibility conditions on nar- lamp applications. onto the road. row roads. Between the reflector and the lens, there is a multi-position light shield (aper- BENEFITS FOR DRIVERS ture) which can appear in different SYSTEM CONFIGURATION shapes. These shield shapes are projected As for any glare free high beam system onto the road by the lens. The different To ensure overall optimal light functions, like the LED headlamp presented here, shapes are located on a rotating drum and to avoid any visible separation the primary benefit for the driver is the which is activated by a stepper motor. On between the two modules, they must be possibility to drive on high beam with- the headlamp module used on the VW aligned with a precision of ±0.1°. This out glaring other traffic participants. Passat, for example, there are five differ- is the reason why they are mounted on This means, first of all, improved visibil- ent shield shapes, corresponding to the the same bracket inside the headlamp, ity in all traffic conditions. For instance, light shield’s five different positions. In 2 with an adjustment made during head- a recent study conducted by Darmstadt the beam patterns of the five different lamp assembly. Technical University [3] showed that the shield shapes are shown (glare free high Between the headlamp housing and use of glare free high beam improved beam left and right counts as one). the main bracket, there is another stepper the detection distance for obstacles by The headlamp module itself is motor, the third one in this headlamp 50 %, compared to a similar vehicle mounted on a swivelling bracket, similar which is used for automatic levelling con- equipped with a xenon low beam. The to the solution used for dynamic bending trol system (automatic adjustment on same study also showed that this signif- light. A stepper motor is used to move beam pattern according to vehicle load icant increase in detection distance is this bracket. With 300 steps over a range and its inclination, in order to optimise obtained without any increase in dis- of ±15°, it is thereby possible to achieve the beam pattern position in every condi- comfort due to glare, for either the a very high level of accuracy which makes tion to avoid glare for other drivers). Like equipped vehicle or other vehicles. the dark gap between the detected vehicle the other stepper motors, this one is also and the lighted area almost invisible for the driver. By way of comparison, if a less accurate system was used, for example with a 1° resolution, the minimum gap would be 2 m for a vehicle 100 m away, or around 4 m for a vehicle 200 m away. With this resolution, neither the oncom- ing lane nor the sidewalk would be lit up which would significantly reduce the improvement in visibility compared to an analogical system. As regards photometric performance, this module provides 315 lm luminous flux for the low beam function and 950 lm for the high beam function. Even if the maximum illumination value (respectively 2 Beam patterns for the five different shield shapes respectively light functions 50 lx for low beam and 125 lx for high (glare free high beam left and right counts as one shape and function)

28 www.autotechreview.com LED Xenon

tions which drivers are familiar with. A less measurable advantage, but one which is also very beneficial in terms of driver comfort, is the “smoothness” of the transitions between functions. This is

Country light due to the combination of both the mod- ule principle and the continuity offered by the stepper motors and the different system laws coming from the vehicle itself, including filtering of information from the camera.

City light BENEFITS FOR OEMS

In order to propose vehicles combining improved aerodynamics for better power efficiency with enhanced styling, OEMs are looking for increasingly compact light- ing modules. This is presented here with the multi-functional module which offers various advanced lighting functionalities within one single unit. In addition, the 40 Motorway light mm height of the module (compared to the more usual 60 mm on most products with similar functionalities) leaves room around it so that the DRL can be inte- grated around it. This means that the OEM’s brand awareness is clearly visible and fully com- patible with the headlamp design. The High beam module also offers the possibility of hav- ing a bezel with a heat sink styling directly mounted around it thus the over- all design is enhanced, to provide a more technical look. Another significant benefit is the standardisation of the module which can be used on different vehicle platforms. It could be exactly the same module (including DRL and style bezels), or the same module with different exterior Glare free high beam elements (for example for vehicles with a

3 Illumination level comparison of the new LED system (left) to xenon system (right) completely different optical key differenti- ators). In both cases, significant savings can be made in terms of development, The same type of effect is also visible more yellow and has a not so long range. since no new styling and no new module with the motorway function: this is acti- Since the module is embedded on a validation are required. vated when the speed exceeds 110 km/h. swivelling bracket, it also offers the possi- For most vehicles today, the head- Here, the left limit of the beam is raised bility of having the dynamic bending light lamps come in several versions: usually a from 70 to 120 m. This can be transferred functionality with each of the functions low range, and a high range with to a difference which represents 1.5 s (country light, city light, high beam, improved styling and performance. In the when driving at 120 km/h. 3 shows a motorway and glare free high beam). case of headlamps with the ADB function- illumination level comparison of the new This means that all the best lighting ality, it is also common to have three ver- LED system with a conventional xenon performances can be maintained on sions. For example, there is the base ver- system. This is presented for the five dif- every type of road, 4. Such a solution sion first of all, with performances equiv- ferent driving situations country light, city adds functionalities and enhances perfor- alent to halogen systems today which can light, motorway light, high beam, and mance compared to previous systems, also use LED as an energy saving light glare free high beam. The xenon light is without compromising the existing func- source. Then there is a mid-version with autotechreview June 2016 Volume 5 | Issue 6 29 Cover Story AUTOMOTIVE LIGHTING

DRL, brackets, style bezels, etc. would remain the same.

CONCLUSION AND OUTLOOK

With this type of new multi-functional module by Valeo, it is been demonstrated in the new VW Passat that it is possible to offer a differentiated appearance with a sleek lens only 40 mm high, and at the same time provide full high-performance lighting with the Adaptive Driving Beam (ADB) using the latest generation of LEDs. Thanks to its concept of a rotating drum activated by a stepper motor to create five different beam patterns, the overall sys- tem architecture is fully compatible with what has previously been developed for xenon bulbs. The development and inte- gration into series production vehicle applications is therefore easier and faster. So one might imagine that such a mod- ule could be deployed on several applica- tions – with the same styling signature or with slight updates. This sort of approach to standardisation is key to providing more technology at a reasonable cost, while keeping a considerable degree of flexibility in styling, and thereby giving the designer considerable freedom. For future evolutions of modular approach for glare free high beam func- tions, the engineers have several perspec- tives in mind, such as power efficiency improvement, size reduction for easier integration, and new functionalities thanks to new beam patterns.

REFERENCES [1] Fleury, B.; Evrard, L.; Ravier, J.-P.; Reiss, B: Expanded Functionality of Glare Free High Beam Systems. In: ATZworldwide 114 (2012), No. 6, pp. 44-49 4 Projected beam patterns as road isolux lines [lx] on a colour scale for the five different light functions, [2] Burkert, A.: Der Passat B8 fährt sich besser specifications in m bayerisch. In: http://www.springerprofessional.de/ der-passat-b8-faehrt-sich-besser-bayer- isch/5393018.html of 22 October 2014 [3] Zydek, B.; Schiller, C.; Polin, D.; Khanh, T. Q.: improved performances (like xenon level), the common low beam and high beam Evaluation of Headlamps with a Glare-free high Beam Function. In: ATZworldwide 116 (2014), No. usually with enhanced styling (for exam- functions are usually similar. 6, pp. 46-51 ple with lens modules instead of having a In these cases, solutions are preferred reflector). Between these two versions, a which avoid new tooling and an excessive number of elements inside the lamp are development effort. This is possible with changed, and that could entail a complete this type of modular approach described new design with a new tooling set for the here: While the high version uses multi- inner components. functional beam, the mid-version could In general for the third high-value ver- use a bi-function module (low beam and sion, the OEMs add only light functions high beam) only. All the other elements, Read this article on such as the glare free high beam whereas such as complementary light module, www.autotechreview.com

30 www.autotechreview.com Moving energy made easy ... for robotics

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IGUS.indd 1 21-11-2014 15:02:52 Cover Story AUTOMOTIVE LIGHTING EVOCATIVE LIGHTING DESIGN FOR PREMIUM INTERIORS

With the RGB-LED light source, which can show various colours, a new generation of ambient lighting has entered the automobile interior. Dräxlmaier developed the innovative Paspol welting light design for premium interiors and uses illuminated ornamental seams to create a special feeling of space for the passengers inside the vehicle. Now, any number of colours can be created and displayed with a single light source appearing alternately.

Authors

DIPL.-ING. MANFRED WINKLBAUER is Department Head for Light and Product Innovation in the Interior Pre-development at Dräxlmaier Group in Vilsbiburg (Germany).

© Dräxlmaier DIPL.-PHYS. BERNHARD BAYERSDORFER is Employee in the area of Product Innovations, Pre-development of Light COLOURS PROVIDE WELL-BEING well-being, as studies [2] show. Based on and Optics at Dräxlmaier Group in AND ATTENTION this, scientists are convinced that light has Vilsbiburg (Germany). a positive effect on concentration while Time is valuable, so drivers and passen- driving, too. This is confirmed also by gers want to use it sensibly, even sitting in on-going EU-wide studies [3], showing that a traffic jam – listening to their favourite indirect lighting in a car could contribute music, relaxing in a seat with an integ- to more safety, especially when driving at rated massage function, or connecting night.

DIPL.-PHYS. JOSEF LANG with other people or the Internet using Previously, interior lighting could only is Employee in the area of Product modern communications technology. In be done in one colour using monochromic Innovations, Pre-development of Light order to fulfil the wishes of their sophist- light-emitting diodes (LEDs) in the col- and Optics at Dräxlmaier Group in icated customers, various premium auto- ours of red, orange, yellow, green, cyan Vilsbiburg (Germany). mobile manufacturers have for some time and blue. But different white tones are been equipping the interiors of their top possible if blue LED chips are combined models with ambient lighting [1]. Light with phosphor. For two-colour combina- and colour have a well-known influence tions, there were Duo-LEDs. With the new on the psyche: They affect our mood and RGB-LEDs, Dräxlmaier can now create

32 www.autotechreview.com and display as many colours as necessary with a single light source appearing alternately, so that the light displays can be more interesting while costs and installation effort are reduced.

1 Indirect blue INSERTED OR SEWN ambient ­lighting of the centre console in a CONTOUR ACCENTS current Mercedes-Benz C-Class (© Dräxlmaier) Previously, door panels or centre consoles were lighted by a plastic fibre optic con- ductor hidden behind the interior, which sible – in other words, for as much light um-class vehicles are now able to use the illuminated downward. 1 shows the from the light conductor as possible to be on-board computer to select their own indirect lighting of the centre console in a visible on the surface of the piping – and individual colour combinations from the- current Mercedes-Benz C-Class. Using for the textile to not affect the colour of oretically millions of colours. This is pos- this, a floating impression can be created the LED, only light or neutral colours are sible because every RGB-LED is equipped in the interior. With Paspol linear lights, used. When using this in series, be sure with three semiconductor chips in the however, the shapes of the vehicle interior that the colour of the textile fits with the base colours of red, green and blue (= can be emphasised in an even more overall interior. The colour of the wrap- RGB), which are controlled individually impressive way. ping fabric is visible in daylight, although using a LIN bus system. In order to not A much more precise and elegant not in the dark. At night, the new micro- overtax the end customer with this emphasis of the contours in the vehicle chip-controlled RGB-LED illuminates the gigantic colour selection, the automobile interior is made possible by the new wrapped light conductor in a multitude of manufacturers are able to limit the num- Paspol ambient lighting. Here, the flexible colours as a design line. ber of colours available by setting precon- light conductor is integrated directly into figurations. Most likely, there will just be genuine leather or vinyl surfaces. This ten colours actually made available to the uses functional and ornamental seams to MORE COLOUR VARIETY IN THE end customer. the best effect. The thin light conductor INTERIOR USING RGB-LED The end customer can be sure that the made of polymethylmethacrylate (PMMA, ambient colours he or she selects from the better known under its trade name, Previously, only a few colours were used brochure or online will be precisely the Plexiglas) is wrapped in a translucent fab- in a vehicle interior: for example, the same in real life. A microcontroller on ric and inserted into a seam with the combination of amber, ice blue and white. every RGB-LED circuit board assures that retaining profile. Alternatively, the light These are generated using a Duo-LED, the brightness of the light, as well as the conductor is sewn directly into the genu- which is installed in a housing at the end colour precision, will be guaranteed for ine or artificial leather surface material of the light conductor, along with a circuit the life of the vehicle – even after exten- and then laminated in the interior, as board. The two colour chips for amber ded use. Since development and produc- shown in 2. and ice blue are integrated onto the circuit tion come from a single source, produc- Only in-house manufactured, translu- board, and when activated together, they tion-related tolerances are also prevented cent, dirt and heat resistant fabrics are create the combination colour white. so that the calibration is already con- used for coating; these are characterised The design of the RGB-LED functions cluded in the production process [4]. The by a comfortable look and feel, but are differently. This new light technology per- LED brightness is constant over all dis- still very robust. In order for the transmis- mits a colour scenario to turn into an playable colours. The brightness is sion behaviour to remain as large as pos- large colour spectrum: Users of premi- adjustable and can be dimmed if desired.

2 Cross-section (left) and actual photo (right) of the laminated pink-coloured Paspol light conductor in a grey leather surface (© Dräxlmaier) autotechreview June 2016 Volume 5 | Issue 6 33 Cover Story AUTOMOTIVE LIGHTING

Lightning The Way to

3 The black housing for the Paspol ambient lighting system (right) protects the Your Destination . . . circuit board, which is designed for a temperature range from -40 to 85 °C; the 4 Armrest for a concept centre console, with two Paspol light conductors that clear light conductor is on the left (© Dräxlmaier) emphasise the curved shape and the exclusivity of the interior (© Dräxlmaier) Mithabhi Lamps Pvt. Ltd. is leading automoti ve bulb manufacturer in India. We are manufacturing auto- The intelligent microcontroller com- for automotive use has been confirmed, from Dräxlmaier offers a wide variety of moti ve bulbs, miniature bulbs and stop & tail light pensates for changes in the environmental will be used in the future in series produc- op tions for use, even outside the auto- bulbs with our brand “FOKAL“. We have latest bulb temperature, which can have an influence tion by major premium automobile manu- motive industry. End customers appreci- manufacturing technology to produce high quality on the brightness or the colour mixture of facturers. This product innovation with ate discreet lighting and colour selection automoti ve bulbs. the RGB-LED. the almost unlimited colour selection gen- in places other than a car. For example, erates an exclusive, emotional effect in it is possible that these innovations We are supplying bulbs to all major light manufac- the interior and emphasises the premium could be used in airplane interiors and turers, indicators manufacturers and meter manu- DISCREET LIGHTING – MINIMAL character of the automobile. 4 shows the train compartments, in ship cabins or factures in India and also for export market. SPACE REQUIREMENTS armrest of a centre console that uses two high-quality furniture and hotel bars. In We are approved bulb supplier for automoti ve Paspol light conductors. short, anywhere that an exclusive look OEMs to supply bulbs their indicator, tail lights and In tune with the efforts toward lightweight Automobile manufacturers also offer and atmospheric premium ambiance other applicati ons. construction, the RGB-LED and attached the Paspol ambient lighting as a means should be created. plastic light conductor add very little mass to set themselves apart from the com- We are ISO/TS 16949 certi fi ed company having 3 to the scale. Depending on the dimensions petition. Looking more closely at the REFERENCES manufacturing plants equipped with latest bulb of the interior that must be illuminated, developments in past years, it is clear [1] Daimler AG: Mercedes-Benz GL-Klasse, testi ng faciliti es. Our bulbs are inline with the re- Innenraumkomfort – auf alles vorbereitet. In: quirements JIS 7506, ECE R37 and AIS 034 bulb the entire part weighs only a few grams. that ambient lighting will become more http://www.mercedes-benz.de/content/germany/ The Paspol ambient lighting system is also and more important for differentiation mpc/mpc_germany_website/de/home_mpc/pas- regulati ons & specifi cati on. thrifty with regard to installation space in the premium segment. An individual- sengercars/home/new_cars/models/gl-class/x166/ Manufacturing Automoti ve Lamps requirements: The housing’s dimensions ised lighting design can, for example, be facts_/comfort/interior.html, access date: 13 July 2015 are 12 × 17 × 16 mm³, the circuit board used as a means to emphasise and emo- [2] Fördergemeinschaft Gutes Licht / licht.de: AIS 034 & AIS 037 inside is 11 × 8 × 5 mm³ and the light tionalise market identity. Whether it is Wirkung des Lichts auf den Menschen. In: licht. wissen, Ausgabe 19 http://www.licht.de/fileadmin/ E Certi fi ed (ECE R37) conductor connection has a diameter of in the centre console, door panels, Pb Publikationen_Downloads/1403_lw19_Wirkung_ only a few millimetres, 3. instrument panel, headliner or seat JIS C7506 auf_Mensch_web.pdf, access date: 4 August 2015 lead-free Thanks to its small dimensions, the backs – there are innumerable options [3] Lucerne University of Applied Sciences and module can be used flexibly in the auto- for integrating light into the interior to Arts, Engineering & Architecture: Trans.Safe – Im- proving Traffic Safety by Stress Management. In: mobile’s interior, depending on the need. emphasise the vehicle design. http://www.transsafe.eu/, access date: 4 August In the last step of the production process, The new ambient lighting technology, 2015 the installed RGB-LED is connected to the however, is able to do more than just look [4] Reichenbach, M.: Dräxlmaier setzt für neue wiring harness or wiring harness system pretty. It completely justifies its existence Ambientebeleuchtung auf RGB-LED. In: http:// www.springerprofessional.de/draexlmaier-setzt- ISO/TS 16949:2009 Certi fi ed E - Approved AIS Certi fi ed using the correct connector end on the in safety matters. Scientists at the Tech- fuer-neue-ambientebeleuchtung-auf-rgb-led/ back side of the interior. The RGB-LED, nical University in Ilmenau, Germany, for 5007886.html;jsessionid=33B4D641865724ED- which is connected using a four-pole wir- example, have determined that a little 82BCA4110223CF2F.sprprofltc0101, access date: 13 July 2015 ing harness, is designed for a wiring har- interior light at night improves exterior [5] Hucko, M.: Ambiente-Beleuchtung: Lichtblick ness voltage in a range between 7 and 18 vision [5]. Also, navigation in the dark am Autohimmel. In: http://www.spiegel.de/auto/ V. The board, LED, resistor, microcontrol- vehicle interior is much easier with dis- fahrkultur/ambiente-beleuchtung-auto- bauer-ruesten-innenraeume-mit-farblicht- ler and board size are designed to meet creet light sources. It would even be con- auf-a-939786.html, access date: 13 July 2015 the current amperage. A rise of brightness ceivable that individual colours change by current increase is not possible. for certain events. For instance, when a call comes in, or when the driver exceeds Mithabhi Lamps Pvt. Ltd. the speed limit. It could also function as 16/4 Mathura Road, Faridabad-121002, Haryana, INDIA FROM EMOTION TO an exit alert. The light in the door panel SINCE Ph:+91 1294 044 289,+91 1294 044 290; SAFETY CONSIDERATIONS could blink or turn red if, for example, a Fax:+91 1294 043 046 bicycle rider is approaching the car. Read this article on 1984 Visit us: www.fokallamps.com; Paspol ambient lighting, whose suitability The new Paspol ambient lighting www.autotechreview.com Contact: [email protected] 34 www.autotechreview.com

Mithabhi_atrJune2016.indd 1 02-06-2016 17:17:37 Lightning The Way to Your Destination . . .

Mithabhi Lamps Pvt. Ltd. is leading automoti ve bulb manufacturer in India. We are manufacturing auto- moti ve bulbs, miniature bulbs and stop & tail light bulbs with our brand “FOKAL“. We have latest bulb manufacturing technology to produce high quality automoti ve bulbs. We are supplying bulbs to all major light manufac- turers, indicators manufacturers and meter manu- factures in India and also for export market. We are approved bulb supplier for automoti ve OEMs to supply bulbs their indicator, tail lights and other applicati ons. We are ISO/TS 16949 certi fi ed company having 3 manufacturing plants equipped with latest bulb testi ng faciliti es. Our bulbs are inline with the re- quirements JIS 7506, ECE R37 and AIS 034 bulb regulati ons & specifi cati on. Manufacturing Automoti ve Lamps

AIS 034 & AIS 037 E Certi fi ed (ECE R37) Pb JIS C7506 lead-free

ISO/TS 16949:2009 Certi fi ed E - Approved AIS Certi fi ed

Mithabhi Lamps Pvt. Ltd. 16/4 Mathura Road, Faridabad-121002, Haryana, INDIA SINCE Ph:+91 1294 044 289,+91 1294 044 290; Fax:+91 1294 043 046 1984 Visit us: www.fokallamps.com; Contact: [email protected]

Mithabhi_atrJune2016.indd 1 02-06-2016 17:17:37 Cover Story AUTOMOTIVE LIGHTING HEADLAMP OF 2025 – BIONICALLY INSPIRED, ADDITIVELY MANUFACTURED

3-D printing and bionic conquer new application in the passenger car. Edag has produced a combination of ma- terials and processes that make the additive manufacturing of a complete headlamp, except for the reflectors, possible. In the GenLight project, the LED cooling capacity is increased with bionic heat sinks. The headlamp could be ready for series production by 2025.

© Edag

36 www.autotechreview.com Authors THREE DRIVING FORCES TODAY first of all drawn up. In the following, the definition of the functions of the indi- vidual lighting components was done. In There are three driving forces in automot- this process, the Daytime Running Light ive lighting technology today which have (DRL) function was assigned to the bright a lasting effect on headlamp styling. For strips in the start-up screen, while the one thing, it tends to call for a constant lower light strip has a twin function, and DIPL.-ING. KLAUS ZANDER reduction in the vertical dimensioning of operates as a wiping turn indicator. The is Team Leader in Lighting Technology and Simulation and the headlamps. Secondly, the aim is to Light Cocoon’s lower light strip was in charge of the GenLight project have greater luminous power on the road, shortened in compliance with statutory at Edag Engineering GmbH in while at the same time reducing both the provisions [1] covering the width/height Wolfsburg (Germany). weight and cost. In order to meet these ratio of the wiping turn indicator from 10 demands, various disciplines like styling, to 6 (as per January 2015). optical design, development, thermal Sufficient installation space for the management and production technology main light functions lens modules was will have to cooperate even more closely created by re-locating the LEDs for the in the future. It counts, to generate max- DRL functions in the vertical dimension, imum headlamp performance despite the so the use of a light guide was essential DAMIR SOKOLOV, M.B.ENG. is Project Coordinator in fact that development periods and product for the DRL. To enable the DRL signatures Lighting Technology and life cycles are being constantly shortened. to achieve maximum homogeneity, Simulation at Edag Engineering With the GenLight project, engineering volume scatterers were positioned in front GmbH in Wolfsburg (Germany). service provider Edag took up this multi of the light guides. domain approach and transferred it into After the design of the visible side had an additively manufactured headlamp been defined, there followed the concep- concept. The headlamp in Edag’s Light tual design of the projection module level- Cocoon concept car served as a blueprint ling setting. Due to the installation space in the project. By means of plug-and-play, available, only the option of the basic lev- and using additive manufacturing, the elling settings for the main light functions WILLI SCHWARZ is Head of Body Engineering at Edag aim was to develop a photometrically was implemented. In the GenLight head- Engineering GmbH in Fulda ready-for-approval headlamp, and integ- lamp, the two low beam modules are (Germany).. rate it into the car without making any automatically adjusted relative to one serious compromises. The results of this another and via a coupling rod with the work are presented in the following. help of a servo motor, depending on the load condition of the vehicle.

DIMENSIONING AND REQUIRED STYLING MODIFICATIONS BIONIC COOLING CONCEPT MICHAEL FROHNAPFEL is Head of Design Concepts at Edag Engineering GmbH In order to be able to respond to the chal- For cooling of the LEDs for the main light in Fulda (Germany). lenge, a number of optical concepts were functions, a bionic cooling concept

1 Schematic view of the cooling and joining concept for the GenLight headlamp (© Edag) autotechreview June 2016 Volume 5 | Issue 6 37 Cover Story AUTOMOTIVE LIGHTING

according to [2] from the field of construc- the air flow from the front of the vehicle and the required ease of operation. tural theory was taken, to guarantee that into the headlamp housing without the heat dissipation is as efficient as possible. use of additional components. This enabled the mass and volume of the The obvious solution here was the ADVANTAGES OF heat sinks to be reduced. To prevent a additively manufactured body in white of ADDITIVE MANUFACTURING build-up of heat in the headlamp, the the Light Cocoon, in which an air duct cooling elements were fitted to the outside can be created without complex tools, This, however, is where the future of the housing, and dimensioned accord- additional components or joining pro- advantages of additive manufacturing ing to a preliminary study, 1. cesses. This can help increase the stiffness come to bear. In a workshop with a sup- So as not to add yet more weight to the of the body and, as a secondary consider- plier of plastics and the manufacturer of car, for example by adding an active cool- ation, reduce vehicle weight. The air mass a 3-D printer, which uses slightly modi- ing system using auxiliary fans, a natural flow is divided at the rear of the housing, fied granules for injection moulding in resource, namely the airflow, was identi- to cool the individual heat sinks. In order an FDM melting process, it emerged fied as the means by which cooling power to be able to adjust the lens module, a that, with additive manufacturing pro- would be boosted. From a structural point rubber sleeve would be necessary to guar- cesses, it is already possible to present of view, the question was how to direct antee the non-permeability of the housing material combinations of modified

Component of the headlamp Production process Material Availability of technology Bionic structures of the DRL SLS/FDM Plastics ≥ 5 years SLM1 Aluminium Connecting rods SLS/FDM Plastics ≥ 5 years SLM2 Aluminium 3-D fibre FDM3 Plastics + carbon fibres Connecting arms SLS/FDM Plastics ≥ 5 years SLM2 Aluminium 3-D fibre FDM3 Plastics + carbon fibres Holder for headlamp self-levelling SLS/FDM Plastics ≥ 5 years SLM2 Aluminium Ball-end mounts SLS/FDM Plastics SLS: immediately FDM: ≥ 5 years Lens cover High pressure deep drawing Highly transparent plastic (optical grade) < 8 years with additive tools Light guides SLA, PolyJet Highly transparent plastic (optical grade) < 8 years Lenses SLA, PolyJet Highly transparent plastic (optical grade) < 8 years Diffuse DRL panels FDM Plastics, opaque scatter materials < 8 years Housing FDM Plastics < 8 years Front panel FDM Plastics < 8 years DRL cover FDM; SLA Plastics < 8 years; SLA: immediately Main cover FDM; SLA Plastics < 8 years; SLA: immediately Various module covers SLS Plastics sofort Reflector + shutter 3DP Ceramic ≥ 5 years Heat-sink + seal + housing Multi-C FDM PC-TPU thermally conductive plastic < 8 years

Legend FDM = fused deposition modelling 3-D fibre FDM = 3-D fibre-reinforced FDM SLA = stereolithography SLS = selective laser sintering SLM = selective laser melting 3DP = 3-D printing Multi-C FDM = multi-component FDM

1 If the function integration “heat dissipation” is required at high peak temperatures.

2 If high torque needs to be transmitted when using bionically/topologically derived (filigree) minimal structures (material, weight reduction).

3 If high torque needs to be transmitted when using endless fibre-reinforced additively manufactured composite solutions (extreme material/weight reduction)

2 Overview of the headlamp components and their predicted manufacturing processes (© Edag)

38 www.autotechreview.com thermally conductive polycarbonate OPTICAL DESIGN with Thermoplastic Polyurethane (TPU) as multi-component prints. This means Definition of the manufacturing that, in conjunction with a multi-mater- method for the optically non-relev- ial print that will be possible in the ant components was followed by a future, the entire rear wall of the hous- tolerance analysis. The optical sys- ing, including the board support, can be tem, 3, for the low beam was cre- produced in a single production step. ated using an Osram Ostar Head- With this basic concept, work was lamp Pro LED lightsource in con- continued on the detailed design, and junction with a reflector/shutter all the advantages of additive manufac- system and a lens in front of it. 4 turing used. These include the elimina- shows the low beam light distribu- tion of de-moulding directions used in tion of the GenLight concept. conventional tool making. There are still The same system was used for a number of weaknesses with regard to high beam, this time with an adjus- stability, warping and thermal stability ted reflector and a lens without a in 3-D printing processes. On the basis shutter. A tolerance analysis of a material and manufacturing process showed that optical components matrix from the Light Cocoon project, it are printable. The only exception is 3 Optical paths of the GenLight headlamp in low was possible to define suitable combina- the reflector. For this, use can be beam function (© Edag) tions for the headlamp components, 2. made of a simple tool with a great In addition, the question as to many cavities in combination with whether, depending on the additive a vaporising system. past in the next few years. manufacturing process selected and pos- A manufacturing method for making This would also then make it possible sible reworking, active use can be made lenses, for example, was also defined. for light conductors to be manufactured of the different surface qualities of the This is a so-called PolyJet method, in using additive methods. Due to the lack of components in terms of lighting techno- which a combination of synthetic resin installation space available, the design logy, was also looked into. With the and UV-curing can lead to the desired and specification that an optimum homo- main cover, for example, a lower resolu- form. Solutions to the currently existing geneous appearance should be achieved tion of the CAD data file was deliber- material-specific challenges, for example, across a broad angle range, the method of ately selected when converting it into the yellowish discolouration of the lenses coupling the light in the negative x- or STL format, to represent a rough sur- due to the increased absorption coefficient z-axis in the DRL and the turn indicator face. This makes it possible to do away in the short wavelength range, and also light guide were both dispensed with. A with additional, usually expensive, pro- the low level of thermal stability of the specific combination of all three spatial cessing stages such as importing struc- resins used, are expected to be found directions was used when coupling the tures into a tool. On the other hand, within less than two years. In addition, light. Then prism optics were developed extremely filigree representations of sur- there is still a technical limitation on lens and fitted for controlling the light direc- faces can be realised in minimum height (approximately 20 mm), which, tion. These are already technically feas- dimensions in the μm range. however should become a thing of the ible with additive production methods.

4 Simulation result in illuminance representation of the low beam function of the GenLight headlamp (© Edag) autotechreview June 2016 Volume 5 | Issue 6 39 Cover Story AUTOMOTIVE LIGHTING

Further, the use of volume scattering 21 Nichia LEDs (type NJSW172AT) for the On the basis of the headlamp concept materials in front of the lens contributed TFL and 21 additional LEDs (type geometry generated, CFD simulation to the homogeneity. NC2A170A) in combination with self- was carried out using the open source During the development process, developed software. The PCBs are fitted to software OpenFoam, to confirm the cooperated with the styling team, it was a board support here. At the same time, operational capability of the ram-air sys- given up on the original target, which was and in terms of function integration, this tem in conjunction with the bionic heat to give the DRL a totally homogeneous support also acts as a retainer for the DRL sink according to [2]. The validation pro- appearance, instead tolerating a slight light guide and as a heat sink for the cess involved a number of individual inhomogeneity, so as to achieve a carbon LEDs. This enables the number of indi- stages. The first stage involved the fibre structure effect (CarbonLight). vidual heat sinks to be reduced from 45 to simple observation of the thermal con- Although the use of volume scattering 2. After qualifying the material, this duction of the heat sink concept, to materials is currently conceivable, later on bionic structure can be printed on the ensure that the heat input of the LED is in the project it will be necessary to check same machine as the housing. The idea of directed into the actively cooled part of the extent to which granules for injection introducing strip conductors into this the heat sink. This is followed by the moulding, for instance, lend them to this structure is also conceivable, as this evaluation of the air flow which is to purpose, as building up the component would increase the function of the com- dissipate the heat from the heat sink layer by layer might make it possible to ponent by adding a degree of freedom. surface. The result can be seen in 6. produce photometric properties. These measures could lead to a drastic The material that was first used for the reduction in the number of elements heat sink was aluminium, so as to be able used, which would cut assembly costs. to compare a conventional heat sink INDIVIDUALISATION BY USING material with a thermally conductive LIGHTING TECHNOLOGY AS A plastic. The thermal conductivity of cur- STYLING ELEMENT CFD FOR THERMAL VALIDATION rently available plastics is lower than that

The DRL signatures should in the future be separately controllable by the car con- nectivity system, either by HMI or remote control. Depending on the driver opera- tion characteristics – like sporty, efficient or normal –the DRL can be adapted. In 5, the three possible modes of a Switch- able DRL (SDRL) are presented. In Sport mode, only the upper signa- ture can be selected, in Eco mode only the lower and in Normal mode both, ⑤. A further possibility for personalising and individualising the vehicle also presents itself. Under the given basic conditions, this concept is worth discussing from an approval certification point of view. In addition, a wiping turn indicator was also constructed in the lower signature area, 5 Representation of the switchable daytime running light (SDRL) – with low beam (left column) and without using self-developed PCBs with attached low beam (right column) (© Edag)

6 Temperature profile in the bionic heat sink (© Edag)

40 www.autotechreview.com of aluminium by a factor of about 10. As turing methods presented are already suit- the initial assumption, a low flow speed able for use in low-volume series produc- was set. This helped to increase the cool- tion, while on the other, the headlamp ing power of the heat sink. This approach with all of its components should be proved to be quite adequate for the alu- viable in 2025. The ram air system imple- Thanks minium heat sink. For the plastic with the mented has been proven to be fully func- considerably lower thermal conductivity, tional, and, with the help of 3-D printing, The authors thank Jörg Ohlsen, CEO of Edag, for however, even a significant increase in the can help to reduce weight. his support of the GenLight project, and the flow speed was not enough to adequately In addition, the cooling capacity of the Edag project team for their support in technical cool the LED. bionic heat sinks is increased. Taking into and organisational matters: Dr. Martin Hil- The final stage served to identify a account the fact that a certain technical lebrecht, Head of the Competence Centre for plastic that, under the given conditions, is level of maturity of the manufacturing Lightweight Design, Materials and Technology, capable of cooling the LED. This means methods presented will be achieved in the Fulda (Germany); Michael Begert, Innovation that what is needed is a plastic with a future, the described concepts can be Manager at the CC for Lightweight Design, thermal conductivity coefficient that transferred into series production. Finally, Materials and Technology, Fulda; Shakoor Salih, exceeds conventional, currently available the Switchable Daytime Running Light Project Leader Lighting Technology and Simu- thermally conductive plastics by a factor (SDRL) introduces a degree of freedom to lation, Wolfsburg (Germany); Sven Orloff, Team of 4. Although plastics that have these the concept of individualisation, and the Leader for CAE, Hamburg; Martin Morgenstern properties are currently conceivable, they CarbonLight gives DRL a new appearance. and Jan-Eike Rieks, System Integrators for are not yet economically feasible due to Infotainment and Connectivity, Wolfsburg (Ger- the fact that current series projects are REFERENCES many); Martin Fiedler, Project Leader for Light very much a niche market. [1] Economic Commission for Europe (ECE): & Sight Design, Wolfsburg; Matthias Schlegel World Forum for Harmonization of Vehicle Regula- tions (WP.29). http://www.unece.org/trans/main/ and Jürgen Hornig, Model and Prototype Con- welcwp29.html, requested on 15 January 2015 struction, Fulda (Germany). CONCLUSION [2] Herbold, C.; Neumann, C.: Vorbild Natur: Bionische Strukturen zur Entwärmung von LEDs. Lecture, 20. Gemeinschaftstagung Licht 2012 of The GenLight project enabled Edag to Deutsche Lichttechnische Gesellschaft e. V., acquire the following findings: On the one Nederlandse Stichting voor Verlichtingskunde, Read this article on hand, some of the materials and manufac- Lichttechnische Gesellschaft Österreichs and Sch- weizer Licht-Gesellschaft, Berlin, 2012 www.autotechreview.com

Lighting systems, a bright future with plastics

Introducing next generation plastics for a wide range of lighting applications like frontlight frames, bezels, lens holders, wire coatings, lamp holders/sockets and LED lighting systems which offer · Low outgassing · Miniaturization & design freedom · High temperature operating range upto 240⁰C · Thermal management with conductive plastics For more information visit www.dsm.com/automotive PA46 TPE PBT/PET PA6/PA66

autotechreview June 2016 Volume 5 | Issue 6 41 Cover Story AUTOMOTIVE LIGHTING THE NEXT STEP – PURE LASER HIGH-BEAM FOR FRONT LIGHTING

A high-beam module based on laser technology is appealing because of its extensive reach of 600 m. This is thanks to Larp technology from Osram which can achieve six times the luminance of conventional LED white light sources. Following the market launch of laser light by BMW and Audi, Osram is presenting here a technolo- gy demonstrator in the form of a prototype headlight in which the entire high-beam function is provided by laser light sources. Therefore, a prototype is used: the μ-Larp module. By its application the requirements of the UN- ECE-R-112 regulation for high-beam functionality are fulfilled.

Authors

DR. RER. NAT. DIPL.-ING. JENNY TROMMER DIPL.-ING. THOMAS FEIL DR. RER. NAT. JÜRGEN HAGER ROLAND FIEDERLING is an Employee in Automotive is an Employee in Automotive is an Employee in Advanced is Head of Automotive Applications at the Osram plant in Applications at the Osram plant in Development at the Osram plant in Applications at the Osram plant Herbrechtingen (Germany). Herbrechtingen (Germany). Herbrechtingen (Germany). in Herbrechtingen (Germany).

LASER’S FIRST USE IN 2014 headlights of production vehicles. These ogy may influence front lighting technol- laser-based auxiliary high-beam modules ogy and the appearance of cars in the In 2014, Osram introduced their “Laser have a range of 600 m, a distance barely coming years. A fully functional head- Activated Remote Phosphor” technology imaginable until now, giving drivers a bet- light demonstrator is presented, 1, in (Larp) for the first time for modules used ter view of the road even over short dis- which high-beam distribution is pro- as auxiliary high-beam modules in the tances and an even greater degree of duced solely by extremely compact safety [1, 2]. The use of laser technology in μ-Larp prototype modules without the a Larp light source enables the luminance aid of additional light sources. to be increased to levels unimaginable with halogen, xenon (HID) or even LED light sources. Larp technology also gives HOW LASER TECHNOLOGY WORKS headlight designers even greater freedom IN HEADLIGHTS in terms of boosting performance or creat- ing new innovative concepts. The basic operating principle of Larp Following the market launch of laser modules involves focusing radiation from technology by BMW [1, 3] and Audi [2] in laser diodes on a converter, 2. Laser

1 Laser headlight with extremely compact 2014, Osram is using a headlight demon- diodes are used as the light source, with a µ-Larp technology strator here to show how Larp technol- typical wavelength at the blue end of the

42 www.autotechreview.com visible spectrum. The converter consists which the converter is positioned directly that Larp modules will one day have ten of scattering and conversion particles on the semiconductor chip. At present, or more times the luminance of conven- which are embedded in a ceramic carrier Larp modules from Osram produce a tional LED light sources. “Auxiliary” high- (converter matrix). The conversion parti- luminance around six times greater than beam functions which both BMW and cles convert blue light into yellow light. A that from automotive LED light sources Audi have incorporated in their vehicles, certain proportion of blue laser light is currently used in series production. From are good examples of the high perfor- scattered in the converter, with the blend a theoretical point of view there are few mance that lasers can already achieve [1, 2]. of blue light and yellow light producing limits on future development because in white light. contrast to LED light sources the lumi- By using Larp technology much greater nance produced by Larp technology can AREAS OF APPLICATION, luminances can be achieved than with be scaled up by increasing the number of INCREASED LUMINANCE AND conventional LED white light sources in laser diodes. It is certainly conceivable MORE COMPACT DESIGN

What makes Larp modules so interesting? The answer is simple. As it has already been mentioned, the light source has the highest luminance ever achieved. This is a Converter matrix direct measure of the luminous intensity that can be achieved with a lighting sys- tem. For otherwise identical systems (for example imaging optics with a lens hav- Blue Mixed white ing an area A), twice the luminance leads laser light Scattered particles light to twice the intensity of the emitted light in a particular solid angle, and therefore to a greater range. Conversely, to go back to the example, it is also possible to halve the emission Conversion particles area A of the lens and still achieve the same intensity as the comparison system. This means that the same light output that current production systems produce 2 Schematic representation of the conversion, scatter and mixing process in the converter can be achieved with much smaller emis- autotechreview June 2016 Volume 5 | Issue 6 43 Cover Story AUTOMOTIVE LIGHTING

(nm), installed in a package with primary optics, phosphor head and temperature sensor (NTC). On the basis of this design prototype modules with secondary optics and an optically active diameter of only 13 mm were produced. The luminance distribution (false colour image) on the converter is presented in ③ (right).

DEMONSTRATOR WITH μ-LARP PROTOTYPE MODULES 3 µ-Larp prototype module (left) and luminance distribution (false colour image) on the converter (right) Thanks to the μ-Larp prototype modules presented here, more freedom in styling headlights is possible than ever before. The structure of the headlight demonstra- tor is described in the following. Six ⑧ μ-Larp modules are used for the high ⑥ beam function in each headlight. At the ⑤ ⑦ development stage for the headlight dem- ④ onstrator the main focus was on its ③ appearance, with the aim of creating a bezel shape which had rarely been seen ① Cover lens in previous headlight styling and which ② Bezel would be virtually impossible with con- ② ③ Turn indicator with smoked ventional light sources. The design of the glass plate headlight demonstrator is shown in 4. A ④ Controller ⑤ LED low beam projector frame is used to accommodate all the

① ⑥ µ-Larp prototype modules light sources and is the central component with cooling of the headlight. Low beam is provided by ⑦ Mounting frame a LED projection system attached to the ⑧ Housing frame. Each of the μ-Larp modules with secondary optics is attached to the frame by a three-point mounting. This enables 4 Exploded drawing of the headlight demonstrator with six µ-Larp prototype modules each module to be individually adjusted with respect to the low beam and to each other μ-Larp module. In this particular case the laser units are arranged in vertical rows of three, offset in terms of their depth. This arrangement was derived from the bezel which characterises the appearance of the headlight with its narrow light emis- sion openings. The laser diode in a μ-Larp module is form-locked in the housing to ensure heat is removed prop- 5 Luminous intensity distribution of the high-beam from the headlight demonstrator including cover lens erly by the heat sink. A thermal output of around 4 to 5 W has to be dissipated from each of the modules. In this head- sion optics. This therefore opens up com- developed the concept of combining light the very small heat sinks are inter- pletely new styling options, revolutionis- higher luminances with very small optical connected via two duct systems to which ing the current look of front lighting. apertures. μ-Larp prototype modules are a fan is connected. This concept enables used in the technology demonstrator pre- central cooling to be provided with one sented in the following, in the form of a fan and warm air to be directed to the THE μ-LARP PROTOTYPE MODULE headlight, as they are shown in 3 (left). cover lens where it will be cooled as this These modules consist of laser diodes is where temperatures are at their lowest Osram has consistently pursued and with a wavelength of 450 nanometres during a drive.

44 www.autotechreview.com 6 Bird‘s eye view of illuminance, produced from the luminous intensity distribution of the headlight demonstrator with µ-Larp prototype modules – the outline corresponds to the 1-lx line

ECE-COMPLIANT their attention to using the high lumi- The use of lasers in the front lighting LIGHTING TECHNOLOGY nance to design to a lower limit based on systems on production vehicles, imple- the size of the optics, compatible on the mented with Larp technology from The headlight demonstrator is described one hand with the standard requirements Osram, has only just begun. This here in more detail. It is the first complete for high-beam distribution and on the method of producing light has great high-beam unit based on laser technology other with the system tolerances. The potential to revolutionise lighting tech- that meets the photometric requirements active surface of the optics has a diameter nology in the next few years in terms of as defined in the relevant statutory regula- of only 13 mm. The headlight demonstra- performance and design. Obviously, this tions (UN ECE-R-112). These regulations tor therefore has aperture values for high- technology is currently restricted to spe- however merely stipulate a minimum beam automotive applications that are far cial vehicles at the luxury end of the requirement which most car manufactur- below those of current standard series market but already industry insiders are ers support with their own photometric products. This opens up a wide range of showing great interest, and customers specifications for creating “beautiful” and options for headlight designers. Depend- are intrigued by new lighting solutions, sophisticated high quality distribution of ing on the light distribution requirements too. Osram, the lighting specialist, has light on the road for the driver. (ECE-R-112 and OEM specifications), the dared to look into the future and found Even though it is not a headlight man- number of modules can even be reduced. that laser technology for headlights ufacturer, Osram took such aspects into could migrate from an auxiliary high consideration in designing the distribu- beam to full high-beam functionality. tion of light for the headlight demonstra- CONTROL Car manufacturers can make use of tor. They struck a balance between the benefits of the Larp technology to ECER-112, sufficient horizontal side illu- The laser modules are operated with a differentiate themselves from their com- mination, vertical illumination and maxi- nominal constant current of 1.2 A. To petitors impressively. Osram is continu- mum luminous intensity at the core of protect the sensitive laser diodes from ing to work on Larp technology. At pre- the beam. The high-beam distribution of damage caused by uncontrolled current sent, the next generation of laser mod- the headlight demonstrator is shown in peaks it is necessary to control them ules is already in development. 5. Two of the six μ-Larp modules are with suitable electronic drivers. The NTC Luminances of 1000 cd/mm² and more responsible for basic high-beam distribu- sensor integrated in the μ-Larp prototype will be achieved – that is about ten times tion, two others act as boosters to module indicates the temperature in the the luminance of previous light sources. increase the maximum luminous inten- module and can be read continuously. If sity in the centre, and the remaining two the temperature rises too high the cur- REFERENCES provide broad horizontal illumination. rent supplied is reduced with the aid of a [1] Weber, S.; Buck, A.; Amann, C.: Laser Light in the BMW i8 – Design, System Integration and A comparison between the illuminance dimming curve stored in the electronic Test. In: ATZworldwide 116 (2014), No. 9, pp. 44- of the demonstrator‘s light distribution driver so that the diode can be operated 49 and the bird‘s eye views from the publica- in the temperature range for which it has [2] Fries, B.; Gut, C.; Laudenbach, T.; Mühlmei- er, M.: Laser Light for the Audi R18 e-tron quattro tions [1, 2] in 6 shows that the headlight been designed. Racing Car. In: ATZworldwide 116 (2014), No. 6, demonstrator can produce a similar distri- For future systems it is conceivable pp. 24-27 bution of light to that created by high- that the modularity and resultant differ- [3] Werkstetter, M.; Weber, S.; Hirth, F.; Amann, beam plus booster. On the basis of the ent partial lighting functions could be C .: Laser Light in the BMW i8 – Controlling and E/E Integration. In: ATZelektronik worldwide 9 developments in lighting technology used in conjunction with a camera-based (2014), No. 4, pp. 14-19 described before, this headlight is capable control system to illuminate specific of a range of up to 540 m. Thanks to the areas of the road and surroundings in modular design of the optics, the horizon- certain situations. This can be achieved tal distribution of light and the range of by dimming individual modules or the boosters can be changed at any time switching them on or off. by using different optics. In addition to designing full high beam Read this article on distribution, Osram engineers also turned SUMMARY AND PROSPECTS www.autotechreview.com autotechreview June 2016 Volume 5 | Issue 6 45 TECHNOLOGY audi AUDI RANGE DRIVE – SHOWCASING TECHNICAL MIGHT

The entire range of Audi cars on sale in India and an airstrip sounds like a fantastic combination, which turned real a few days back at Hosur, Karnataka. At the event, Audi also launched the new R8 V10 Plus and gave us an opportunity to drive it as well. Key takeaway for us was the ability to assess the versatility of quattro in a con- trolled environment, right from a luxury sedan to a supercar. Here’s our detailed report from the first of its kind Audi Range Drive, which was split into three parts – Sportscar experience, A Drive and Q Drive.

46 www.autotechreview.com AUDI R8 V10 PLUS LAUNCH & DRIVE

Audi India had its entire fleet of vehicles on sale in India lined-up at the Hosur airstrip, but the highlight was the launch of the R8 V10 Plus at ` 2.6 cr, ex- showroom, Karnataka and its drive later in the day. The new R8 V10 Plus is pow- ered by a naturally-aspirated 5.2 FSI Quattro V10 mid-engine with a power output of 610 hp. In addition, the new model uses a more advanced mix of materials, making it lighter than the ear- lier generation of the R8. As a result, the R8 can now propel from a standstill to 100 km/h in just 3.2 s and continue The 4l V8 TFSI engine in the RS7 produces 560 hp to its top speed of 330 km/h. What really sets the R8 V10 Plus apart is its naturally-aspirated engine that turbo vehicles down in the rev band. Off spinning the wheels. Since space was lim- stands out in a sea of turbocharged vehi- the line, the R8 accelerated with ferocity ited on the airstrip, we managed a top cles. On the airstrip, the benefit of this and precision as Quattro ensured that all speed of 252 km/h but even at that speed configuration was clear as the R8 didn’t of the power being generated was used the R8 was accelerating without any signs have any of the lag associated with the for launching the vehicle ahead and not of power fade.

autotechreview June 2016 Volume 5 | Issue 6 47 TECHNOLOGY audi

Quattro’s working and capabilities were easily identifiable off-road, where loss of traction on one wheel is automatically offset by transferring power to the other wheels

Gear shifts were quick as the seven- ity to transfer power to the wheels with pointment here was the steering, which speed S tronic transmission made use of traction, which helped the Q range over- felt artificially-weighed with very little shift-by-wire technology, which means come the obstacles. feedback. shift signals are relayed through electronic Quattro has been an evolving technol- sensors and does not involve any conven- ogy since its inception and is configured tional cables. Braking from high-speed differently in every Audi car. While on ROUND-UP was a confident affair as the ceramic the Q range of vehicles, it is aimed at brake discs kept brake fade away despite maximising grip to get out of low-trac- The Range Drive organised by Audi India the cars making constant runs in the tion spots, in the R8 V10 Plus, it’s for the media turned out to be a nice hands of different journalists. Since there designed to offer better handling at attempt at showcasing their entire range were no turns available to test the han- higher speeds. The regular quattro dis- of cars and technologies. The star of the dling capabilities of the car at the airstrip, tributes power at a ratio of 40:60 show was the R8 V10 Plus, which in its we’ll provide more insight into the vehicle between the front and rear axles. Should older form was already one of the largest and its technologies once the car becomes it become necessary, this differential can selling supercars in the country. In its available at a later stage to us. send as much as 60 % of torque to the more powerful, lighter and smarter new front and as much as 80 % to the rear. version it seems logical that the new R8, On the R8 V10 Plus, the core of the quat- also the fastest Audi ever, will continue QUATTRO tro is a viscous coupling at the front axle from where its older sibling left. In addi- that includes a package of plates that tion, we also got to experience the turbo- The most popular attraction after the R8 rotate in a viscous fluid. The coupling charged engines of the brand on the RS7 V10 Plus drive for most journalists normally sends about 15 % of the power and RS6 Avant. In a nutshell, Audi India turned out to be the Q Drive, wherein to the front and up to 30 %, if needed. did what one would expect a leading lux- we drove the Q3, Q5 and the new Q7 on During the A drive, we were asked to ury carmaker to do – celebrate the accept- a purpose-built off-roading track. The drive any of the cars from the A range ance of the brand in under 10 years in the track was well-designed and involved back and forth a winding road leading country. And it surely did that in style. some obstacle, which put the quattro to a lake. The numerous bends and cor- technology and driver skills to test. At ners on this 16 km road highlighted the times, the vehicles were subjected to sit- versatility of the quattro technology. We Text: Arpit Mahendra uations, where at least one wheel had drove an A8 through this road and were Photo: Audi no contact with the surface and the sec- impressed at the ability of the quattro to ond wheel was bordering on the lines of ensure something as big and heavy as losing traction. It was in such situations the A8 dialled-in effortlessly into turns Read this article on that the Quattro stepped in with its abil- and exited with aplomb. The only disap- www.autotechreview.com

48 www.autotechreview.com

TECHNOLOGY CNC MACHINES SPEED, FLEXIBILITY THROUGH IN-HOUSE part PRODUCTION

Porsche Motorsport is bringing sophisticated components to the racing track with state-of-the-art CNC ma- chines, as well as process chain from DMG MORI. While the racing team cooperates with a lot of suppliers, the technology partnership with DMG MORI has long and lastingly influenced the internal possibilities in pro- duction as well. Its experience of working with sophisticated industries such as aerospace and automotive, gives the leading global manufacturer of CNC-controlled Lathes and Milling machines a distinct advantage, writes the author.

Authors

ANKUR AGARWAL is Marketing Manager at DMG MORI in Bangalore (India)

1 Dittmar Lienert (L) and Frank Jahn (R) record the work schedule in CELOS® and document the production

50 www.autotechreview.com INTRODUCTION

For Porsche a perfect season has come to an end: They took the overall victory at the 24 Hours in Le Mans, won the Manu- facturers’ World Championship title at the penultimate round in Shanghai – and have been crowned the drivers’ World Champions too. The success can be attrib- uted to the team’s long-standing experi- ence, and most of all consistent and con- tinuous further development of the Por- sche 919 Hybrid.

PRODUCTION PROCESS 2 The DMG MORI Virtual Machine simulates the programmes written by Dittmar Lienert in Siemens NX CAM 1:1

To produce components for its racing cars with increased flexibility and speed, Por- ciently big for the respective components amongst others undercarriage parts and sche Motorsport has built its own and and the performance of both machines crankshaft housings, but also operational ultra-modern component production as impresses in the area of speed as well as equipment that plays a big part in suc- new core competence. Short response on quality level. cessful racing. Modifications of the times and flexibility are deciding factors The process chain offered another fil- numerous components always occur at for success in the field of motor sports, lip to component production. “The Sie- short notice between the individual races. said Frank Jahn, responsible for the Por- mens NX CAM provides the required pro- “Programming in NX CAM and simultane- sche team for component production. For gramming strategy for even the most ous simulation of the programmes saves a this reason, in parallel to the numerous complex machining operation. And we tremendous amount of time, as errors in co-operations with first class suppliers, an check feasibility and ensure 100 % colli- my programming work or even possible in-house production has also been set-up. sion safety with the virtual machine,” collisions are displayed instantly,” said The challenge for this project has been said Jahn, while explaining the invest- Lienert. This also renders the time-con- enormous, and the team had to invest in ment in the software solution. The Por- suming running in of the programmes on both technology and personnel. sche Motorsports team often needs to the machine superfluous. The development of an in-house com- deliver top results in the form of high- Within the scope of complex compo- ponent production is also a direct result of quality components within 24 hours, and nent production, the CELOS® user inter- the co-operation with DMG MORI – a pre- hence the complex components must be face on both machines also proves to be mium sponsor and technology partner of machined error-free at the first attempt, of great support. Jahn also referred to the the Porsche team – and the machine man- reasoned Jahn. work schedule: “Based on photos, we ufacturer with comprehensive know-how record components as well as clamping of CNC technology. Usually, it is the devices in CELOS® and manage cut edges highly complex components that need to SIMULATION ADVANTAGES and tools.” This also facilitates the be available within the shortest possible required seamless documentation in time and with the highest quality. In addition to the machines and process production. For the Porsche team, a DMU 65 chain, simulation plays a critical role in monoBLOCK® and a CTX beta 800 the production process of components. In formed the machine basis. The produc- fact, Dittmar Lienert, who is responsible CONCLUSION tion process was complemented by using for programming and machining of the the DMG MORI process chain – con- components, explained that the DMG Jahn concluded that the DMG MORI pro- structing and programming with Siemens MORI Virtual Machine holds the same cess chain and CELOS® helps the Porsche NX CAD/CAM, followed by a 1:1 simula- importance for the team as the racing sim- Motorsports team programme, simulate tion of the NC programme in the DMG ulator for the pilots. “It enables the 1:1 and produce any complex parts for its rac- MORI virtual machine. simulation of real machining on the PC – ing cars fast and error-free. This way, said “The combination of the versatile CTX including machine kinematics and real Jahn, “we contribute to the head start our beta 800 – it is equipped amongst others control – and we got to where we wanted teams in Le Mans and elsewhere bring to with a Y-axis and an oil mist circuit a lot faster,” he said. Lienert had joined the racing track.” breaker – and the 5-axis DMU 65 mono- the team, when component production BLOCK® allows us complete freedom was established. with regard to production,” underlined The demanding range of applications Read this article on the operator. The work areas are suffi- of the development department includes www.autotechreview.com autotechreview June 2016 Volume 5 | Issue 6 51 event CTO ROUNDTABLE 3.0

HOW ELECTRONICS IS CHANGING THE WAY WE DRIVE

1 2 Building further on the success of the previous two editions, Auto Tech Review successfully delivered the 3rd edition of the event – CTO Roundtable 3.0 – on May 6, 2016 in New Delhi.

The automotive electronics industry in India is currently at a nascent stage and is lagging behind its foreign counterparts in terms of capacity and R&D capability. 3 4 It is estimated that 65-70 % of auto elec- tronics requirement of OEMs in India is still met through import from countries like China and Taiwan. It is in this back- ground that we organised the third edi- tion of the CTO Roundtable with the theme of ‘New Trends & Innovation in Powertrain Electronics, Infotronics, Con- nectivity & Convergence’. The inaugural session was set in motion by a presentation on “A roadmap to the future of mobility” by Anuj Chan- dna, Automotive & Transportation Sector (1) Anuj Chandna; (2) BM Baveja; (3) Dr Tapan Sahoo; (4) Chandan Sawhney Senior Analyst, EY. He stated that about

52 www.autotechreview.com 5 6 7 8

(5) Fernando Ventura; (6) Suraj Ghosh; (7) Amit Jain; (8) Sirish Batchu

2.5 bn people will be added to the A presentation by Chandan Sawhney, spective on how modern advancements world’s urban population by 2050, result- Head Electronics, ERC CVBU, Tata in semiconductor technology is helping ing in an increased number of vehicles Motors highlighted the increasing elec- system makers to increase the perfor- and related problems. In the long-term, tronic content in commercial vehicles mance matrix of their products in autonomous vehicles would form a criti- and how this would lead to an increased response to tightening regulations across cal link in the integrated urban mobility number of ECUs, and hence a need to vehicular areas. as more than 90 % of road accidents consolidate these ECUs for an effective Suraj Ghosh, Principal Analyst, South take place due to human error, he stated. vehicle network. He also talked about Asia Powertrain Forecasts, IHS Automo- The keynote address was delivered by the key add-on engine parts for the legis- tive, provided an insight into the future BM Baveja, Senior Director & Group lative requirement of BS VI by 2020, all trends of powertrain electronics in India Coordinator, R&D in the Department of of which are electronic. and also shared that according to IHS esti- Electronics & Information Technology, Fernando Ventura, Powertrain and mates, the average cost of upgrading pre- Government of India. He highlighted the Safety Division, Automotive & Discrete sent diesel passenger vehicle engines dis- work being done by the government in Group, STMicroelectronics, gave a per- placing 1.5 l or less to meet BS VI by 2020 the area of connectivity and mentioned that Information and Communication (ICT) technology is being researched upon as a key growth area for electromo- bility in the coming years. He also stressed on the need for having Intelli- gent Transportation Systems (ITS) and smart roads with road safety systems.

POWERTRAIN ELECTRONICS

The session began with a presentation by Dr Tapan Sahoo, Sr Vice President (Engg, Research, Design & Development), Maruti Suzuki India Ltd. Apart from the BS VI legislation scheduled for 2020, Indian OEMs also need to conform to real driving emissions in the same time- frame, he argued. Although specifics haven’t been shared yet, it means that OEMs will need to have a certain level of hardware, software and calibration ready to ensure they’re able to meet the legisla- tion. This will pose a challenge in the form of having a need to have a robust exhaust-treatment system and a valida- tion system in different demographics and exclusive software. autotechreview June 2016 Volume 5 | Issue 6 53 event CTO ROUNDTABLE 3.0

9 ❿ cycle of vehicles, which will require moves such as consolidation of global vehicle platforms. Edoardo Merli, Director of Automotive Product Group, Marketing and Applica- tion, Greater China and South Asia Region, STMicroelectronics said that the growing importance of connectivity and infotainment in vehicles will lead to the creation of a new equilibrium in the automotive industry, consisting of the traditional auto companies along with the new participation of technology and ⓫ ⓬ internet players. Sirish Batchu, Head, Infotronics Tech- nology & Advanced Electronics, Mahin- dra & Mahindra added to these points by pointing that due to the emergence of technology companies such as Google and Apple and other new stakeholders, traditional automakers will have to revisit the vehicle development plan, as the traditional method is time-consuming and might not fit into the scheme of

(9) Edoardo Merli; (10) Shrinivas Gadkari; (11) Gaurav Batra, Associate Director, EY; (12) Tarun Aggarwal, things for future. VP (Electrical, xEV & Electronics Division), Maruti Suzuki India Ltd The final presentation in this session was delivered by Shrinivas Gadkari, Director of Design Engineering, Cadence will be between 70,000 to 80,000 on the cle’s occupants. Amit Jain, Country India. He talked about the opportunity to final vehicle price. Head, Visteon Electronics India, brought leverage neural networks to overcome forth an estimate that the connected car the problem of picking the right features. market, valued at about $ 12 bn in 2012, Neural networks have already been cho- INFOTRONICS, CONNECTIVITY will grow to about $ 50 bn by 2018. He sen for many computer vision applica- & CONVERGENCE also mentioned that the cost of electron- tions and Gadkari explained how ics on percentage of the vehicle cost will Cadence products are capable of carrying The second session involved presenta- rise from 30 % in 2010 to 50 % by 2030. out this function. tions on the growing importance of con- In order to keep up with the rapid pace nectivity and related technologies for of electronics, the automotive industry delivering a better experience to a vehi- will need to shorten the development ROUND-UP

Both the technical sessions were followed by a panel discussion each involving speakers from that particular session. Both panel discussions invited a healthy exchange of dialogue between the dele- gates from various facets of the industry and the speakers/ moderators. Auto Tech Review also confirms that the 4th edition of the CTO Roundtable will be held around the same time, next year. To watch the complete video of the event, please go to the following link:

http://live-24framesdigital.netdna-ssl. com/autotech/webcast/060516/

Read this article on www.autotechreview.com

54 www.autotechreview.com rootsIndustries_atrJune2016.indd 1 27-05-2016 14:51:49 SHOPFLOOR SOUTHCO TECHNOLOGY DIVERSITY IN ENGINEERED ACCESS HARDWARE

A significant part of the in-cabin experience of a vehicle depends on the touch-points in the cabin. Constant in- teraction with these touch-points over a period of time requires them to exude a sense of quality. With increas- ing penetration of electronics in vehicles, these touch-points are now being deployed with technology beyond the mere operation of a function. Southco is one such company that is expanding its global presence on the back of its product portfolio comprising of more than 25,000 products, including latches and hinges.

56 www.autotechreview.com A global leader in engineered access hard- claimed to be assembly-friendly, saving ware, with operations in more than 30 labour time and also help lower tooling countries, Southco has built a strong port- investment, making it a better value prop- folio of products through its 70-year-old osition for its customers. Within latches, journey. Set-up as a specialty pipe manu- the single-point rotary latch and an offset facturer for the Pennsylvania oil industry single-point rotary latch constitute the two in 1899, it was only in 1945 that Southco key products in India. started manufacturing specialty fastener We also talked about Southco’s dual- and latches, marking its entry into the point latching, which is a newer offering segment that specialises in ‘touch points’ and is known as the Coupler System. The such as locks, hinges and handles. system features a two-point, dependent In India, the company is headquar- pawl latching system, which retracts both tered in Pune, Maharashtra and carries pawls simultaneously, allowing flexibility out manufacturing at a plant in the same in actuation styles, reducing the risk of city. Recently, we made a trip to the false latching. There’s a mid-sized coupler plant and spoke to Veeresh Manrai, as well, which features a compact mecha- General Manager, Business Develop- nism for supporting smaller applications ment, Indian Operations, Southco India such as centre consoles, cup holders and for centre-console hinging, wherein an Private Limited for a detailed under- small compartments. Southco has occupant can hold a centre console lid or standing of its business in the country. designed the Coupler to be flexible, offer- inner tray steady at any position, stop ing various actuation options such as and lock the centre console lid into a push-button, lift-paddle, side-pull, lock- pre-determined position and also benefit LOCAL SUPPORT STRATEGY ing, non-locking and electromechanical. from the lesser effort required to operate Southco follows a ‘Total Programme the panels. The company follows a local support Management’ approach, wherein it offers Explaining the technology further, strategy for its customers globally, and all services from the design phase to final Manrai told us that precision position con- the flourishing Indian economy brought product. The company is now focusing on trol hinges use specially shaped bands or it to India. Operations in India started developing electronic locks and position- sickle torque elements that apply radial around a decade back, and the company ing solutions and wireless technologies, pressure against a shaft to create friction today caters to various industries includ- beyond its solutions for latching, fasten- between the two surfaces. By utilising a ing automotive, aerospace, off-highway, ing and positioning. variety of shaft and torque element com- railway, marine, healthcare and data cen- Positioning technology involves posi- binations with different alloy steels, heat tre enclosures. tioning hinges and display mounting treating, lubricants, and assembly pro- From its fairly large portfolio of solu- solutions. Headrest solutions feature cesses, these devices are able to deliver a tions, two key products in the Indian integrated torque hinges, which makes wide range of capabilities with more pre- automotive market include glovebox and operation smoother and aids better posi- cise tolerances for consistent torque con- centre console latches, which have been tioning of the headrest. Torque devices trol and long-lasting performance. used in recently launched vehicles such are increasingly becoming popular due to With an increasing focus of the global as the Mahindra TUV 300 and KUV 100, the wide range of benefits they offer. automotive industry on electronics, we among other customers. These latches are This technology enables position control discussed the electronic locking technolo-

Injection-moulding is fully automated through two machines, while assembly is semi-automated autotechreview June 2016 Volume 5 | Issue 6 57 SHOPFLOOR SOUTHCO

not only reduces the labour requirement but also maintains a higher and consist- ent level of quality. Post the clamping, the unit goes for the assembly process, which is a combi- nation of automatic and manual pro- cesses. The line here involves a mix of locally-manufactured products and those that are imported and assembled here. All products supplied to Mahindra are manufactured locally but those used in the new Ford Figo Aspire compact sedan are imported from the UK and assembled in Pune.

www.autotechreview.com May 2016 | Volume 5 | Issue 5 Now, Also AvAilAble oN

It’s on 16 IntervIew ROUND-UP Thomas Schulze, BD Director, Automotive, Spirent Communications & Bhaskar HS, Director, Spirent Communications (India)

20 study With revenue of ` 24 cr in 2015, Southco Making India a World Class Automotive Manufacturing Hub

is still a small operation in India. Despite 60 new vehIcle Ducati Diavel Carbon – Focus on technology and adoption of modern manufacturing equipment and processes bodes well for the that, the company impressed us with their Desirable Identity Dilemma company’s product competitiveness focus on technology. For something seem- ingly as simple as latches, the technology they already have and are working on for gies by Southco and the difference they machine (CMM) by Nikon, which offers the future was quite surprising. The fact offer from the conventional solutions. exceptional accuracy of up to one micron. that the company has simple and proven Electronic access combines physical secu- In simpler measurement terms, one products along with the expertise to scale- rity with electronic intelligence to protect micron is equal to 0.001 mm. up to more demanding electronic systems, valuable assets and information. In auto- We were shown the entire process of beckons well for its future. motive interiors, electronic locking mech- making the latches that are supplied to The torque controlled systems too anisms can be networked directly into a Indian customers such as Mahindra, hold good potential as OEMs continue to vehicle’s electrical system to secure glove Visteon, Ford and Tata Motors, among add features from higher-end vehicles to boxes, media bins and other storage others. The manufacturing process starts mass-market ones. In India specifically, areas. This not only improves the user- from the injection-moulding machines, one can clearly see the rapid pace at automotIve electronIcs –– experience but it also enhances the inte- two of which are installed at the plant. which consumers are becoming aware of cockPit, communication & connectivity Powered by rior styling. We were told that if required One of them is an 80 tonne unit, while vehicle technology and finer details such Bluetooth can also be combined with the larger one is 150 tonne. One of the key as cabin experience. EACH electronic locking technology to increase raw materials used as the base for the In India, the company has over 40 the security levels. component is nylon. The raw material is employees presently and it expects to first loaded into a bin loader and under- grow at a healthy rate in the coming goes a dehumidifying process, which years, primarily on the back of new prod- SHOPFLOOR ensures no moisture is passed ahead in ucts and technologies. It is positioned the manufacturing process. well in the market with potential and the Our conversation about the company and The injection-moulding machines are right products, more importantly a wide its technology made it clear that Southco, hydro mechanical, making use of water range of products for all sorts of applica- although small in revenue terms in India, for cooling purposes. Water is supplied tions. It’s this diversity of products that has a strong focus on developing the right to the machine from tanks outside the in our opinion will help the company technology. The same approach was also shopfloor. The plastic is heated in these grow at a healthy pace in the coming evident on the shopfloor. The plant is machines to the point it changes form to years, including achieving its stated 2016 small in size, but is equipped with the lat- liquid. After this, the liquid plastic is revenue target of ` 30 cr. est technology. Product development or passed onto a mould, which is clamped R&D in particular is primarily carried out in the clamping unit inside the machine. Text & Photo: Arpit Mahendra in global centres with India providing crit- The company has 17 moulds presently ical information related to customer and will continue to increase the count AUTO TECH REVIEW | SPRINGER INDIA PVT. LTD., 7th Floor, Vijaya Building, 17 Barakhamba Road, New Delhi – 110001. Ph: +91 11 45755888 | Fax: +91 11 45755889 requirements. Globally, Southco has 17 as the product portfolio continues to Advertising: [email protected] | Editorial: [email protected] | Subscriptions: [email protected] manufacturing locations, including India. expand. Fully automatic in nature, these Read this article on Reach us at: www.autotechreview.com The first piece of equipment we came machines only require human interfer- www.autotechreview.com across was a coordinate-measuring ence for instructional purpose. Doing so

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60 new vehIcle Ducati Diavel Carbon – Desirable Identity Dilemma

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Subscription_ATR_Jan'12.inddATR_Subscription ad.indd 1 1 24-12-201101-06-2016 16:24:4116:18:31 NEW VEHICLE Datsun redi-go

DATSUN redi-GO – BEST FROM THE BRAND YET

Japanese carmaker Datsun presently has two models on sale in the country – GO and the GO+ – the first being a no-thrills hatchback and the latter being the country’s cheapest seven-seater vehicle. However, despite the unique positioning of these vehicles, none of them has experienced a sales run akin to their name. This is Dat- sun’s third year in the country, and it is ready with the redi-GO, its third product in the Indian market. Does it have the substance to take on established competition? We were recently invited by the company to drive the car in Kolkata. During the drive, we found out if the redi-GO has the missing areas from its siblings covered well, or are there holes in the dyke yet.

60 www.autotechreview.com The redi-GO is built on the Renault Nis- san Alliance’s CMF-A platform, just like its cousin Renault Kwid, and is being positioned as an urban cross targeted at the A segment. The development of both these cars was started simultaneously, and the common platform meant a lot of parts and systems, such as the engine, gearbox, chassis and sub-frame compo- nents, are common as well. We were told the cars have as much as 50 % in com- mon, allowing the RNA to keep develop- ment cost low.

EXTERIOR DESIGN A 799 cc petrol engine with 53 hp and 72 Nm of torque powers the redi-GO First look of the Datsun redi-GO and one cannot help but appreciate the designers for staying largely true to the concept in such cases. Datsun designers have, CABIN EXPERIENCE showcased earlier. The idea of merging however, cleverly created a stack of three two body styles – compact crossover and lines on the redi-GO with varying strength Step inside the cabin and the redi-GO’s urban hatchback has resulted in a good of visibility and angles. These lines, the character undergoes a transformation looking vehicle. The angular grille flanked middle one on the lower part of the doors from funky, happy and youthful to the by swept-back headlamps lends the redi- rises and merges effortlessly with the tail need of meeting basic needs – simple and GO with a funky and distinct front-end. lamp, breaking the monotony of an other- cost-challenged. The cabin is a mix of hits In order to resemble a crossover and to wise large metal area. and misses, space being one of the key hit offer the segment-leading 185 mm of The rear, although not as funky as the areas of the vehicle. The space on offer in ground clearance, the redi-GO measures front, bears a clean design and looks the redi-GO left us surprised given the fairly tall even when compared to the properly modern and graceful. Datsun expectations from the exterior footprint. existing tall-boy cars in the segment. At calls the redi-GO’s design language Front seats are wide and accommodat- 1,541 mm, the redi-GO is 31 mm taller YUKAN, which in Japanese means brave ing with pronounced side support bol- than the Hyundai Eon, the second tallest and bold. Our assessment of the design sters, which are effective while going car in this segment. While this height has is pretty much in line with the compa- around turns. Space at the rear is best-in- its benefits, which we’ll explain in a ny’s claim. The redi-GO certainly looks segment and in fact is better than the while, the huge expanse of sheet metal different from existing models and in a Maruti Suzuki DZire compact sedan. The mostly leads to a dull-looking side profile good sense. extra-long seat offers good under-thigh support and is more comfortable than most of the car's competitors. Headroom too is generous and people over six feet in height too won't have their heads brush- ing against the roof. The dashboard bears a minimal yet functional design. However, it lacks the central touch screen as found on the Renault Kwid. We were told the dash- board design of the redi-GO was finalised before that of the Kwid because of which the screen couldn't be integrated. That also implies we could see a variant with the central touch screen at some stage in the future. While overall space engineering inside the vehicle is appreciable, the front doors have exposed metal above the door pock- ets, a visible sign of cost-cutting. The door pockets are flat and can't even accommo- Centre-console seems basic and the audio system offers CD, MP3, USB and Aux-in connectivity date 500 ml bottles. The centre console autotechreview June 2016 Volume 5 | Issue 6 61 NEW VEHICLE Datsun redi-go

Overall exterior design is youthful, funky and manages to mask the height of the vehicle well enough

tunnel though can house two bottles. 0.8 l petrol engine does an acceptable ROUND-UP Plastic quality and build are average job of moving the vehicle. Driveability and amid exposed bits and joints, we also through the five-speed transmission is Datsun has managed to offer a good look- came across a few plastic bits coming off, zippy in low-end in first two gears but ing, practical and spacious vehicle with such as one plastic part on the front wind- at speeds beyond 90 km/h the engine the redi-GO. While these urban qualities shield. Datsun officials though assured us struggles to keep the momentum going. go in favour of the vehicle, there are areas that the cars brought for the media drives Being an urban car this isn't much of a such as build quality, weak mid-range of were pre-production models and the ones negative though. What could've been the engine, fit & finish and pronounced sold in the market will have these issues better is the NVH proofing since the cost-cutting going against it. While these sorted largely. engine does get quite loud by the time are areas that many consumers might not you're around 3,000 rpm. mind compromising on, the redi-GO's We couldn't test the handling in the problem is the strong competition it is pit- DRIVING EXPERIENCE traffic of Kolkata but the redi-GO felt ted against, especially the Maruti Suzuki well-balanced for the regular urban Alto and the Renault Kwid. Our drive was a short one limiting us to commutes and occasional mild off-road- The Alto has been the top selling stretch the legs of the redi-GO. In traffic, ing due to its best-in-class 185 mm model in the market for years together, the redi-GO is generally decent and the ground clearance. and Renault has made a strong entry in the mini hatchback segment with the Kwid. It’s going to be an uphill task for Datsun India to make a dent in their sales, but there are quite a few positives going for the vehicle, as we’ve highlighted ear- lier. It could also look at introducing the 1 l engine that powers the Renault Kwid, but that is an aspect Datsun officials refused to confirm or deny. For now though, along with pricing, how the com- pany approaches the market would deter- mine its acceptance among the urban cus- tomers in the country.

Text & Photo: Arpit Mahendra

Segment-leading 185 mm ground clearance keeps the redi-GO’s underbelly safe from most obstructions on Read this article on Indian urban roads www.autotechreview.com

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01_safetyPrintAd.indd 2 31-05-2016 14:56:12 DECODING TECHNOLOGY

IT’S MORE THAN LIGHTING

DR ARUN JAURA European Advisory Committee, SAE International, USA Automotive lighting has transformed radi- natural progression. From an exterior styl- cally over time – powered by acetylene or ing standpoint, LEDs offer uniqueness to oil-fuelled lamps (late 1880s) to electric the looks and branding opportunities for headlights (1904), sealed beams (1939), OEMs. LEDs are less susceptible to vibra- clarity, heat resistance and ease of injec- halogen lamps (1962), High Intensity Dis- tion than filament lamps and offer optical tion moulding for complex lens designs. charge (early 2000), LEDs in 2004, and design flexibility. LEDs consume approxi- There are several new grades of polycar- the laser beam headlights in 2013. mately 85 % less energy, and last nearly bonates that help OEMs to become more Regulations, both operational and ten times longer than incandescent bulbs. creative with their styling and branding. safety, have changed considerably and as They generate much less heat thus allow- Innovative ambient lighting in the always consumers have been ever ing for smaller, thinner packaging and cabin is another influencer, while decid- demanding. The regulations requiring improved installation and styling options ing to buy a vehicle. Ambient lighting cre- headlamps to be on during low-visibility for inner ambient lighting too. Interest- ates an ergonomic environment that is weather, had generated research in the ingly, the industry also switched to LEDs more relaxing for the occupants, provides areas of low-beam headlights, daytime on construction and repair trucks, since a perception of extra value and a safer running lights (DRLs), or fog lights, and these were a lesser drain on the vehicle feel. With car-pooling becoming more dirt build up. Emphasis on glare, pedes- battery and are also energy-efficient. popular, each occupant is seeking privacy trian safety and street lighting, high speed Today, some OEMs in the high luxury and separate personal light to be able to expressway driving were other influencers segment have switched to lasers. The work or read in the vehicle. Another in change of regulations and innovative laser units are 30 % more efficient than aspect of car sharing in a home is that the lighting solutions. LEDs, and can illuminate up to double vehicle is driven by multiple drivers in the During the switch from sealed beams the distance (about 2 km). Lasers are same home. Each one desires different to HID, the technological evolution used for high beams as they are not as intensities and prefers unique display col- examined the stopping distances under focused as LED lights, while LEDs are ours on the instrument panel. Homoge- different headlamp illumination condi- used for low beams. nous lighting with accurate dimming and tions and concluded that HID had a providing excellent visual comfort is a pri- greater mean stopping distance than hal- mary need of the driver in any case. ogen headlamps. HID also offered higher ROLE OF MATERIALS luminous efficacies to achieve brighter forwards light. Materials have been another major ena- CONCLUSION bler in changing the face of automotive

lighting. Outer lenses for automotive Energy management and reduction of CO2 ADVENT OF LED & headlights are predominantly formed from are overarching drivers, besides safety and OTHER TECHNOLOGIES polycarbonate resin, and also increasingly legislation, and need to be holistically to form inner lenses. This resin has excel- implemented during the development and In 2004, LED lighting systems became a lent thermal stability, impact strength, choice of automotive lighting systems. The integration of multitude of gizmos makes it prudent to manage energy and battery size in the vehicle. The standard 52 Amp-hr battery is stretched too far in a conventional vehicle and soon 84 Amp-hr may become a standard feature. Today its more than just automotive lighting – it’s stitched together with the underlying attributes of affordability, relia- bility and longevity that are the trident of innovative sustainable mobility.

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