www.autotechreview.com April 2013 | Volume 2 | Issue 4 NOW, ALSO AVAILABLE ON It’s on 14 INTERVIEW Nalin Mehta, Managing Director Mahindra Navistar Automotives Ltd 18 TECHNOLOGY FORESIGHT Ultra-Capacitors for Electric Vehicles: Future Perspetives 60 NEW VEHICLE Honda CR-V — Flexible, Practical & Better ELECTRIC VEHICLES— CONCEPTS, SOLUTIONS & COMPETENCE POWERED BY Complete solutions in precision metallic coil springs I N S T Compression Springs T U T Static and Dynamic E of These are coiled helical SP RING TECHNOLOGY springs made from spring steel wire, that can resist compressive load. Extension Springs 1. Suspension Springs - These are normally close Torsion Springs Front Fork & Shock coil springs of circular These resist an applied Wire Forms Absorber cross sections, with the torque when the ends are These are made on forming 2. Engine Valve Springs end usually a hook or subjected to angular machines, in different shapes, 3. Clutch Springs loop, used in computers, displacement, used in adaptable to required 4. Rebound Springs brakes, etc. transmission, etc. applications. Seat Belt Springs Used for operation of Seat Belts of 4-Wheelers, made out of textured rolled hardened and tempered high carbon steel strips in various sizes. A to Z product range as per Customer’s designs, applications, sizes and Internationals standards Regd. Office & Works Manufacturing Unit-II Plot No. 192 A, Sector-4, E-56, Industrial Area, Haridwar-249 401 IMT Manesar-122050 Gurgaon, Haryana, India Uttarakhand, India Tel.: +91-124-4763200 Fax: +91-124-4365189 Tel.: +91-1334-221301 Fax: +91-1334-220128 E-mail: [email protected] E-mail : [email protected] ISO 9001 EDITORIAL E-VIABILITY? Dear reader, To question the viability of electric vehicles, at a time when Mahindra Reva has launched its latest bet, the e2o, might sound a little preposterous. But recent studies and developments within the industry do demand a serious look at the practicality of pure electric vehicles. The Indian government has announced the National Electric Mobility Mission Plan 2020 with some ambitious intentions. While most of it looks promising on paper, the current reality is quite different. Globally, consumers continue to show little interest in EVs primarily because of the well-documented issues with high cost, short driving range and lack of charging stations. And the situation in India isn’t any different. Aggressive goals set aside by many countries are now being rethought and reworked. Many vehicle makers too are reconsidering their EV plans. Even Takeshi Uchiyamada, the father of the Toyota Prius, is questioning the promise of battery electric vehicles, claiming EVs haven’t worked out to be ‘a viable replacement’ for gas-powered cars. In October 2012, academics in Norway published a study that claims EVs could be more polluting than is widely assumed. It highlighted the counterproductive promotion of EVs, when the electricity consumed is produced from oil and coal. Another study conducted in the UK recently has named India the least green country for electric cars, essentially because of the country’s overdependence on coal to meet its power generation demands. The study argues that in India and China, where power generation is heavily coal-based, electric cars result in emissions similar to traditional petrol vehicles. It claims that carbon emissions of EVs in countries with predominantly coal-based generation aren’t different to an average petrol car. A Deloitte study in 2011 expects mass adoption of EVs in India to be ‘gradual’. With the current generation of technology, the actual EV buyers would be in the region of 3-5 % by 2020, the report stated. While these may not be in sync with the NEMMP targets, it is clear that viability of EVs would not just depend on government subsidies, but largely on removing significant technology barriers that exist today. DEEPANGSHU DEV SARMAH Editor New Delhi, April 2013 autotechreview.com April 2013 Volume 2 | Issue 4 1 COVER STORY ELECTRIC VEHICLES — CONCEPTS, SOLUTIONS & COMPETENCE 24, 32, 36, 42 | Long before petrol became the preferred power source for mobility, electricity was a tried and tested power source for vehicles. Issues such as low range and speed almost brought an end to these vehi- cles in the 1920s. More than nine decades later, the same issues continue to hinder the electrification of mass-mobility. In this issue, Auto Tech Review takes a look at the technology developments, challenges and viability of electric vehicles. GUEST COMMENTARY 12 Strategic Technology Management in Indian Auto Component Industry Vice President (Engineering) – Electrical, xEV, HVAC & Electronics Systems, Maruti Suzuki India Limited INTERVIEW 14 “We are Uniquely Positioned to Take Advantage of Future Challenges” Nalin Mehta, Managing Director, Mahindra Navistar Automotives Ltd (MNAL) 2 CONTENTS NEWS COVER STORY SHOPFLOOR 4 Interactions 24 Technologies, Architectures for 56 Mahindra Navistar — Growing in 8 News Electrified Vehicles Stature, Acceptance Johannes Fuchs, Markus Lienkamp TECHNOLOGY FORESIGHT 32 Transmissions for Electric Vehicles NEW VEHICLE 18 Ultra-Capacitors for Electric Vehicles: Claudio Torrelli Future Perspectives 60 Honda CR-V — Arghya Sardar, Suresh Babu Muttana 36 Systems Competence for Flexible, Practical & Better Electromobility Thomas Röhrl, Gregor Schmitt, Lutz-Wolfgang Tiede DECODING TECHNOLOGY 42 Assessing the Customer Value of 64 Hybrid/ Electric Vehicle Charging Electric Vehicles Danny Kreyenberg, Jörg Wind, Jan Devries, Alexandre Fuljahn OTHERS 01 Editorial TECHNOLOGY 03 Imprint 48 Investigating a Range Extender Running on Bio-Diesel Michael Aschaber, Wolfgang Beuer 54 Volkswagen XL1 — Future Mobility Benchmark COVER PRODUCT Mahindra Reva IMPRINT Editor: Deepangshu Dev Sarmah Publisher & Managing Director: Editorial & Business Office: [email protected] Sanjiv Goswami Springer India Pvt Ltd 7th Floor | Vijaya Building | 17, Barakhamba Road Principal Correspondent: Arpit Mahendra Design & Production: Bharat Bhushan Upadhyay New Delhi – 110001 | India [email protected] [email protected] + 91 11 4575 5888 (P) | +91 11 4575 5889 (F) Deputy Manager – Ad Sales: Sudeep Kumar Auto Tech Review (ATR) is a monthly magazine focussed on automotive technology, and appears 12 times a year. Views and opinions expressed in this magazine are not necessarily those of Springer [email protected] India Pvt Ltd. No part of this magazine can be reproduced in any form, including photocopies and For Subscription orders and reader registrations, information retrieval systems, without the prior written permission of the publisher. Springer India For Editorial Contribution, write to the Editor at please visit www.autotechreview.com Pvt Ltd Limited reserves the right to use the information published herein in any manner whatsoever. [email protected] Printed and Published by Sanjiv Goswami on behalf of Springer India Pvt Ltd. Printed at Gokul Offset, Okhla Industrial Estate, Phase – I, New Delhi and published at Springer India Pvt Ltd, 7th Floor, For Advertisements, write to Deputy Manager – Ad Sales at Or, contact Deputy Manager – Ad Sales at Vijaya Building, 17, Barakhamba Road, New Delhi. [email protected] [email protected] ©2013, Auto Tech Review autotechreview April 2013 Volume 2 | Issue 4 3 INTERACTION DASSAULT SYSTEMES, JD POWER DASSAULT SYSTEMES | MODULARISING THE VALUE CHAIN in collaboration with Local Motors and can carry numbers lowers the usage of materials and emis- out functions such as reconnaissance and deliv- sions. The overall development time too would au- ery & evacuation in the battlefield. The vehicle tomatically reduce and so would the unexpected- was designed with inputs from over 12,000 ness of any unforeseen delays. Importantly, during members of an online community. Participants the design process the manufacturability of a car were asked to submit their designs online after too can be tested. This helps make the entire which they were reviewed. Using the Dassault process streamlined and efficient as going back software, the vehicle went from a concept to pro- to the drawing board is significantly reduced. totype stage in six months. Dassault is presently offering solutions, which Chowdhury said that this span is usually in can also help companies track their supply chain the range of six years for such vehicles developed and logistics and make them more efficient. Manu- in a traditional way. Using the right software and facturing is another area, where OEMs spend a lot feedback from people during development though of money and making changes is extremely expen- helped shorten the cycle to just 10 %. Applying sive. Using Dassault products, companies can vir- similar processes within the automotive industry tually create factory and check parameters such as could reap huge benefits for companies in the movement of people and machinery. The overall Cluster solution is the buzzword for all industries form of lower cost, better products and flexibility factory layout can be optimised for maximum space today, including the automotive sector. Increas- in product portfolio. utilisation and safety standards. Co-development ingly, manufacturers are looking for a cluster of In one of our earlier issues, we mentioned the by engineers from a supplier and OEM too becomes solutions offered by a single provider, because a huge gap between the development cycles of cars more efficient as they’re able to work together in streamlined supply