global automotive research centre (garc) about garc ... · pdf filethe garc which is under...
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Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Global Automotive Research Centre (GARC) is a unit
under National Automotive Testing and R&D
Infrastructure Project (NATRiP) housing the facilities for
comprehensive testing services. GARC provides
certification testing and R&D support to the
automobile vehicle and component manufacturers in
India. The GARC which is under construction is spread
over 304 acres with combined office space and test
labs at the SIPCOT Industrial Growth Centre near
Chennai at Oragadam.
Global Automotive Research Centre (GARC)
About GARC
Powertrain Lab
Vehicle Evaluation Lab & Test Tracks
Safety Component Lab
Fatigue Lab
Advanced Passive Safety Lab (APSL)
EMC & EMI
Infotronics & CAD/CAE
Recycling Demo Unit (RDU)
Academy
Planned Facilities
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
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Reception
Nursery
Headquarters
Canteen
Photometry Lab (Certification)
Infotronics & CAD/CAE
Crash Lab (APSL)
Fatigue Lab
EMC & EMI Lab
Pump House
Safety Component Lab (Certification)
Pedestrian Safety & Airbag Lab (APSL)
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Powertrain
Recycling Demo Unit (RDU)
Fuel Station
Control Tower (VEL)
Client Workshop (VEL)
Steering Pad Test Track
Test Hill Track
External Noise Track
Braking Surface / Abs Test Track
Special Braking Zone - 1
Special Braking Zone – 2
Oval Track
Overpass Bridge
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Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Advanced Passive Safety Laboratory (APSL)
Pedestrian Safety
Legform
Upper LegformChild Head
Adult Head
Pedestrian and occupant safety lab is the first of its kind in south India. This lab has been built to cater the need for the automobile
manufacturers all over India. The pedestrian lab and occupant safety lab has the ability not only to perform tests according to Indian
standards but international regulations as well.
Legform
Upper Legform
Headform
Free Flight Headform
Occupant Safety
Body Block
Guided Headform
Headform Pendulum
Knee Impact
Ejection Mitigation
Pedestrian & Occupant Safety Laboratory
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
Main structure on rail system
Motorized movement
Positioning using encoders
Maximum speed : 54 km/h
Impact point precision : 5 mm radius
Longitudinal regulation : 1500 mm
Lateral regulation : +/- 2000 mm
Vertical regulation : 500 – 3000 mm
Transversal beam regulation : 1000 mm
Universal Launcher
FMH Characteristics
Max.Velocity : 7 m/s
Velocity accuracy : + 0.20 km/h
Repeatability : + 0.15 km/h
Impactor Mass : 6.5 kg
Horizontal angle : 0° to 360°
Max.horizontal divergence : ±0.10
Vertical angle : -10° to 50°
Max. Vertical Divergence : ±0.1°
Impact point precision : 5 mm radius
Standards Covered
Regulation 78/2009 (Phase I /II)
Euro NCAP – Pedestrians
FMVSS201U - US Regulation
GTR9 (Global Technical Regulation)
TRIAS 63-2004,Japanese Regulation
JNCAP – Pedestrian
ECE R12 & ECE R21
AIS-100
Other Characteristics
Laser pointer for precision
Static calibration and dynamic calibration benches for the impactors
Head drop test stand
Bedplate with T-slots for mounting the fixtures
5 degrees of freedom
Additional Facilities
High speed cameras of 2000fps recording capability
Aicon 3D system for measuring deformation
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Advanced Passive Safety Laboratory (APSL)
Pedestrian Safety
The Airbag testing lab is equipped with Surefire airbag test system with 8 squibs which can send current to eight different airbag at the
same time and environmental chamber which is required to test the static deployment of airbag as a component and as a full vehicle. The
environmental chamber is drive-in chamber which can simulate a temperature from - 65°C to 100°C
Camera maximum specification 1024 x1024 pixel 2000FPS
Two 500 GB SATA hard disk drive
UPS provided Camera and controls
Lights with adequate illumination provided (36kW)
F stop setting provided.
Up to 2 of one brand of imagers including :
• Saved test profiles
• Interactive control mode
• Auto-test mode
• Auto colour correction
• Auto AVI creation
• Multiple save location
• Database driven
Powerplay Software - Playback in single frame
Airbag Testing Laboratory
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
Climatic Chamber
3000 x 5500 x 3000 mm (WHD) (test area)
Temperature range is -65 ̊ C to 100 ̊ C (+/- 0.5 ̊ C)
Simpati Software to document and monitor the test
Access window 6 Nos. of size 1100 x 1500 mm
Deployment can be carried out in 10 seconds
The maximum floor load possible is 3000 kg/sq.m
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Certification Laboratory
Goniophotometer
The Photometry Lab provides standard measuring services for our customers in the field of lighting and light signalling devices for motor
vehicles. This laboratory includes certification services for lighting and light signalling devices as per CMVR and Developmental testing as
per national and international standards or regulations such as AIS, ECE & SAE.
Make : LMT Lichtmesstechnik GmbH Berlin
Vision : GO- H 1600
Maximum Test Object Dimensions
• Weight : 50 Kg
• Width : 1600 mm in horizontal axis
• Table : 220 mm x 570 mm
• Servo Mo or controlled crossway
Photometry Laboratory
Reflectance & Transmission Measurement System
Integrating sphere (Φ 500 mm) which measures the
reflectance(ρ), diffuse reflectance(ρd),
transmittance(τ) and diffuse transmittance(τd)
values in terms of percentage for Rear View Mirrors
as per AIS:001,ECR:46
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
Integrating Sphere
Luminous flux measuring equipment with
integrating spheres are standard measurement of
luminous flux of lamps or luminaries
The equipment is constructed according to German
Standard DIN 5032, part 1 & fulfil the requirements
of CIE publication No.84“ The Measurement of
luminous flux
Transmission & Diffusion Measurement System
Measure the determination of stray-radiation of
transparent material, inside defined angular areas
as per AIS:010, IS: 2553, ECER: 43.
Spectral Measurement System
SMUV measures the light solutions particularly in
the UV, Visible and NIR as per AIS: 010, 012, 34, ECE
R: 037,099.
Profile Projector
ISP– Z3015 digital measuring projector is a precise
& excellent effective measuring instrument
integrating optic, mechanic & electricity.
Dimension Measurement of the Automotive Light
Sources AIS:034, ECR:037,099.
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Head Restraint Test Bench
This lab is equipped for endurance testing of various automotive components. These facilities are being used for the certification of
Hydraulic brake hose, Steering impact, Non plastic & plastic fuel tanks, wheel rims, Control cables, Pneumatic coupling, Retention and
release of the windows, wheel guards, wheel nuts, wheel disc, Safety belt, Seat, etc.…
Electrical based with load cell and displacement sensor
Back form actuator : 500 daN load, 400mm stroke
Head form act. (long.) : 500 daN & 700mm
Head form act. (vert.) : 75 daN & 500mm
Movement ranges : Y - 1 m, Z - 2.5 m
Linear force : 890 N
Torque (R-Point) : 530 Nm
Trigger : 10 I/O channels
Safety Components Laboratory
H Point Manikin
The H-point (or hip-point) Manikin is being used to
find out the relative location of an occupant's hip.
Certification Laboratory
Traction Compression Machine / UTM
Capacity : 50 kN
Speed Range : 0.1 – 500 mm/min
Clearance b/w columns : 405 mm
Cross head travel : 1100 mm
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
Bumper Impact Pendulum Rig
Impact Speed : Up to 10 Km/h
Mass (Arm) : 800 to 2500 kg
Arm Length : 3500 mm
Height Impact : 350 - 700 mm
Length of pendulum arm : 3.5 m
Weight regulation plates : 50 kg, 25 kg, 10 kg
Speed measurement device using laser beams
Fuel Tank Impact Pendulum Rig
Impact Angle : Up to 45⁰
Impact force : Up to 30Nm
Interior Fittings Test Rig
Z-axis Rotation : ±90 deg
Y-axis Rotation : ±10 deg
Acceleration : 200 g
Frequency Range : 0 - 3000 Hz
Speed sensor Range : 0 - 25 km/h
Other Test Rigs
Durability of Retractor
Emergency Locking of Retractor
Micro slip & Abrasion Test
Bus Window Life Cycle Test
Pneumatic Coupling
Window Retention Test Rig
Speed Sensor : 50 mm/min
Displacement Sensor : 300 mm
Pressure : Up to 210 bar
Height adjustable : 850 to 1400 mm
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Electrodynamic Shaker 6T & 3T with Chamber
This lab houses the equipment for evaluating structural dynamics of components/aggregates simulating real time loading conditions etc.
There are two Electrodynamic (ED) shakers associated with respective climatic chambers. The ED shakers intended to perform durability
tests for components under dynamic loading at high frequencies.
Rated Force : 6000 Kgf & 3000 Kgf
Maximum frequency : 2000 Hz & 2000 Hz
Displacement (pk - pk) : 51 mm & 51 mm
Maximum velocity : 2 m/s & 2 m/s
Maximum acceleration : 115 g & 90 g
Payload capacity : 700 kg & 500 kg
Armature dia : 440 mm & 360 mm
Mounting Base size : 1.2 x 1.2 m & 0.8 x 0.8 m
Vibration Shaker Laboratory
Fatigue Laboratory
Climatic Chamber
Usable Size : 2 x 2 x 2 m & 1.5 x 1.5 x 1.5 m
Temp range : -60 to +180°c & -60 to +180°c
Temp rate : 4 k/min & 4 k/min
Humidity : 10% - 95% RH & 10% - 95% RH
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
Fatigue Laboratory
Four Poster - Passenger Cars
Max. sprung mass/corner : 1050 kg
Max. unsprung m/corner : 60 kg
Actuator Rated f/corner : 51 kN
Max. Acceleration : 39 G
Max. Displacement : ±125 mm
Wheel Base & Track width : 1800 - 3200 mm, 1200 - 1800 mm
Wheel pan tire sizes : 135/70R12 to 275/35R20
Multi Axle Simulation Table (Mast) with Chamber
Max. Payload : 680 kg
Total Payload (incl. table) : 1438 kg
Acceleration
• Vertical Axis : 11 g
• Longitudinal Axis : 5.8 g
• Lateral Axis : 5.9 g
Configuration : Stewart Platform (6 DOF)
Upper Table Size : 2 x 2.2 m
Actuator Peak Force : 54 kN
Bandwidth : Up to 100 Hz
Climatic Chamber Spec
• Temp. Range : -30°C to +80°C
• Humidity : -10 to 95% RH
• Dimension : 2.5 x 2.5 x 2.3 m
Universal Test Benches
Capable of testing variety of automotive components and its
sub- assemblies.
Linear Actuator
• Max. Static Force : 15, 25, 50 & 150 kN
• Max. Stroke : 150, 150, 250 & 150 mm
Rotary Actuator
• Max. Static Force : 10 kNm
• Max. Stroke : ± 45 deg
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
The type of tests that can be performed in the Mileage Accumulation facilities are as follows:
Standard endurance testing according EC, EPA, Indian, Japanese or other regulations
Specific Drive Cycles, e.g. customer defined accelerated endurance cycle, vehicle running in cycles, journey simulation, etc.
Customer defined (R&D) tests (e.g. in vehicle gearbox testing, simulated vehicle operational tests)
Performance Tests
The systems are equipped with Robot driving (Auto Pilot).
The equipment are designed to function on 24x7 basis.
Mileage Accumulation Chassis Dyno Laboratory
Powertrain Laboratory
Auto Pilot
Advanced Computer Controlled driving robot for the
test driving.
Operating Temperature Range : -40°C to +80°C
High degree of accuracy & repeatability for test
results
Throttle & RPM Control, Load Variations, Tolerance
limit, of the drive cycles can be changed/controlled
as per the customer demand and need.
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
2/3 Wheeler Chassis Dynamometer
Type : 2/3 Wheeler Chassis Dyno with
+ AC Motor (648 mm Dia roller)
Make : AVL Zollner
Max. Axle load : 1000 kg
Max. Speed : 200 kmph
Inertia Range : 80 kg to 1000 kg
Max. Permissible
Power of the Test vehicle : 82 KW (110 HP)
Max. Tractive Force : 1500 N @ 198 km/h
Robot Make : Stahle - Germany
Test Condition : At Ambient Condition
without emission facility
4 Wheeler Chassis Dynamometer
Type : 4X4 48” Chassis Dyno + AC Motor
Make : AVL Zollner
Max. Axle load : 4500 kg
Base Inertia : 1200 kg
Max. Speed : 250 kmph
Wheelbase : 2000 to 4000 mm
Inertia Range : 454 kg to 5448 kg
Max. Permissible
Power of the Test vehicle : 432 KW (580 HP)
Max. Tractive Force : 14400 N @ 108 km/h
Robot Make : Stahle - Germany
Test Condition : At Ambient Condition
without emission facility
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Vehicle Evaluation Laboratory (VEL)
STEERING
PAD
SPECIAL BRAKING ZONE - 1
SPECIAL BRAKING ZONE - 2HIGH SPEED / OVAL TEST TRACK
BRAKING SURFACE / ABS TEST TRACK
GARC test tracks are being used for the development and certification of vehicles. some of the test that are being conducted by VEL
includes - steering effort test, turning circle diameter, pass by noise test, interior noise test, stationary noise test, maximum speed of
vehicle, gradeability, parking brake, service brake, abs test, dimensional check, tell tales symbols check, speedometer calibration, coast
down test etc..
Test Tracks
External Noise Test
Track
Total Length ISO Surface(ISO 10844-2011)Acceleration LaneDeceleration Lane
: 661m: 40 X 28 m: 310 m: 311 m
IS 3028, ECE R51, ISO 362, IS 10399,
ISO 5130, ISO 13325
Steering Pad
Maximum Radius (m)Acceleration Lane (m)Testing Radius (m)
: 100: 350: 5.2,12.5,15, 20, 30,
40, 50, 60 & 80
IS 12222, IS 11948, ECE R79
Test Hills Track
Gradient 6 & 8% (L x W in m)Gradient 12%Gradient 18%Gradient 28%
: 135 x 7 - Asphalt: 95 x 5 - Concrete: 75 x 5 - Concrete: 59 x 5 - Concrete
IS 14664, IS 11852, ECE R13, AIS 003
Oval Track
Total Length (Km)Straight LengthNo of LanesMax Speed (Km/h)Braking Zone
: 4.468: 1402.2 m x 2: 2 each of 4 m width: 120: 18m & 13m width
IS 11852, IS 14664, IS 14785, IS 10278, IS 11827, IS 11877,
IS 11921
Braking Surface
Track
Acceleration Lane (m)Stability Zone (m)Frontal Safety area (m)Lateral Safety area (m)Provided withSurface Type
: 645: 215: 140: 20.4 & 22.4: Water sprinkler: Ceramic, Bassalt,
Asphalt
IS 10376, IS 11716, IS 13670, IS 11852-
2003(Part9), ECE R13
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
Vehicle Weighing Pad
Capacity / Pad : 500 Kg (3 Nos)
Capacity / Pad : 1000 Kg (4 Nos)
Capacity / Pad : 10000 Kg (8 Nos)
Steering Sensor Kit
Torque : 50 Nm & 250 Nm
Vehicle Speed Sensor
Speed Range : 250 Km/h
Accuracy : ± 0.2% FSO
Frequency : 250 Hz
Fuel Flow Meter
Flow Rate : ( 0.5 to 250) at 5 bar 120 L/Hr
Pedal Force Transducer
Force : 0 to 1500N
Hand Lever Force Sensor
Force : 0 to 500N
Data Logger
IMC : DAQ
Control System : Industrial Laptop
Pass by Noise Meter
IS 3028/ISO 362
Equipment
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Automotive Infotronics Lab is one of the Centre of Excellence in GARC. The general purpose of the Automotive Infotronics lab is to offer a
platform for training, developing, testing, evaluation and validation of Electronic Control Units devoted to vehicle or vehicle components in terms
of the hardware and the software.
Infotronics
Automotive Infotronics Laboratory
Hardware - In - Loop System
Hardware in loop system shall contain, A real time simulation of HIL system
for communicating with various IO of a Gasoline, Diesel ECU and chassis ECU
like ESP, ABS, ASR, etc. HIL simulation is a technique that is used in the
development and testing of complex real-time embedded systems.
Measurement, Calibration, Diagnostics and Fleet Validation (MCDF)
MCDF Performs measurement, calibration, flashing and diagnostics activities
on the ECU. Online & offline calibration of one or multiple ECUs can be done
at a time.
MATLAB
MATLAB® is a high-level language and interactive environment for numerical
computation, visualization, and programming. MATLAB is intended primarily
for numerical computing, an optional toolbox uses the MuPADsymbolic
engine, allowing access to symbolic computing capabilities.
Climate Control
Steering
Telematics
Body Controls
Plastic Precision
Powertrain
Chassis
Suspension
Security
Safety
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
CAD/CAE Laboratory
CATIA V6 & SIEMENS NX
CATIA V6 & SIEMENS NX aid us in the
creation, modification or optimization of a
design
Basic theme of FEA (Finite Element Analysis) is to make
calculation at only limited number of points and then
interpolate the results for entire domain.
Hypermesh aid us in reducing degrees of freedom of a
object from infinite to finite with help of discretization
(Meshing -> Nodes & Elements).
Higher the mesh refinement, Higher the result accuracy
Design
Altair Hyperworks
Meshing
Finite element analysis (FEA) is a computerized method for
predicting how a product reacts to real-world forces,
vibration, heat, fluid flow, and other physical effects. Finite
element analysis shows whether a product will break, wear
out, or work the way it was designed.
Hyperworks (OptiStruct & RADIOSS) aid us in analysis of the
component
MSC Fatigue solver aid us in predicting life/failure of the
component in initial design phase
MSC Software & Altair Hyperworks
Finite Element Analysis
Plot E1, SIPCOT Industrial Growth CentreOragadam, Mathur Post
Sriperumputhur TalukKanchipuram Dist - 602 105
Tamil Nadu, India
For further details, please contact:
Mr. M.V. RamachandranSite Head – GARC
[email protected] & www.garc.co.in
E N S U R I N G S A F E D R I V E
Recycling Demo Unit is a significant first step in developing a modern and viable auto recycling industry in INDIA.
RDU Project
Recycling Demo Unit (RDU)
Key outputs of this project
Automobile manufacturer to design vehicles for this dismantling
OEM’s can identify materials to be used which is recyclable and are
reusable
Ration for process flow manuals which comprises of dismantling
Process flow, Segregation, Recycling
Will help the government for framing a legislation which will pave
way for recycling of end-of-life vehicles in India
Highlights of RDU Facility
SEDA Airbag neutralizing kit
Fork lift
Bailing press to produce bales of size
16”x16” weighing 60 to 100 kg
Oxy - Acetelene gas cutting
Weighing machines
Building Size (m) : 35 x 25
Dismantling Area (m) : 16 x 7
Parts Storage Area (m) : 16 x 7
Total building area (Sq.m) : 510
Vehicle body storage area (Sq.m): 600
GLOBAL AUTOMOTIVE RESEARCH CENTRE
E N S U R I N G S A F E D R I V E
Upcoming Facilities
Crash Core & Dummies (APSL)
Electro Magnetic Compatibility & Interference (EMC & EMI)
Powertrain Laboratory
• Vehicle Test Cell
• Engine Test Cell
• Climatic Vehicle Test Cell
• VV / VT Shed
Tilt Test Platform
Test Tracks
• Oval Track
• Braking Surface Track