global automotive research centre (garc) about garc ... · pdf filethe garc which is under...

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


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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


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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Tamil Nadu, India





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



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



Tamil Nadu, India





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



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



Tamil Nadu, India





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



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.



Tamil Nadu, India





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



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



Tamil Nadu, India





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



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



Tamil Nadu, India





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.



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



Tamil Nadu, India





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



Vehicle Weighing Pad

Capacity / Pad : 500 Kg (3 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



Tamil Nadu, India





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



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



Tamil Nadu, India





Recycling Demo Unit is a significant first step in developing a modern and viable auto recycling industry in INDIA.

RDU Project


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



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

global automotive research centre (garc) about garc ... · pdf filethe garc which is under...

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