Designing and Styling (CAD CENTRE)

The CAD centre is equipped with 53 state-of-the-art CAD stations and the latest software. The CAD centre is a vital organ of ERC's Cab Design Section.

CAD designing involves development of vehicle specifications, styling interiors and exteriors, reviewing the styling from the engineering and aesthetic points of view, virtual prototyping to check for design acceptability and feasibility of manufacture.

Based on this information, several running prototypes are made and tested. It is only after all flaws, if any, are corrected using CAD systems, that vehicles are approved for mass production.

Minimising Noise (ANECHOIC CHAMBER)

Anechoic chamber is a highly sophisticated noise and vibration laboratory, the nerve centre of which is a vast chamber lined with 88,000 cones projecting at various angles from the walls and ceiling. It is one of its kind in India and is developed completely with in-house facilities.

A number of cones, made of glass wool, are covered with fire retardant material and absorb sound generated within this chamber. There are rubber dampers, and a meter-thick wall of air surrounds the chamber itself. Designed to achieve 99.5% noise absorption, the chamber is used to test noise and vibration levels created by vehicles.

For e.g. The noise of a door being shut, the click of a switch or an engine being started.

Durability Testing

• Test Tracks
• Four Poster Servo-Hydraulic Test Facility

Test Tracks: High-speed tracks are specialized tracks for testing endurance of cars and commercial vehicles. The Tata Motors torture tracks and high-speed tracks in Jamshedpur and Pune are the only one of their kind in the country. The torture track has 4 segments. Each segment affords a different type and level of stress testing for the vehicle chassis and aggregates. The tracks subject the chassis to shock, twisting, and bending loads. 1000 cycles on this torture track are equivalent to approximately one and a half lakh kms of running on regular roads. It thus provides a valid test of chassis and vehicle durability.

Four Poster Servo-Hydraulic Test Facility: Four Poster Servo-Hydraulic Test Facility consists of four posts for mounting the vehicle. The vehicle is subjected to vertical motions equivalent to road undulations similar to actual runs on a test track. These tests conducted in a lab under controlled conditions are accurate and unaffected by external factors that could hamper testing activity.

Reducing Emissions

A specialized laboratory has been set up to measure levels of emission of vehicles using either petrol, diesel or CNG. This laboratory helps Tata Motors achieve fuel consumption efficiencies that would conform to international standards, under varying driving cycles. It stands testimony to Tata Motors commitment to help bring down levels of atmospheric pollution caused by vehicular exhaust.

Facilities

Engine Performance

• Test Beds
• Chassis Dynamometer Emission Lab
• Electrodynamic Vibration Shaker Platform
• Instrumentation Laboratory

Test Beds: Tata Motors has 24 engine test beds for engine development. These are fully automated with computerised data acquisition and logging. They are used to test performance, endurance, and durability. They are also used in development of components and other engine aggregates.

The dynamometers ranging from 200 Hp to 500 Hp are capable of looking after all the existing and future petrol, diesel, and CNG engines of Tata Motors. Three test beds are equipped with emission analysers. They are engaged in emission development for Euro norms. Six test beds are equipped with 'Intake Air Conditioning Systems' to feed combustion air at ref. temp, pressure and humidity to the engine.

The latest addition is a contemporary "High Dynamic Transient Dynamometer" (HDTD) installed in December 2000 which permits all 'chassis dynamometer' drive cycles to be run on it. It has an Emission System, Dynamometer and Software. The powerful software simulates the driver and all vehicle aggregates like gearbox and drivetrain, other than the engine. Top

Chassis Dynamometer Emission Lab: The ERC has a specialised AVL Zollner Chassis Dynamometer with a 508mm-twin roller for checking the emission levels of chassis. It is certified by UTAC, TUV, INTA and ARAI. With a 125 kw generator, it can cater to the maximum vehicle speed of 210 km/h. Inertia simulation ranges from 567kg to 3000 kg. The Horiba 9000 emission system has separate CVS units for petrol and diesel. Top

Electrodynamic Vibration Shaker Platform: It is used for testing engine components and assemblies against vibrations. It works with a rated force of 2000 kgf on X, Y, and Z-axis. The maximum displacement is 40 mm and the maximum acceleration is 65g. It has a platform table size of 1000x1000 mm. The whole set-up has a PC based control and automation system. Top

Instrumentation Laboratory: The 'Instrumentation Laboratory' at ERC Engines is equipped with a range of instruments to assist engine development. These include data acquisition systems, air flow meters, blow-by meters, smoke meters, oil consumption meters, incometer & topometer, piston profile tester, FIP test rig, Swirl test rig, and many other support equipments to cater to routine engine development activities. Top

Engineering Research Centre (ERC)

The Research Centre at Jamshedpur regularly upgrades components and aggregates. A well-equipped torture track enables rigorous and exhaustive testing of modifications before they are used as regular fitments.

The Engineering Research Centre in Pune was setup in 1966 and is among the finest in the country. It has been honoured with two prestigious awards - 'The DSIR National Award for R&D Effort in Industry - 1999' and 'National Award for Successful Commercialisation of Indigenous Technology by an Industrial Concern - 2000.'