OEMs are facing new challenges to improve the existing technologies and develop next-generation ones for the new mobility in shorter times. Reducing market responding time along with new complexities are paving the way for virtual simulation, which displaces physical tests and prototypes by virtually replicating product development, testing and manufacturing with simulations. Emmanuel Leroy, Executive Vice-President Industry Solutions at ESI Group, explains, “We enable our customers to drastically reduce every additional physical prototype by using our solutions. In the end, only one physical prototype is required to validate the whole concept. We envision that one day we may be able to virtually certify a product from end to end.” Excerpts:

Q) How did the Covid impact the software and services businesses of ESI Group?

The Covid pandemic has accelerated the need for more digitalisation within the industrial market. It has also somehow accelerated the readiness level of our customers and made solutions such as virtual prototyping even more relevant. Indeed, we enabled the continuity of our clients’ business. The use of virtual prototyping allowed them to continue designing, testing and prototyping their products. Our human-centric approach – one of ESI Group’s four outcome solutions – was particularly used by our customers to ensure the continuity of their businesses: using virtual reality to experience the product from home.

During pandemic times, we also provided our CFD (computational fluid dynamic) solutions to help investigating different scenarios to demonstrate the effect of occupant proximity, ventilation systems and contamination avoidance unique to each office and plant environment. ESI Group developed different virtual scenario, based on its facilities in India, to optimise the return to offices and on plant – especially on a car assembly line.

How the growing complexity of part process is influencing the virtual testing?

We notice that the automotive industry is facing more and more draconian regulations, disruptive technologies, intensifying competitions and shortening response time. Coupled with these, customers are getting more demanding on quality, reliability, safety and production deadlines in the business. Indeed, end users are no longer looking for products but for results (flight hours instead of engines, number of possible kilometres instead of electric car, etc.) and they seek for committed and responsible automakers to motivate their buys. At ESI Group, we have understood these preoccupations and we have defined four primary solutions answering our customers’ expectations.

The first one is the Pre-certification and Validation, enabling gains in performance and productivity. The purpose is double: meeting certification and validation requirements like crash, safety and fatigue issues in the first attempt and then increasing productivity with predictive models and process automation.

The second outcome is Smart Manufacturing, which enables to establish the right manufacturing processes to meet the performance indicators for industrial products and processes.

The Human-Centric Product and Process Validation, our third outcome, focuses on humans by implementing an operator-centric approach to ensure the efficiency of assembly, maintenance operation and the safety of human interactions.

The last one, Pre-experience, is the most advanced solution of ESI Group. Here, our customers and the operators do not look at the product itself, but virtually experience a product, component, subsystem or system under numerous conditions and environments.

Using these approaches, we identify industry challenges from the customer’s perspective and support them in achieving their results.

Finally, as products are getting more complex, one of our strengths is our end-to-end multi-material assembly solution with modelling of different materials (steel, aluminum, composite) and manufacturing processes, covering all the product development cycle.

What will be the growth drivers for the internal combustion engine-driven vehicles business?

Safety is essential and will remain a key driver in the future. Today, the active safety is gaining traction owing to the regulations and overall trends. There is an increasing demand for smart integrated safety, which caters to both active and passive what?

Alongside there are regulations on Co2. In Europe, the Worldwide Harmonised Light Vehicle Test Procedure (WLTP) Norm is challenging and will eventually be implemented in other countries. Regarding Co2 reduction, we focus part of our research and innovation around engine efficiency, aerodynamics and light-weighting, as we did with Bentley for instance.

OEMs are also looking to reduce the manufacturing cost and development time which are leading demand for virtual prototyping, digital twin and shifting OEMs’ investment from hardware to software. The end-to-end value and the digital continuity from the early design to the production is essential to achieve these goals.

OEMs are exploring possibilities to manufacture ICE vehicles and EVs on the same line. Being a solution provider for the smart manufacturing process, how do you see this as a challenge?

Some OEMs assemble EV and ICE vehicles on the same line and look for flexibility, while others use completely dissociated platforms. We, consequently, must find the right strategy regarding their requirements. The new upcoming challenges in CASE mobility manufacturing will bring even more complexities from components to manufacturing. We have to consider the complexity to train the operators: our virtual reality solutions are key here. We help our customers by providing training, on both ICE vehicles and EVs manufacturing processes to their team, even from different place around the world, gathered on the same interface. This solution gathers all stakeholders (from operators to QHSE officers and plant managers) around the same product. This immersive tool helps getting complementary feedbacks early on in the process.

Where do you find more competencies or comfortability — in the complete vehicle design or component design?

Clearly, we are positioning ourselves on the whole vehicle design as it gives the most significant benefit for the OEM and other customers. We are talking about an end-to-end value that we can demonstrate on full scale CAE demonstrators. When it comes to a standalone component, the complex interactions between components and environment are not well taken into account and can lead to reduced predictiveness. In this case, we come up with a holistic view of the problem itself. It is how we defined the four outcome solutions introduced earlier.

Do you think that virtual prototypes will, at a 100 percent, completely replace physical ones ?

Virtual prototypes are step by step replacing physical prototypes. Nevertheless, I think physical prototypes remain today essential to certify the product at the very end of the development phase. To give an example, in 2019 Renault succeeded a 5-star rating of its Clio 5 on the Euro NCAP safety certification test with a single physical prototype, the one needed for the consumer test. Virtual certification is a topic discussed within the automotive ecosystem, allowing to solely relying on the simulation from end to end. But we are not at that point right now.

Which is your largest market for automotive business?

The automotive industry is the most significant contributor to our total revenues. Today, Japan is the largest market for our automotive business. However, India has been an important market for ESI, and it has been growing quite well over the years.

Most of our engineering developments teams, for both our software and our platforms, are based in India.

What are the challenges in the business?

The increasing complexity I mentioned before is definitely a challenge, but it also brings opportunities to us. Our end-to-end multi-material, multiprocess solutions and chaining capabilities are key to overcome the challenges of the automobile market. Due to the ever growing content of electronics, system simulations and systems of systems techniques are improving as well. Our focus is to strengthen our collaboration with partners in the ecosystem to support the customers in solving their complex problems. (MT)

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Chennai-headquartered electric vehicle company Raptee.HV has opened an electric mobility Centre of Excellence at Rajalakshmi Engineering College, establishing an industry-academia partnership focused on electric vehicle technology.

The new facility, inaugurated on World EV Day, is spread across 3,000 square feet and will operate under the Raptee.HV Academy initiative will introduce industrial exposure and prototyping tools to academic institutions.

The project represents an INR 5 million investment and accompanies a Memorandum of Understanding signed between Raptee.HV and Rajalakshmi Engineering College. The agreement covers industrial training, site visits, guest lectures, internships, academic courses and research projects.

It is designed for students across electrical, electronics and automotive engineering; the laboratory contains a Raptee.HV T30 motorcycle, core electric vehicle components, a stripped motorcycle fitted with digital twin technology and equipment for testing battery packs, electric motors, power electronics, charging systems, vehicle communications and diagnostics.

Dinesh Arjun, Co-Founder and CEO, Raptee.HV, said, "The next generation of mobility will be built by engineers who understand the machine from the cell to the software. But you cannot build that understanding from a classroom alone. You have to get your hands dirty, take systems apart, question how they work, experiment and build again. The HV Lab is our attempt to bring that experience into engineering education. If even a few students walk out of this lab wanting to build the next great EV technology, we have done our job."

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Zuno General Insurance has launched Fuel Guard, a car insurance add-on offering financial protection against component damage caused by manufacturer-approved blended fuels.

The policy addition targets private motor vehicles in India as alternative and blended fuel adoption expands across the country. The coverage applies to specified engine and fuel-system parts in cases of accidental or unforeseen damage arising directly from approved blended fuel use.

At present, the insurance cover eligibility is restricted to private cars registered on or after 1 April 2023, provided the vehicle manufacturer has endorsed the specific fuel blend used. Vehicle owners must adhere to the manufacturer's prescribed maintenance schedule without making unauthorised modifications to the engine or fuel system. Fuel Guard can be added to private car package policies, standalone own-damage coverage, bundled options and three-year long-term policies.

Shanai Ghosh, Managing Director and CEO, Zuno General Insurance, said, "At its core, Fuel Guard is built around a simple idea: as the mobility ecosystem evolves, insurance protection needs to evolve with it. At Zuno, we continuously look at how changes in mobility are shaping customer expectations and ownership experiences. Fuel Guard reflects our effort to translate those insights into simple, practical solutions that make protection more relevant in everyday life."

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JSW Group and Volkswagen Group have signed a non-binding memorandum of understanding (MoU) for a proposed 51:49 alliance involving JSW Green Mobility Limited and Skoda Auto Volkswagen India Pvt Ltd. No official statement or press release has been issued by either the JSW Group, Skoda/Volkswagen yet regarding the development. 
“The signing of the non-binding MoU has actually taken place,” claimed an industry source. Pointing at the news in Economic Times, he said, “The non-binding MoU paves way for further negotiations between the two organisations in terms of valuation and other factors.” 
“The non-binding MoU would explore setting up of a strategic joint venture in India that would develop, manufacture and sell passenger vehicles for the domestic as well as international markets,” he added. 
Stating that the nature of vehicles would include ICE, electric and hybrid powertrain ones, the source averred, “The non-binding MoU would pave the way for internal approvals, regulatory clearances and other nitty-gritties such as sourcing, manufacturing, technology, localisation, management etc. before a concrete structure is engineered by both the companies and the groups that control them by the end of this year or early next year. 
Entering India is 2000, Skoda, the Czech passenger vehicle arm of the Volkswagen Group has been driving activities for Volkswagen and Skoda brand of vehicles in India. While the Chakan (Pune) plant has been under Volkswagen, the Shendre MIDC (Chhatrapati Sambhaji Nagar) plant has been under Skoda. The Volkswagen Group premium luxury vehicles of the Volkswagen, Skoda and Audi brand are assembled at the Shendre MIDC facility. It has been some time that the Volkswagen Group is looking to turn the Indian operations into a regional hub catering to the immediate neighbouring markets among others. 
Holding a 35 percent stake in JSW MG Motor India, which involves SAIC Motors and is separate from JSW Green Mobility, the JSW Group has presence across steel, infrastructure, energy, cement, paints and automobiles. While there have been reports indicating plans to increase its holding to 45 percent in JSW MG Motor India, the Group has committed up to USD 3 billion over five years in investment in its automotive arm, which includes the building of a greenfield manufacturing footprint at Chhatrapati Sambhaji Nagar. 
The development about the non-binding MoU between JSW Group and Volkswagen Group, the source claimed, has taken place at around the same time the CEO of Skoda Auto, Klaus Zellmer, and the CEO of Volkswagen, Thomas Schäfer, were visiting India. 
 

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Japanese automotive major Honda has become the first company globally to earn a five-star rating in the products and services category of the FIA Road Safety Index. The award was presented at the Autodromo Nazionale Monza during the FIA Formula One Italian Grand Prix.

The FIA Road Safety Index measures organisational impacts on road safety across operations, supply chains, products and services. The FIA expanded the index from a 3-star to a 5-star framework, introducing modules for planning, performance monitoring, safety culture management and supply chain or product coverage.

To qualify for the updated framework, Honda expanded its assessment scope to cover 17 countries, representing over 90 percent of its global motorcycle and automobile sales volume. The evaluation reviewed Honda's safety governance, global fatality tracking, safety technology deployment and traffic safety data disclosures. The company maintains targets to halve traffic collision fatalities involving its vehicles per 10,000 units sold by 2030 compared to 2020 levels, with a long-term goal to eliminate traffic collision fatalities by 2050.

Mohammed Ben Sulayem, President, FIA, said, “Road safety remains one of the world’s most urgent challenges, and no single organisation or sector can address it alone. Progress depends on action at scale across the public and private sectors, uniting all stakeholders around our shared goal of saving lives on the road. The FIA has an important role to play in accelerating that change for road users worldwide. Alongside our work with companies, we encourage governments to consider how the FIA Road Safety Index methodology can support regulatory compliance frameworks and strengthen road safety standards globally. We aim to build a shared culture in which road safety is recognised as a fundamental responsibility. I congratulate Honda on leading the way and becoming the first organisation to receive five stars.”

Willem Groenewald, FIA Secretary General for Automobile Mobility, Sustainability and Tourism, said, “The expansion of the FIA Road Safety Index to five stars marks an important step in our ambition to make road safety a measurable and accountable part of corporate decision-making. Organisations worldwide have a significant influence on road safety through their operations, employees, products, services and supply chains. With this expanded methodology, they can not only understand that impact more broadly, but set targets, measure progress, showcase in-depth commitment and continuously improve their performance. Honda becoming the first organisation to achieve the new five-star rating demonstrates the level of ambition we want the Index to inspire. We hope this milestone will encourage many more organisations across the public and private sectors to measure their road safety footprint and take concrete action to save lives.”

Mikihito Kojima, Assistant Vice-President and General Manager of Traffic Safety Promotion Operations, Honda Motor Co, said, “We are deeply honoured that Honda safety initiatives have received the 5-Star rating, the highest recognition in the FIA Road Safety Index. At Honda, our goal goes beyond delivering safer products. We look to the safety of each and every customer who uses our products, and everyone sharing the road around them. Through the advancement of our safety technologies, activities to promote safe driving and riding practices, and a clearer understanding of how traffic collisions occur so that we can keep improving, we work to reduce the number of traffic collisions themselves. The FIA Road Safety Index brings visibility to corporate road safety efforts, and has given us a clearer view of where we stand today and of what we need to address next. We see this recognition as an important milestone on the way to our challenging goal of achieving zero traffic collision fatalities involving Honda motorcycles and automobiles globally by 2050, and we will continue to take on that challenge. We also hope that the FIA Road Safety Index will encourage broader commitment to road safety among companies and organisations worldwide beyond individual companies and industries, helping to drive road safety forward across society.”

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