The challenge faced by Tata AutoComp was to design and develop state-of-the-art components while keeping Indian operating conditions of overloading, rough roads and extreme weather conditions in mind. It is for the first time that driver, co-driver and occupant safety and comfort was given importance in the heavy vehicle segment. The emphasis is on enhancing the aesthetic appeal of the vehicle, smoother ride, high power, ease of handling, and comfort and safety of the driver and the co-driver.
The design and engineering teams at Tata AutoComp worked closely with the development team at Tata Motors to deliver a superior product.
Details of the various components supplied:
Cabin exterior and interior: This is the first time that a heavy commercial vehicle in India is designed with a driver cabin made of light materials like plastics and composites. Tata AutoComp Systems’ Interiors & Plastics Division and Automotive Composite Systems’ have contributed major components in plastics and composites which go into building the cabin.
In fact, the Interiors & Plastics Division has been there as an Early Supplier Involvement (EIS) in this project from the styling surface in Italy. This has resulted in overall reduction of the weight of the cabin as compared to the traditional sheet metal, leading to enhanced styling and durability.
Seating systems: The seating system is specially developed to ensure total driver comfort and safety. ISRI-TJC, a joint venture between Tata Johnson Controls Automotive Ltd. and Isringhausen GmbH, first did a benchmarking of all global truck seating systems. The seats were designed and developed in Germany meeting Indian and global standards. The designs also took into account Indian road conditions.
This is the first time that a seat with integrated seat belt meeting the AIS and ECE regulations is introduced. The driver seat is fitted with world class mechanical or pneumatic suspension mechanisms that allow vertical height adjustment, fore and aft movement, tilt mechanism for cushion, adjustable lower and upper lumber supports and high density foam and bolsters for additional comfort. The seats are also fitted with a heater option to provide comfort in extreme cold conditions.
Braking system: The air braking system developed by Knorr-Bremse is designed with a braking system pressure of 10 bar against 8.1 bar currently offered on similar vehicle platforms for better braking performance. An advanced air processing unit replaces the traditional air dryer to ensure better air management as it is a combination of air dryer and oil separator and has a multi-circuit protection valve, thus offering higher reliability and service life.
To offer modularization and better space management, an integrated pedal unit has been developed. The hand brake valve has been designed with a trailer check function. Over and above, a state-of-the-art trailer braking system with ABS has also been developed.
Currently the trailer performance is not governed under Indian regulations. Hence trailer manufacturing is largely an unorganised industry. Introduction of this advanced trailer braking system will vastly enhance dynamic behaviour and road safety of tractor / truck and trailer combinations in the World Truck.
Wiring harness: For the first time; a new fuse and relay box based on bus bar with F-F terminal has been introduced in a commercial vehicle. This has helped reduce 75 circuits. A special bulk head has also been designed for as an interconnector between the front and dash wiring harness. This will help in trouble-shooting, enhance serviceability and ensure ease of fitment on the vehicle. The routing of the entire harness on the vehicle has been developed with 60 different clamping options.
Headlamp and fog lamp: This is another first of its kind in Indian commercial vehicles where the head lamp designed by Tata Visteon Automotive Ltd. comes with the poly ellipsoidal system (PES) lamp. This offers excellent light spread and sharp beam cut-off to ensure no glare for the on-coming driver. The high beam is designed to give one of the highest light output of over 100 lux for clear nigh time visibility.
The compact lamp aesthetically blends well with the overall exterior design of the vehicle while meeting global standards of light output. The specially designed fog lamp provides additional visibility in challenging weather conditions.
Suspension systems: The Tandem Bogies suspension systems indigenously designed by TACO Hendrickson Suspension Ltd. take into account all Indian operating parameters like road conditions, overloading and ease of serviceability to ensure better ride handling and control. The suspension systems have been designed to perform up to 15-25 per cent overloading consideration.
This world class technology has been made cost effective with 100 per cent localization of components. The range includes suspension products for all kinds of heavy vehicles under this program from rigid truck to high-end tippers. The 48-ton inverter bogie suspension developed for the tipper is the first of its kind being introduced. Over and above, all the bogies suspensions use rubber bolster to offer better shock absorption.
Outer rear view mirror: The mirror cluster developed by Tata Ficosa Automotive Ltd. incorporates special mirrors that offer clear visibility of all the sides of the vehicle as well as a wide range rear approaching vehicles. This will ensure good visibility of the vehicle’s immediate environs to the driver for better safety.
