Tata AutoComp Systems
powers Tata Nano
24 March 2009
Tata AutoComp Systems Limited (Tata AutoComp),
one of India's leading auto component conglomerates, today announced
significant contribution of the company in engineering, design and
supplying of components to the Tata Nano.
Tata AutoComp has contributed the following
components for Tata Nano:
Company / Joint Venture
Tata AutoComp Systems Limited - Interiors and Plastics Division
Bumpers, dashboard, cockpit (front console),
door handles, door and pillar trims, air vents and several
powertrain plastic components such as cylinder head cover,
timing gear cover, etc.
Tata Johnson Controls Automotive
Tata Toyo Radiator
Radiator fan module
Tata Yazaki Autocomp
EMS harness body, wiring harness body and battery
Tata Visteon Automotive
Air intake manifold
Tata Ficosa Automotive
Gear shifters, rear view mirror sets andwasher
Tata AutoComp GY Batteries (TGY)
Speaking on the occasion Mr R
S Thakur, Executive Director and Chief Operating Officer – Tata
AutoComp Systems Limited said, "Our teams have been working
closely with Tata Motors right since the inception of the project,
to design and engineer various components, keeping the cost, superior
quality and performance parameters in mind which required design
and process optimisation. We are proud to be associated with the
Tata Nano, an engineering marvel, which is both, pioneering and
path-breaking for the automotive industry worldwide. Tata AutoComp
has a head-start in this emerging market."
Tata AutoComp has demonstrated high
design and engineering skills while designing the components for
the Tata Nano. Besides cost, the other challenge the team at Tata
AutoComp faced was trying to lower the weight of each component.
This brought about development of specially designed and engineered
components and systems.
In most cases, Tata AutoComp was
developing the various components for the first time. From day one,
the Nano was conceived as a small car with space at a premium. To
get the components to fit into a small space, without compromising
on functionality, safety or aesthetics was a challenge. It was this
challenge that led to a lot of innovation.
Components from company / joint
Engine cooling systems
(Tata Toyo Radiator)
It was the first time in India, that a car was being developed
with the engine at the rear. This meant that airflow would be hampered
and space would be a constraint yet the solution was expected to
be scalable to meet the cooling needs of the scaled-up versions.
The team at Tata Toyo Radiator came up with many innovations
the styling of the rear doors to facilitate air intake, the fan
motor which drives the fan as well as the fan blades were redesigned
to increase efficiency as well as air directors were developed to
direct air on to the radiator core.
Engine induction system (Tata
This is the first time in India that an engine induction system
was made in plastic. While this has helped reduce the weight of
the component substantially, its major benefit came in terms of
far superior performance. Compared to the traditional aluminium
EIS, this one delivers consistent air to the engine, thereby ensuring
Automotive batteries (Tata
The battery developed for Nano by Tata Green Batteries is based
on its existing and superior calcium-calcium (Ca-Ca) technology.
To begin with, the battery is being fitted under the driver’s seat.
The first attempt was to ensure that there are no emissions that
affect the health of the driver and the co-passengers. The superior
Ca-Ca technology ensured a benefit of no top till 1lakh kilometres.
Second, the battery had to be light yet offer superior performance.
Special small-sized plates were designed with envelop type separators
to ensure that there are no short-circuits which are common in such
batteries. Besides this, various safety features like individual
cell ventilation and flame arrestors have been provided, making
the batteries absolutely safe.
Wiring harness (Tata Yazaki
Nano is designed with the engine at the rear, but the battery
in the front. This meant that the wiring harness and the battery
cable had to be developed that would work even in the upgraded versions
of Nano. The most crucial part in the entire circuit is the fuse
box. The team at Tata Yazaki designed a new fuse box based on the
bus bar technology with FF terminals. This helped in reducing 21
circuits without compromising on the functionality.
Seating systems (Tata Johnson
The seating system had very challenging cost targets. The seats
had to be light in weight, offer good seating comfort as well as
good overall body support and meet all safety requirements. Certain
functionalities like the driver seat (as well as the co-driver seat
in the higher models) being able to recline along with forward and
backward movements had to be incorporated. The rear seats had to
be designed to be foldable to enhance the rear cabin space. With
such tall specifications, the design team at Tata Johnson Controls
came up with innovative solutions that enhanced the aesthetics in
a cost effective manner. The front seats are based on a single brace
structure instead of individual rails, a frame and the right amount
of foam to ensure that the overall seating comfort was taken care
Interior and exterior plastic
parts (Tata AutoComp – IPD)
The interior and exterior plastic parts include bumpers (in
body colour for the higher models), instrument panel, air vents,
cockpit (central cluster assembly), door handles, door trims, pillar
trims and various engine and powertrain plastic parts. These were
innovatively designed and engineered to achieve weight reduction,
without compromise on functionality, aesthetics, regulatory and
quality parameters. For instance, the air vents in Nano needed a
protective grille to avoid small objects (like coins) falling into
the HVAC circuit. This was achieved by integrating a Honeycomb grille
into the Bezel, thus reducing the total number of parts. The recess
in the front dash board is an intelligent design to provide space
to the occupants to keep small items while travelling.
Windshield washing system (Tata
The windshield washing system faced severe space and packaging
challenges. After much iteration, a relatively very small yet complete
(with all the functionality that most cars offer), was developed.
A sleek washer tank was developed which is fitted in the front of
the car (under the hood).
Gear shifter (Tata Ficosa Automotive)
It is for the first time in India, that such a small car will
have a cable type gear shifter (as opposed to rod type). This helps
in two ways; firstly it reduces the weight of the overall gear shifter
system and secondly, makes shifting of gears very smooth and effortless
a great boon for the driver.
Inner and outer rear view mirrors
(Tata Ficosa Automotive)
The inner rear view mirror was redesigned to incorporate the
cabin lighting system, thereby reducing the total number of components
required. The outer rear view mirrors in body colour were designed
to enhance the style quotient of the car.
About Tata AutoComp Systems
Tata AutoComp Systems Limited (Tata AutoComp), promoted
by the Tata Group, provides products and services to the Indian
and Global automotive OEM’s as well as Tier 1 suppliers. Its clients
include Ashok Leyland, Audi, BMW, Fiat, Force Motors, Ford Motors,
General Motors, Honda, John Deer, Mahindra & Mahindra, Mahindra-Navistar,
Man, Mercedes-Benz, Nissan, Piaggio, Renault, Tata Motors, Toyota,
Volkswagen and Volvo-Eicher. Tata AutoComp has own capabilities
in Automotive Interior & Exterior Plastics, PV Suspension Systems,
Engineering, Vehicle Tracking Systems and Supply Chain Management.
Tata AutoComp has 14 joint ventures in partnership with leading
companies from the Global Auto Component Industry and has manufacturing
facilities spread across India, Germany and China.
With over 30 manufacturing facilities
and five engineering centres, Tata AutoComp is rapidly growing its
business. For more information, please visit www.tacogroup.com