December 2014

Our Vision
To be a world class R & D centre assisting the automotive sector and to render services in the field of
automotive design, test and validation.

Our Mission
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To assist industry in adopting cutting edge technology in component and vehicle development.

To adopt world class work practices in technology services and innovation.

To build technical expertise driven by team work and commitment.

To strive to deliver quality services for total customer satisfaction.

To be a front runner in establishing global standards in the field of Automotive testing and R&D.

Our Quality Policy

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To provide Research & Development, Design Testing, Certification, Homologation and

Calibration support to Auto Industry.
To guide Indian Auto Industry to manufacture safe, reliable and environmental friendly vehicles/
components.
To provide a work environment and culture that promotes innovation and initiation through
training and teamwork.
Continual improvement of our processes, quality of our services and infra-structure to meet the
varying needs of customers.

The International Centre for

Automotive Technology

he International Centre for Automotive Technology (ICAT) was set up in

2006 and is the first of the new world class centres coming up under the
National Automotive Testing and R&D Infrastructure Project (NATRiP).
ICAT has been certified for ISO 9001:2008, ISO 14001:2004, OHSAS
18001:2007 by TUV, Nord.
ICAT has been accredited with NABL ISO 17025:2005 for Photometry/
Safety glass/ CNG & LPG Components/ Material Physical Properties/ Chassis
& Engine Dynamometer Lab/ Vibration testing/ Electronics & Electrical
Components/ Vehicle Performance Tests/ Tyre testing
ICAT is emerging as a comprehensive technical partner of the automotive
industry and currently undertakes the following major activities:
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Our Location
The International Centre for Automotive Technology (ICAT) is located
at Manesar, Haryana on Delhi-Jaipur Highway (about 40 Kms from
Delhi International Airport). The strategic location of ICAT in the
automotive hub at Manesar provides the automotive and component
industry faster access to the testing and developmental facilities.

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Homologation and Certification

Developmental Projects & Testing
Automotive R&D Projects

The Government of India has recognised ICAT as one of the accredited

'Type Approval and Homologation' agencies in India under Central Motor
Vehicle Rules (CMVR) 126 and has also been recognized as Scientific and
Industrial Research Organization (SIRO) from Department of Scientific
and Industrial Research (DSIR), since Feb 2010, by BIS for Tyre Testing,
Safety Glasses and by Central Pollution Control Board (CPCB) for
Emission and Noise testing of Generator Sets.
With the capital investment of ` 48.52 crore (US $ 10.54 million) and the
facilities spread over 8 acres (32,376 sq.m) of land, the centre is rendering
valuable services to the automotive industry in the country in a big way.
Many clients are using the facilities for homologation, development and
sponsored projects.
An additional investment of ` 930 crore (US $ 210 million) is earmarked
by NATRiP for setting up additional testing facilities and test tracks. An
additional land of 46.29 acres (1,87,335 sq.m) has been allotted for
expansion. By 2016, ICAT would be one of the most modern automotive
technical centres in this part of the world and would meet the full range of
testing, R&D and homologation requirements for automotive industry
both OEMs & component manufacturers.

Homologation & Certification

The notification of Ministry of Road Transport and Highways (MoRT&H) vide GSR 276 (E) dated
April 10, 2007 under Central Motor Vehicle Rules (CMVR), authorizes ICAT to function as an
independent Type Approval and Homologation' agency. ICAT has created facilities/ capabilities to
run national and international homologation programs. Our
Certification team assures in-time certification and accurate
measurements for compliance of various regulations, including CMVR
as amended from time to time.

Testing of all vehicles is undertaken in accordance with

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CMV Rules

European Regulations

FMVSS

Development trials are carried out as per user defined requirements for
the following parameters :

ICAT would also provide global trade related testing and certification
services to OEMs within India and outside in active collaboration with
the Vehicle Certification Agency (VCA) of the UK Government, with
which ICAT has signed an MoU. ICAT also work as homologation
partner with TUV- Nord, TUV- Rheinland, IDIADA, CCIC Korea etc.
(Homologation agencies for international services).

Maximum speed

Brake performance

Fuel Consumption

Feature benchmarking

Acceleration and Performance

City / highway fuel consumption

Constant speed fuel consumption

Endurance and durability running

Research & Development

Our Research and Development team consists of highly qualified, competent, innovative and self
motivated engineers backed by 'state of the art' testing and development facilities. In a short span, the
centre has started undertaking advanced industry sponsored R&D projects in the areas of frontier
technologies. Projects are kept strictly confidential and backed by trustworthy relationship with the
industry and institutions.

We believe that our customers will solely be determined by our ability to consistently deliver
unparalleled automotive technical services with accuracy in conformance to global standards.

ICAT Competency Centres

Vehicle Evaluation Laboratory (VEL)
Vehicle Evaluation Lab (VEL) is
involved in conducting road
worthiness trials for all categories
of vehicles ranging from twowheelers to heavy commercial,
construction equipment vehicles
and agricultural tractors. Besides
conducting performance
evaluation tests, we also
undertake bench-marking
projects for vehicle integration,
vehicle calibration and subjective
driveability evaluation.

Performance measurement /
Bench marking
Drive ability trials
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Ride and handling evaluation

Power train evaluation

Tyre and suspension development

Tyre Noise Testing

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Coast by Noise

Wet Grip Test

Dimension measurement using coordinate measuring machine (CMM)

Major Test Facilities :

n GPS based DAS Vbox 3i
n Optical sensor based DAS
n Measuring Steering wheel
n Fuel flow meter
n Speed sensor L350 aqua
n Sound pressure level sensor
n Pedal and hand lever force sensor
n Wire potentiometer,
Pressure transducer
n RV4 sensor - for X Y & Z axis
Dynamic Camber angle
Dynamic Steering angle
Dynamic Wheel position
n ABS Performance test
n Survival Space test
n Faroarm CMM
n LMS sound measuring system
n Tire Traction Trailer
n Wheel Skid
n Peak Incipient Friction

Slip sensor S350

Wheel slip measurement
Body Slip measurement
Velocity
Acceleration x axis and y axis
Distance measurement
Oxfords RT 3002
Position
Velocity
Acceleration x, y, z
Orientation
Angular rates Yaw, Roll and pitch
Angular Acceleration
Slip Angle
Sound Absorption Coefficient measurement of
Pavement
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Facilities

Powertrain Laboratory

Test Equipment

The Powertrain Competency is in the fields of :

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Vehicle/Engine Emission & Certification Testing
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Vehicle/Engine Performance Testing
Apart from the certification, development projects of following nature are also undertaken:
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Performance measurement (Engine and Vehicle) & optimization
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Fuel consumption measurement and optimization (Engine and Vehicle)
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Emission tests and optimization including EGR, catalytic convertor, etc.
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Engine optimization and development including engine mapping, exhaust temperature optimization, exhaust
after treatment technology evaluation and catalytic convertor development, ECU calibration (gasoline),
engine/vehicle performance benchmarking
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Research work to conduct design and development work on a wide range of components for engine,
transmission and vehicle

ENGINE TEST CELL (ETC)

CELL I

CELL II

CELL III

CELL IV

CELL V

Controller Software

CP Engineering

HORIBA-STARS

CP Engineering

iASYS

iASYS

Dynamometer

Eddy Current

Transient

Capacity

250 kW

462kW

550 KW

35KW

250 KW

Make

API COM

HORIBA

API COM

DYNALEC

SAJ

Max RPM (rpm)

9000

5000

7000

10000

8000

Max Torque (Nm)

2000

2680

4000

100

1200

Emission Analyzer

HORIBA MEXA
7400D

Particulate Measurement

HORIBA MDLT

HORIBA MDLT

Airflow measurement

ABB, Sensyflow

AVL AFM

Applicable Standards and Regulations:

NOVA Microtrol 6
ABB, Sensyflow

Weighing Balance

Type Test Capabilities as per IS standards

The Following equipments are available for metrology of engine component as per IS:10000 Part V
Measuring Instrument

BS II / III / IV, GSR 286 (E), 111 (E) & 686 (E) & 84 (E)
Trem II / III, Trem III A, GSR 83 & 84 (E), 165 (E) &
ISO 8178 PTO (IS:12036)
GSR 771 (E)

DIGIMATIC
DEPTH GAUGE

DIAL BORE
GAUGE

DIGIMATIC
HEIGHT GAUGE

SLIP GAUGE
SET

DIGITAL BLADE
MICROMETER

DIGIMATIC
VERNIER CALIPER

DIGITAL
TENSO METER

WEIGHING
BALANCE

COMBUSTION ANALYSIS SYSTEM

System capable of measuring in-cylinder intake air, exhaust & fuel line pressure at
various operating conditions at 0.5 deg Crank Angle resolution up to 10,000 rpm

Portable Genset

GSR 535 (E)

Data Acquisition System for crank synchronized data with configuration:

Power Tiller

GSR 589 (E) & ISO 8178

Endurance Test
Type Testing

BOSCH

Sartorious, MP5

GSR 642 (E) & 276 (E) BSII / BSIII

FTP of 2w (Petrol), 3w
(Diesel, CNG, LPG) and
4w (Petrol, Diesel, CNG, LPG)

BOSCH

AVL 439

Indian Regulations

Genset
Construction Equipment
Engines (Off-road Vehicles)

HORIBA MEXA 7100D

Smoke Measurement

All categories of engines can be tested as per various National and International Standards
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MoRTH/CMVR/TAP-115-116
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Automotive BS-II, BSIII & BS-IV (ETC, ESC, ELR, FAS, etc)
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ISO 8178 (Trem II, III & Trem III A) for Genset, CEV, Tractors & Power-Tillers
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Tractor smoke test as per EPA 40 CFR - Part 89
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FTP test as per IS: 14599
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Portable Genset Diesel, Petrol & Kerosene run
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Durability test as per customer desired test cycles.
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Endurance Testing
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Facilitate certification for other countries through accredited and authorized agencies
such as VCA, TUV etc.

Automotive
Tractor

Eddy Current

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40 Analog input channels.

Provision for CAN Bus input
Sampling Frequency Per Channel - 800 kHz
Post Processing software for data analysis.

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GSR (84) E, IS : 14599

As per applicable standard or customer cycles

VEHICLE TEST CELL (VTC)

IS 10000 / 13018 etc.

Vehicles upto 3500 kg can be tested for various emission parameters: Hydrocarbon, Carbon Monoxide, Carbon Dioxide, Nitrogen
Oxides, and Particulates, as referring Emission norms in India. Vehicles are tested for Type Approval and conformity of production
as applicable to Petrol/Diesel/LPG/CNG vehicles. We also undertake development work for vehicles operating on NonConventional fuels such as ethanol blended fuels, HCNG and others.

Testing as per International regulations such as Euro & EPA

Provision for LVDS and TTL inputs

24 Digital input and output channels
Crank angle and time based measurement
Gas Exchange Analysis

In addition, for development work, vehicle emmission can be tested for non methane hydrocarbons, aldehydes, ketones etc as
desired. Power Test and Maximum Speed test, Range test and Electrical Energy Consumption test, as per the regulation for battery
operated vehicles are also performed on Chassis Dynamometers. The facility for 2/3/4 wheeler Mileage Accumulation and Fuel
Consumption Measurements Tests Dynamometers is also available (with robots) and Drivers Aid Facility for undertaking
durability and fuel consumption measurement tests under controlled conditions.

Applicable Standards and Regulations for Emission Testing

International Regulations

Sealed Housing for Evaporative Determinations (SHED) Facility:

US Regulations

EPA Part 86

European

70/220/EC for 4 W
97/24/EC for 2 W
Global Technical Regulation No. 2 (WMTC)

Sealed Housing for Evaporative Determination (SHED) is used to measure evaporative emission from the
gasoline 4-wheeler vehicles as per the Indian, ECE (EURO III & IV), EPA and CARB Regulations. SHED can
also be used to measure evaporative emission from the gasoline 2/3 -wheeler vehicles as per CARB
Regulations.

BS II (Gasoline and Diesel)

GSR 77 (E) for 4 W

GSR 720 (E) for 2/3 W

The specifications of SHED are:

BS III (Gasoline and Diesel)

GSR 686 (E) for 4 W, 84 (E) for 2W & 3W

VT / VV SHED -Variable Temperature, Variable Volume SHED system:

BS IV (Gasoline and Diesel)

GSR 84 (E) for 4W & 431 (E) for 2W

LPG/CNG

GSR 589 (E) & GSR 284 (E) for 2/3/4 W and GSR 84(E)

BS III (WMTC)

GRS 515(E)

Battery operated vehicles

GSR 589 (E), AIS 038, AIS 039, 040, 041 as per
S.O. 1365 (E)

Type: Webber EMI Model 101 VV / VT SHED

Inside Dimensions: 94.0 (2.4m) H x 119.5 (3.0m) W x 255.5 (6.5m) L
Temperature Control:
Temperature Control Range: 45 F to 120 F

Temperature Resolution: 0.1 F and Accuracy: +/- 0.3 F

Temperature Control:

Facilities
VEHICLE TEST CELL (VTC-1)

VEHICLE TEST CELL (VTC-2)

Volume Compensation System: Movable Roof (MR)

Minimum SHED test volume: 1661 cu-ft (47.0 cu-m)

Resolution: 0.05 cu-ft (0.001 cu-m) and

Accuracy: 0.10 cu-ft (0.002 cu-m)

Maximum SHED test volume: 1927 cu-ft (54.5 cu-m)

Fuel Conditioning Cart

Type: Webber EMI Model 107 Fuel Conditioning Cart
Physical Dimensions: 75 high x 53 wide x 35 deep (approx.)

Fuel Flow Rate: 3 12 gpm

Temperature Range: 50 90 F (varies depending on application)

Temperature Control: 0.1 F

Heating Capacity: 2 4 kW (depending on application)

Cooling Capacity: 12-18 kBtu/hr (depending on application)

Canister Conditioning Bench

Type: Webber EMI Model 110 Canister Conditioning Bench
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1) Chassis dynamometer for emission testing of 4

wheeled vehicles.
Test Cell Configuration:
Automation system : GEM 201 application
software
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Chassis dynamometer 1219.2 mm(Dual roller)
Make AVL Zollener
Power : 150 kW
Max Speed : 200 km/h
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AMA 4000 Emission Analyser Bench (make
AVL)
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CVS- 4000 (make AVL)
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Full Flow Particulate (FFP) 4000 (make AVL)
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AVL 437 Smoke meter
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AVL 444 Di gas Analyser (4 gas measurement)
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AVL Fuel Mass flow meter for Liquidfuel
consumption measurement
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Data acquisition system for temperature,
pressure and other parameters
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Weather station (DBT, WBT, RH, Baro) (make
Vaisala)

2) Chassis dynamometer for emission testing of

2/3/4 wheeled vehicles.
Test Cell Configuration:
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Automation system : GEM 201 application
software
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Chassis Dynamometer 955mm (single roller)
Make AVL Zollener
Power : 70 kW
Max Speed: 200 km/h
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AMA 4000 Emission Analyser Bench
(make AVL)
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CVS- 4000 (make AVL)
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Full Flow Particulate (FFP) 4000 (make
AVL)
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AVL 437 Smoke meter
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AVL 444 Di gas Analyser (4 gas
measurement)
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Data Acquisition system for temperature,
pressure and other parameters
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Weather Station (DBT, WBT, RH, Baro) (make
Vaisala)

To precondition the canister by purging and loading up to breakthrough at a specified flow rate, as per
the ECE, EPA and CARB test procedure and to determine the nominal working capacity of the canister.
Canister Conditioning Bench is Equipped for loading two canisters simultaneously and up to four
canisters sequentially.
Flow Rates: Purge to 50 slpm, Butane to 1400 grams/hour and
Nitrogen to 50 slpm

Enclosure dimensions: 72H x 24W x 36D.

Mass Flow Controller Accuracy: +/- 1% of full scale.

Repeatability: +/- 0.15% of full scale.

MECHANICAL AND ENVIRONMENTAL LAB

Mileage Accumulation Chassis Dynamometer Facilities

MACD-I

MACD-II

MACD-III

Main Equipments:
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4x4 dynamo meter for 4 wheeler

n AVL 200 Kw Permanent Power
Consumption of Front & Rear
Roller
n 48 + 0.01 Roller Diameter
(Front & Rear)
n Vehicle Inertia Range - 454 kg 5448 kg
n Vehicle Wheel Base Range -2000-4000 mm
n Max. Speed of each Roller -- 250
kmph
n Robot Driver -- Stahle SAP 2000 -compatible & easy to be installed &
follow cycles on various vehicle
orientations & customized vehicle
gear shift patterns

2 / 3 / 4 Wheeler Chassis
Dynamometer

2/3 Wheeler Chassis Dynamometer

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Burke E Porter 160 Kw

Permanent Power Consumption of
Front Roller
Vehicle Inertia Range
-- 100 kg - 4000 kg

Roller. Diameter 48 inches

Max. Speed of each Roller
-- 200 kmph
Robot Driver -- CP Engineering

AVL 55 Kw Permanent Power

Consumption of Front Roller
Vehicle Inertia Range -- 80 kg 1000 kg
Vehicle Wheel Base Range -- 648
mm

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Max. Speed of each Roller -- 200

kmph

Robot Driver -- Stahle SAP 2000 -compatible & easy to be installed&

follow cycles on various vehicle
orientations & customized vehicle
gear shift patterns

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Combined Vibration & Environmental test system [Shaker Capacity 1000 kgf
& 3200 kgf Temp. Range -60C to 200C ]
Expansion, Burst & Whip test rigs for hydraulic brake hoses [Max. Hose Length :
600 mm]
Ozone Chamber [Range : 0 to 500 pphm]
Dust and water Spray chambers [Size : 1m x 1m x 1m]
Cyclic Temperature & Humidity chamber [Range : -40C to 180C]
Cyclic Salt Spray chamber (M/s. Atlas, USA)
Servo Hydraulic system : (M/s. MTS, USA) [ 50 kN actuator & Controllers,
15 kN actuator for shock absorber testing, speed upto 2.5 m/sec.]
Weather-O- Meter (M/s. Atlas, USA. Model: Ci4000, Lamp: Xenon Arc)
Bumper test facility for M1 category vehicle
Wheel Rim test facilities
Thermal Cycle Chamber (Make : Weiss, Germany, Size : 2.5m x 2.5m x 2.0m)
Tyre test facilities (up to 15 ton capacity)
Flywheel burst tester (upto 9000 RPM)

Technical Capabilities:
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Certification of rear view mirrors, automotive horns, hydraulic brake hoses, door
hinges and latches, metallic, plastic fuel tank, safety glasses, horn installation, rear
view mirror installation & pillion hand hold testing for 2 / 3 wheelers as per CMVR.
Developmental testing as per various National & International standards/regulations
viz. ECE, JIS, SAE etc.
Endurance testing of automotive components with linear servo hydraulic system.
Environmental testing under controlled temperature, humidity, weather conditions
etc.
CNG/LPG testing as per ISO:15500, ECER-67
Certification of Pneumatic Tyres as per IS:15633, IS:15636 & IS:15627
Certification of Wheel rim as per IS:9436 & IS:9438

The details of some the safety components together with the AIS/ECE regulations those
can be certified/ tested are as follows:
Sr. No.

Component & Materials Evaluation Lab (CMEL)

With ever-increasing public concern over the safety of automotive occupant as well as pedestrians, the safety critical
components are evaluated as per the existing and upcoming national and international regulations/standards viz. IS,
AIS, ECE, JIS, SAE etc. ICAT specializes in testing of automotive components and is committed to support the
automotive industry in carrying out Research and Development as well. Following are the major thrust areas where we
can work with the automotive industry in developing cutting edge technologies to compete globally:

Description of component / Test

IS/AIS

ECE/EEC

1.

Hydraulic Brake Hoses

IS:7079 - 2008

2.

Rear View Mirror - Performance requirements

AIS: 001

R46

3.

Rear View Mirror Installation

AIS: 002

4.

Safety Glasses - (automotive & general purpose)*

IS :2553- Part 1 &2

R43

5.

Door Locks & Hinges

IS : 14225

R11

6.

Metallic Fuel Tanks for automotive vehicles

IS : 12056

7.

Plastic Fuel Tanks for automotive vehicles (4W)

IS : 15547

R34

8.

Metallic & Plastic Fuel Tanks for 2 & 3 Wheelers

IS : 14681

97/24/EEC

9.

Wheel Fasteners & Hub Caps Requirements

IS : 13941

Mechanical, environmental & electrical testing related to active & passive safety related and other automotive
components.

10.

Testing of Pillion Hand Holds for 2 Wheelers

IS : 14495

93/32/EEC

11.

Testing of Anti-theft Devices for 2 Wheelers

AIS : 074

Photometry testing and product development related to all lighting & signalling devices intended for use in
automotive applications.

12.

Alloy Wheel Rim Testing for Two Wheelers

AIS: 073 (P1)

13.

Sheet Metal Wheel Rim for 2 / 3 Wheelers

ICAT is geared up to assist its clients on development projects which involve drawing technical specifications and
evaluation of various safety critical components e.g. plastic fuel tanks, bumpers, steering wheels/columns, lighting &
signalling devices etc. with the supporting facilities including combined vibration & environmental test set up (sine
sweep, discrete, random etc.) as per customer specified standards. Fatigue/Endurance testing of automotive
components with linear servo hydraulic system, environmental testing under controlled temperature, humidity,
weather condition are also carried out.

14.

Wheel Rim Testing for 4 Wheelers

15.

Spoke Wheel Rim Testing for 2 Wheelers

16.

Tyre Testing*

17.

Fuel Tanks for Agricultural Tractors

18.

Fatigue/Endurance Testing on Linear Servo Hydraulic System

(Capacity :- 50 kN, 125 mm stroke actuator) 15 kN,
125 mm stroke actuator with high speed upto 2.5 m/sec.)

ICAT is capable of designing and fabricating its own rigs depending on the requirement and simulations involved.

AIS: 073 (P2)

IS : 9436 & IS : 9438

AIS: 073 (P3)

IS: 15636, 15633 & 15627

R54, R30, R75

AIS : 104 (F)

As per customer's
supplied specifications
* NABL Accredited & BIS approved Test facilities

Sr. No.
19.

Description of component / Test

IS/AIS

Combined Vibration & Environmental Testing system

(Shaker capacity 1000 kgf & 3200 kgf Electrodynamic vibration
shaker & Temp. Range : -60C to 200C)

20.

CNG/LPG Component Testing

21.

Seat for buses

ECE

As per customer's supplied specifications

OR
Relevant OEMs standards /procedures
As notified in CMVR

ISO:15500, ECER-67

AIS 023

PHOTOMETRY LAB :
Technical Capabilities:
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Brief Technical Specification of the Equipments for Development Tests :-

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Sr. No.
1.

Brief Technical Specifications

Combined Vibration &

Environmental test system

A. Electrodynamic Vibration Shaker :Force Rating : 1000 kgf

Force Rating : 3200 kgf
Force Rating : 3000 kgf
B. Environmental Chambers:Size : 1m x 1m x 1m (Temp.: -60OC to +200OC)
Size : 2.5m x 2.5m x 2m (Temp.: -30OC to +60OC)
Size : 1.5m x 1.5m x 1.5m

Expansion & Burst test rigs for

Hydraulic Brake Hoses, CNG &
Wire Braided Hoses

Standards :IS : 7079 - 2008, SAE J 1401,FMVSS 104

Length of hose : upto 1000 mm
Max. Burst Pressure : upto 2000 bar

3.

Whip Test rig for Hydraulic

Brake Hoses

Standards : IS - 7079, SAE J 1401, FMVSS 104

Range of Hose Length : 200 to 600 mm
Max. 04 hoses can be tested at a time.

4.

Ozone Chamber

Standards : IS : 7079 -2008, SAE J 1401, FMVSS 104,

Ozone concentration Range : 0 to 500 ppm
Temp. Range : Ambient to 70C
Flexing of hoses can be done inside the chamber.

5.

Resonance Fatigue Tester

Force capacity = + 400 kN, Frequency = 30 to 120 Hz

For Fatigue Testing of connecting rod, crank shaft, etc.
Make: SincoTeq, Germany

6.

Dust Chamber

Standards : IS : 1884 1993, SS : 15.1,

IS : 8339 1993, IP : 55,65 etc
Temp. Range : Ambient to 60C

7.

Water Spray Chamber

Standards : IS : 1884 1993, SS : 15.1,

Temp. Range : Ambient to 60C
No. of Showers : 08 @45
Speed of Table : 2 to 12 rpm

8.

Sound Level Meter

Range : 40.5 to 120.8 dB (A)

9.

Cyclic Temperature & Humidity

Chamber

Temp. Range
Humidity Range

10.

Salt Spray Chamber

Standards : ASTM 117, G85A5, D1735, SAE J 2334,

CCT - I,IV, MCT - 2M, Custom Program : upto 11
Temp. Range : upto 45C
Make : MTS, USA

2.

11.

Dust
Chamber

10

Test Equipment

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The details of Photometric components together with the AIS/ECE regulations that can be
certified/tested are as follows:

: -40C to 180C
: 20% to 98%

Sr. No.

Actuators :i. 50 kN with Load cell

ii. 15 kN with Load cell
HPU :- Flow : 200 lpm, Pressure : 210 bar
For the fatigue/endurance testing of Leaf Springs, coil springs,
Tractor Links, Shock Absorbers etc.

Servo Hydraulic System

Ozone
Chamber

Cyclic Salt
Spray
Chamber

Environmental
Testing
Facilities

Weather-OMeter
(Ci4000)

Water Spray
Chamber

Measurement of spatial intensity distribution of the lamps, which include lighting and light
signaling devices (like headlamps, fog lamps, stop lamps, direction indicators, reversing lamps etc.)
Retro-reflection measurement of reflex reflectors, tapes, markings etc.
Measurement of luminous flux and luminous efficiency of bulbs (incandescent, metal halide, HID, LED etc.)
Lighting installation- and headlamp leveling device test.
Luminance measurements of rear registration plate lamps, surfaces (roads, screens, etc.)
High Security Registration Plate (HSRP) testing
Measurement of lifetime of the bulbs and lamps
Dimensional measurement of bulbs
Measurements of glare characteristics of lamps
Measurement of reflectivity and transmittance of different materials
Tests on lamp under controlled conditions (voltage, temperature,
humidity)
Colorimetric measurements on lamps, lamp covers and various industrial
products (plastics, textiles, etc.)
LED measurement
UV & IR measurement

Cyclic
Hot & Cold
Chamber

Description of Component/Test

IS/AIS

1.

Head lamps and Front Fog Lamp

AIS : 010, 012, 062

1, 19, 20, 56, 57,

98, 112,113, 45, 123

2.

Tail, stop, direction indicators, reverse,

high mounted stop lamps, fog lamps,
side repeater lamps, Side marker lamps
Rear Fog Lamps

AIS : 010, 012, 062

6, 7, 23, 38,
39, 87, 91

3.

Rear registration plate lamp

AIS-010/AIS-012

4.

High security registration number plate

5.

Reflex reflector

IS8339 / AIS : 057

6.

Retro Reflective Tapes, Retro reflective

markings and rear marking plates

088, 089, 090

69, 70, 104

7.

Advanced Warning Triangle

AIS 022

27

8.

Automotive Bulbs

IS 1606/ AIS : 034

37, 99

9.

Installation requirements for lighting

& signaling devices

AIS : 008, 009 & 030

48, 53, 74, 86

ECE

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11

Sr. No.

Description of Component/Test

IS/AIS

10.

Head Lamp Leveling device (HLLD) Test

AIS : 008

11.

Automotive Horns

IS:1884

R28

12.

Horn Installations

AIS : 014 / IS:15796

ECE

AUTOMOTIVE ELECTRICAL & ELECTRONICS LAB:

CAPABILITIES : Automotive
Electrical & Electronics Lab (AEEL)
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Brief Technical Specifications of the Equipments:

Sr. No.

Test Equipment

Brief Technical Specifications

Photo-Goniometer & retro-reflection

measurement unit
(M/s LMT, Germany)

5 degrees of freedom two rotations and 3 translations along

with photo-sensors measuring lux and candela values for various
lighting and signalling devices as per AIS:010, 012, 057,
ECER-01, 06, 07, 20 etc.

2.

Luminance meter (M/s LMT, Germany)

Luminance measurement in candela per meter

square as per AIS:010, 012 and ECE-04

3.

UV, Color Luminance factor measurement

system [spectral range 200-1100nm]

UV output- and the color measurement as per AIS:010, 012,

034, ECER:037, 099, 027, AIS:022, 088

4.

Integrating sphere (1m dia.)

Spectral luminous flux measurement as per

AIS: 034, ECER:037, 099

5.

Bulb dimensional measurement

(10 X mag.)

Dimensional measurement of the automobile bulbs

as per AIS: 034, ECER:037, 099

Bulb endurance test rig

Life test measurement of the automobile bulbs

as per AIS: 034, ECER:037, 099

6.
7.

Color endurance test of Signaling bulb

As per AIS: 034, ECER:037, etc.

8.

Sound Level meter

Range : 40.5 to 120.8 db (A)

9.

Bulb Testing : Climatic Chamber

Range : -40 C to +180 C Humidity : 0 to 100%

10.

Photometry Testing
A. Standard Intensity Bulb : W141G

n
n

One stop solution for EMI-EMC, Electrical,

Environmental, Mechanical testing of
Electronic Sub-assemblies (ESAs).
Testing as per OEM specific standards such
as TATA, Nissan, Toyota, General Motors
standards etc.

n
n
n
n
n
n

Development of customized test rigs for

customer specific projects
Execution of joint projects for product
development
Certification of White goods & IT Systems
E-Homologation coordination & CE
marking

n
n
n
n

Turn Key project on testing of ECUs

Electrical Tests on Lock Assembly Steering
Tests on Electronic Rust Proofing module (ERPM)
Abrasion Resistance Test on Coaxial Cable
OC & SC Test on Shock Controller
ESD Test on Steering Lock & keyless key
IP 66 Test on LED Destination Board for buses
ESD Test on AC/DC CDI
Tests on Horn (HT/LT), Speedometers
EMI-EMC Tests on Engine ECU
Turn Key project on Scuff Plate, Foot Light
Testing relays, Switches, Harness & Fuses
Photometry Testing of Headlamps/Lights
Transient tests on Accelerator Pedal Sensor
Testing of spark plugs, siren, antenna, Street Lamps
Testing of ITS products such as Vehicle
Tracking System (VTS)
Testing of Bus ITS/LED destination boards as per
UBS-II Guidelines
Validation testing as per OE specifications (e.g.
NISSAN, TOYOTA, GM, TATA, HONDA standards etc.)

Standards Covered:
n
n
n

B. Luminance Standard : LN 3

n
n

n
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1.

Complete execution of Design Verification

Plan & Report (DVP&R) for all Electronic
Sub-assemblies (ESAs).

Some Projects Completed

n
n
n
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Luminous Intensity approx.: 271.7 cd

Power Supply : 30.276V, 5.830A
Co-related color temp. 2856 K (Standard Illuminant A)
With Luminous Flux controlled tungsten halogen lamp
Correlated color temperature: 2856 K (Standard Illuminant A)
luminous Intensity: 3846.50 mt
luminance: 1197 cd/m2
Power supply : 230 V, 50-60 Hz

AIS004-3

JASO D 001-94

28401NDS02 (Nissan Standard),

ECE R 10

JnNURM II (MoUD-II)

JIS D 0203/5701/0204/1601

TST257/233

AIS 018 / GSO 1626

ISO 8854:2012 ; IS 3141

DIN 40050-9

AIS 038 / 048

Other standards

Test Facilities:
11.

LED Measurement set-up:A. Spectro-radiometer

n
n
n
n

Special range: 350-1050 nm

Spectral Resolution: 1.5 nm
Interface : USB 2.0
Power supply : 230V, 50Hz

n
n

B. Integrating sphere for single LEDs

n
n
n
n
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C. Integrating sphere for LED clusters

& luminaries

n
n
n
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n

12

Diameter: 0.5 m
Reflectivity: >97%
Spectral Range: 300-2400 nm
Capable of 2 m & 4 m configurations
LED measurement as per CIE 127:1997
Compatible for all range of LEDs
Diameter: 2 m
Reflectivity: >97%
Spectral Range: 300-2400 nm
Capable of 2 m & 4 m configurations
LED measurement as CIE 127:1997

EMI-EMC Test Setup

High Temperature Glass Fogging Test
(NISSAN STANDARD)
Irradiation Test under controlled condition
(NISSAN STANDARD)
High Pressure Car Wash Test (Up to 90 Bars)
(Honda Standard)
Water Spray & Water Sprinkle Test
(JIS D 0203)

Vehicle Alarm System (AIS:076)

Thermal Shock (-40 to +150 deg. In < 10 s)

IPXX test facility up to IP 69

Starter Motor Test Rig

BOV: Requirements for construction and

functional safety (AIS038)

Alternator Test Rig

Combined Vibration & Environment Chamber

Impact Test (JIS D 5500)

Thermal Cycle Chamber

Weather Resistance

AC Spark Tester (10kV AC)

Battery Testing (AIS:048)

Hot impulse Test Rig

Vacuum Collapse Test Rig

13

Sr. No.

Test Equipment

Brief Technical Specifications

1.

Alternator Test Rig

n
n
n

2.

Electrostatic
Discharge
Tester

n
n
n

3.

Battery Tester

n
n
n

4.

Programmable
and DC Power
Supplies

n
n
n
n

5.

Function
Generator

n
n
n
n
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6.

Ultra
Compact
Simulator
for
Automotive
Transients

n
n
n

7.

Starter
Motor
Test
Rig

n
n
n
n
n

Voltage range : 12, 24 & 42 Volt

Output Current : 0-200 Amp
Speed : 0-8000 rpm
Complies with IEC 61000-4-2, IEC test level operation 1,2,3,4
and JASOD 001:94
Maximum test voltage : + 30 KV
Capable of contact & air discharge testing
Easily configurable for any test conditions using
various in-built modes like step & sequence
operation for multi point discharges
Voltage measurement : 0 60 V
Internal Resistance measurement : 3 m - 3
Temperature measurement : 0 60oC

Output Voltage range: 0 120 V

Output current range: 0 834 A
Capable of sequence programming & constant power operation
Voltage, current & overvoltage protection programming
No. of channel: 2
Capable of generating sine, pulse, ramp, arbitrary etc waveforms
Sampling rate: 1 GS/s
Amplitude 20 mV p-p to 10 V p-p
Operating mode: Continuous, Sweep Modulation & burst
Input Maximum Voltage DUT: 60 V
Input Current DUT: 150 A
Ability to configure different pulse characteristics.
Sequence of test can be programmed
Test Impulses According to ISO 7637-2 & 7637-3
(Pulse 1, 2, 3a & 3b) (also with CCC method, 4 and 5]
For tests beyond standard's requirements the waveform
parameters of the Micro pulse generator can be varied in
a wide range by means of the Freestyle mode.
Voltage range: 12 & 24 V
Power range: 0.5 kW Upto 4.0 kW
Torque Measurement: Max upto 10 Nm
Speed Measurement: 8000 rpm
Temperature measurement range of chamber: - 40 Deg C to
+ 80 deg C. Capable of performing following tests:
l
l

8.

IPXX Facility

n
n

9.

Thermal Shock Chamber

n
n
n
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14

No load test
Run torque test

l
l

l
Load test
Lock torque test
Light run test

It classifies the degrees of protection provided against the

intrusion of solid objects (including body parts like hands and
fingers), dust, accidental contact, and water in electrical
enclosures for road vehicles.
Protection against the ingress of water: 0-9K
Protection against the ingress of solid foreign objects
(including dust) / access to hazardous parts: 0-6K

Calibration Laboratory (CAL)

The Calibration Laboratory maintains calibration of all
the equipment at ICAT and provides calibration services.
The laboratory has reference standards from known
companies, like Fluke-USA, Hart Scientific-USA, and
ISOTECH-UK etc. traceable to International / National
Standards.
Reference Standard are calibrated, maintained &
operated as per the guidelines mentioned in ISO / IEC
17025.

Calibration Capabilities
Sr. No.

Parameters

Description of Equipment/Instrument

1.

Temperature

Dry Block & Oil Bath Calibrator- Various types of

Temperature Sensors, such as SPRT, PRT, RTD etc.
Range: -40C to 140C, 150oC to 1000oC, 30oC to 250oC
o
Uncertainty: 0.16C, 1.5C, 0.26 C
Make:- Isotech & Fluke

2.

Pressure

Pneumatic and Hydraulic Dead Weight Tester

Range: - 5 bar to 50 bar, >50 bar to 700 bar
Uncertainty: 0.19% FS & 0.06% FS
Make: GE & Wika

3.

Weighing Balance
& Weights

Analogue and Digital Balances

Range: 0 to 150 kg
Uncertainty: 0.006 gm
Make: Sartorius

4.

Sound Pressure Level

Sound Level Meters

Range: 31.5 Hz to 16 KHz (94, 100, 114) dB(A)
Uncertainty: 0.2 to 0.5dB (A)
Make: Bruel & Kjaer (B&K)

5.

Acceleration

Portable Accelerometer
Range: 10 Hz to 10 KHz
Uncertainty: 3% up to 2 KHz and 4% above
Make: PCB Piezoelectronics

6.

RPM

Tachometer (Contact & Non Contact)

Range: Up to 20,000 rpm
Uncertainty: 2.5rpm
Make: Monark

7.

Micrometer Calibration

Micrometer Check Set

Range: 0 to 100 mm.
Uncertainty: 0.10m - 0.18m
Make: KC Precision

8.

Vernier Caliper Calibration

Caliper Checker
Range: 0 to 600 mm.
Make: KC Precision

9.

Calibration of Plunger & Lever

Dial indicators, and
Bore Gauges.

Electronic Dial Calibration Tester

Range: 25 mm
Least Count: 0.01 mm 0.001 mm
Make: Kudale Instrument

Temperature Range:-60C to 180C (Ambient temp. to 180C

within 30 min. and ambient temp. to -60C within 90 min.)
Transfer time range:10 sec (Cold to hot chamber and vice versa)
Workspace Dimensions; 500mmX500mmX500mm
Movement Type: Vertical
Display: 12 LED/LCD/TFT color touch screen with
programmable time indicator, temperature, cycle counter

15

Sr. No.
10.

Parameters

Description of Equipment/Instrument

DC Voltage

6 Digital Multimeter
Range: 1mV to 1000V.
Uncertainty: 0.01%
Make: Agilient Technologies

11.

AC Voltage

6 Digital Multimeter
Range: 750V 51 Hz, 1V to 100 V 1 KHz
Uncertainty: 0.18% - 0.15%
Make: Agilient Technologies

12.

DC Current

6 Digital Multimeter
Range: (I) 1W to 100KW (ii) 1 MW to 100 MW
Uncertainty: 0.03% - 0.05%
Make: Agilient Technologies

13.

AC Current

6 Digital Multimeter
Range: 10mA to 11 A.
Uncertainty: 0.07% - 0.05%
Make: Agilient Technologies

14.

Resistance

6 Digital Multimeter
Range: 1.0 - 10 M
Uncertainty: 0.01% - 0.004%
Make: Agilient Technologies

15.

16.

Conductance

Frequency

Material Testing Laboratory

Sr. No.
1.

17.

Duty Cycle

Universal Counter/Timer/Analyzer
Range: 99%
Uncertainty: 0.3%
Make: Pendulum

18.

Time

Universal Counter/Timer/Analyzer
Range: 0 30min & above
Uncertainty: 0.03 sec - 0.6 sec
Make: Pendulum

Equipment

Standard

Mechanical testing of Rubbers & Plastics

Tensile Strength
l % Elongation
l Modulus of elasticity
l Compression Strength
l Load vs. deflection
l Tear Strength
l Flexural Strength & Modulus
l 3 Point & 4 point Bend Testing
l Shear Bond Strength & Adhesion testing
l Shear Testing of Brake Liners.
l Peel Strength
l Load & Stiffness Testing of Gasket materials.
l Compression Set of Rubbers

INSTRON 5500R Series

Universal Testing Machine.
l + 100 kN capacity
l Long Travel Extensometer
Having full scale travel
of 250 mm
l Metal Extensometer having
.01 mm resolution.
l Compression Set Fixture as
per ASTM D 395

ASTM D 412
ASTM D 638
ASTM D 1708 etc
& All other relevant
standards such as
IS/JIS/Customer
Supplied Standard.

Circulating Coolant
Corrosion Test Rig.
Aluminium Heat Transfer
Test rig.
Metal Corrosion in
Glassware Test Rig
Karl Fischer App.
pH-meter
Boiling Point App.
Freezing Point App.
Oil Centrifuge

JIS K 2234, IS 5759

Laboratory oven
Balance
Chemicals as required

As required

Test Rigs as per the

required standards.

IS 15061
FMVSS 302,
Relevant ISO
Standards.

High Voltage Tester

Digital Multimeter
Test Rig for testing Flammability
of wires as required in standard.

JIS C 3406, JIS C 3005,

IS 2465,IS 10810.

DC Power Supply

AIS 028 Cl. No. 4.3.3.

Ross Flex Tester

Demattia Flex Tester

ASTM D 1052- 85
IS 3400 part 16- 74
IS 6664- 92
IS 10702- 85
ASTM D830
IS 3400- Part 8

2.

Coolant Test Facility

Circulation Coolant Corrosion
l Aluminium Heat Transfer Corrosion
l Metal Corrosion in glassware
l pH for all liquids
l Reserve Alkalinity
l Equilibrium Reflux Boiling Point.
l Freezing Point,
l Foaming Property
l Density, Specific gravity
l Amount of precipitate.

3.

Chemical Testing of Polymers

Fluid Ageing
l Brake Fluid & Gasoline Ageing
l Heat & Volume Swell
l Oil resistance such as ASTM & other
reference fluids.
l Dry Heat resistance
l Heat Sag Test
l

4.

Flammability Testing of Upholstery, Carpet materials

as well as inner components of the automobile.
l Horizontal Flammability Test
l Vertical Flammability Test
l Melt Behavier test

5.

Wiring Harness for kits used in the

automotive 2/3/4 wheelers.
l Electrical Wiring Harness
l Flammability testing of wires.

6.

7.

Current limiting devices (Fuse) used in the

automotive 2/3/4 wheelers.
l Performance testing as per AIS 028 Cl. No. 4.3.3
Flex Testing of Rubbers
Rate of crack growth after specified
number of cycles

16

6 Digital Multimeter
Range: Up to 40 S (mho)
Uncertainty: 0.23%
Make: Agilient Technologies
Function Generator
Range: 0.5 Hz - 225 MHz
Uncertainty: 0.005% - 0.003%
Make: Bruel & Kjaer (B&K)

Test Facility

l
l
l
l
l

l
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l

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l

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l

17

Sr. No.
8.

Test Facility

Equipment

Abrasion Resistance of Materials

Abrasion resistance of textile fabrics, ceramic
tiles, coated substrates, painted panels
as well as plastic & metallic specimens.
l DIN Abrasion of rubber specimens

9.

Rebound Resilience of rubbers

Pendulum Rebound Resilience
l Vertical Rebound Resilience

10.

Hardness of Rubbers & Plastics

l IRHD-normal, IRHD-micro, Shore
A for rubbers
l Shore D hardness for plastics.

11.

Polymer Testing
Identification of base polymers & blends in
plastics Identification of filler content in rubbers
& polymers
l Anti degradants, anti ozonants &
stabilizers in raw rubbers

12.

Specimen making Facility

l Cutting specimens as per ASTM Standards
in desired shapes and sizes
l Moulding of slabs for tensile
l Moulding of compression disc specimens

13.

Aldehyde & Ketone Analysis

14.

Oil Testing Facilities

l Determining Flash Point of Petroleum
Products by Pensky Martens Ordinary Type.
l Determine Cloud Point and Pour Point of
Petroleum.
l Determine Aniline Point.

l
l

l
l

l
l
l

16.

ASTM Color Comparator (Artifical Light)

Determining Sulphur Content by Lamp method.
Determining Sulphur Content by Bomb method.
Determining Corrosiveness to copper
Viscosity index by calculation

Material Analysis

Pendulum Rebound
Resilience Tester
Vertical Rebound
Resilience Tester

ASTM D 1054
IS 3400 part11- 85
ASTM D 2632-96
DIN 53512

Rubber Hardness Tester

ASTM 1415
ISO 48, DIN 53519
ASTM D 2240, D 1415
IS 3400 Part 2
ISO 868, DIN 53505

Specimen Cutting Press

Rubber Moulding Machine

ASTM D 412, D 624,

D 1708
IS 3400

HPLC

CARB SOP MLD 104

Flash Point Tester

IS 1448 - Part 21

Cloud Point and Pour

Point Tester
Aniline Point Tester

IS 1448 - Part 10

l
l
l
l
l
l
l
l

Color Comparator Tester

Lamp-Sulphur Content
Tester
Bomb-Sulphur Content
Tester

Microscope with Image Analyzer

Stereoscope
Rockwell Hardness Tester
Micro Vickers Hardness Tester
Abrasive Cut-off Machine
Belt Grinder
Grinder/Polisher Machine
Sample Mounting Machine
Coating Thickness Tester
Brinell Hardness Teaster

IS 1448 - Part 3,
Method-A/B/C/D
IS 1448 - Part 12
IS 1448 - Part 34
IS 1448 - Part 33
IS 1448 - Part 15
IS 1448 - Part 50

MASTER PLAN LAYOUT ICAT - I

TESTING LABS
B1

PT ETC LAB

B2

PT VTC-LAB

B4

FATIGUE LAB

B6

CLIENT WORKSHOP

B7

FUEL YARD

B8

CANTEEN

B9

GENERAL STORAGE

As per
customer
request

Rapid Prototyping Facilities

l

Selective Laser Melting (SLM) - Metal Prototyping

n

Metal Parts

Aluminium, Steel

Selective Laser Sintering (SLS) - Plastic Prototyping

n

18

ASTM C 501,
D 1044,D 3451,
D 3884,D 4060, D 603
ECE R 43, SAE J 369,
J 1530., DIN 53516
ASTM D 5963
IS 3400-Part 3

ASTM D 3677
AIS 066
ASTM D 3156

15.

Taber Abrasion Tester

DIN Abrasion Tester

FTIR Spectroscope
Thin Layer Chromatograph

Standard

Polyamide Parts

Rubber Parts

Transparent Parts

19

Pedestrian Safety Lab (ICAT-II)

n

An investment of ` 570 crore (129 million USD) under NATRiP for setting up added
facilities by way of tracks and testing infrastructure is currently underways at existing
as well as at additional 46.29 acres (187335 sq.m) of land.

The lab is capable of performing the tests on the vehicle upto following specifications:
l
l
l

UPGRADATION UNDER NATRIP

ICAT has set up a Pedestrian Safety Lab at Manesar-2 campus. The purpose of lab is to perform
Pedestrian and Interior tests on Passenger Cars, SUVs and Light Commercial Vehicles.

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Width: 2.8 m.
Height up to windscreen: 2.5 m.
Height up to front bonnet: 1.25 m.
Weight: Up to 3500 kg.

ICAT will be the centre of excellence for

n

ICAT is committed to provide solutions to the local and global automotive

industry in the above two areas.

Component Development - Centre of Excellence (Site I)

The component industry accounts for nearly one third of the India's auto sector turnover. India is
emerging as a major automotive component manufacturing and exporting hub in the world. Keeping
in view the growth potential, ICAT is poised to develop as the centre of excellence for component
design, testing and validation. The centre will house :

Test may be performed according to following

standards
l
l
l
l
l
l
l
l

European Directive 78/2009, EEVC - WG17

Global Technical Regulation (GTR)-9
EuroNCAP (pedestrian).
FMVSS 201U (Free motion head form).
FMMVSS 203 & ECE R12 (Body Block & Linear Impactor).
ECE R21 (Pendulum).
TRIAS 63 2004.
JNCAP Pedestrian.
AIS 100

Universal Launcher

Electrodynamic shakers plus climatic chamber

Plastic and metal sintering rapid prototype machines

Full fledge workshop and tool room for preparation of Jigs and Fixtures

50 kN 'X' Poster Rig for Structural Durability & Vehicle Dynamics

Universal test benches* to perform

Upper Legform Test

3D Measurement Tool

Guided Headform

20

R21 Pendulum Test

Free Motion Headform

(FMVSS 201U)

Adult & Child

Headforms

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Fatigue and Certification Lab (Site-I)

Body Block Test

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Lower Legform Test

Component Development (Site - I)

Noise, Vibration and Harshness (NVH) (Site - II)

TESTS: Represent the three most commonly

injured parts of the body in a pedestrian
collision the head, the femur and the knee
joint. Vehicles are tested at a selection of points
on the bonnet, windscreen and bumper bar;
these impacts are considered the most likely
areas to cause injury.

Centre of Excellence

a)

Dynamic Fatigue Test of Suspension System (including leaf spring suspension system)

b)

Dynamic Structural Fatigue Test (Chassis of a motorbike)

c)

Dynamic Fatigue Test of Vehicle Components (Engine mounting brackets)

d)

Static Strength Test of Vehicle Elements (Bumper, Load separation Devices)

e)

Static Pull Out Resistance Test of Vehicle Elements (Roof Rack System, Emergency Hook)

BiW High Frequency 50 kN MAST with 6 DoF fo High Frequency Durability along with
fixed environmental chamber and Solar Simulation
Impact and devoted test Benches to test Seat Belt Anchorages, head Restrains, Seat
Testing for buses, Interiors of Buses
Impact test Bench Pendulum
Hydraulic and Pneumatic Actuators and Coupling devices for endurance
tests of Couplings
Small and Large Climatic Chambers for Hot and Cold testing of
Automotive Components
Fire Resistance Test System for Plastic Fuel Tank (Ready and open for
Industry) (Site II)

Atmospheric Agent Simulator

Small Acoustic Chamber

Thermostatic water machine

UV Chamber

* Rotary Actuator (10kN-m) is already installed & ready to take up Torsional Fatigue Testing
of Drive shafts, propeller shafts etc.

21

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Power Train Laboratory (Site-I)

Virtual Development Capability (Site-I)

Computer Aided Design (CAD)
NVH (CAE)
Engine Simulation (CAE)

n
n
n

Structural Analysis (CAE)

Acoustics (CAE)
CFD (CAE)

n
n
n

Fatigue Analysis (CAE)

Crash Analysis (CAE)
Vehicle Dynamics (CAE)

n
n
n

The new Power Train lab would have emission testing labs which complies with Indian, European, US,
Japanese, SAE standard
l

CAD
Product Lifecycle
Management
(PLM Software)

n
n
n

3D Geometric Modeling
Part Modeling
Assembly

n
n
n

CATIA V6
UG NX -9.0

Sheet Metal
Surfacing
Drafting

CAE
Structural

n
n
n

CFD
(Computational
Fluid Dynamics)

n
n
n
n

n
n
n

Heat Transfer & Flow Analysis

IC Engine Simulation
Aerodynamic Analysis
Compressors & Turbo Machines Flow Analysis

n
n
n

ANSYS Mechanical
Hyperworks Radioss.
ABAQUS
n
MSC Fatigue
ANSYS CFX
ANSYS Fluent
AcuSolve & Virtual Wind Tunnel

Mechanism Simulation
Vehicle Simulation

Meshing

Hypermesh

Optimization

Altair Optistruct

Altair Compute
Manager

An interactive GUI for submitting job on server & scheduling

MSc SimXpert

n
n

ADAMS
n
Altair Motion View
ADAMS Car

Max. speed: 250 km/h

Max. axle load: 4500 kg

Max Permanent Power : 220 kW

Temperature and humidity

Chassis Dynamometer Lab

4x4 48 compact chassis dynamometer with 2 AC motor

ANSYS Workbench

Cluster Components

Processor

Memory

RAM

Node/CPU Total nodes - 90

16 Core Intel XEON E5-2670 2.60 GHz

900 GB x5

64 GB

Four Shared Memory Processor

8 Core Intel XEON E7-8837 2.67 GHz

900 GB x6

128 GB

Backup- Server

12 Core Intel XEON E5-2620 2.00 GHz

900 GB x6

16 GB

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22

Hardware in Loop
system.
Measurement,
calibration and
diagnostic(MCD)
tools.
Rapid Prototyping
system.
Plant Modeling.

MCD:
Measure, calibrate and diagnose ECU
parameters through various
communication protocols like CAN, ETK,
K-Line, LIN, Flexray using INCA; along
with signals from temperature,
pressure, lambda sensors etc through
various measurement modules.
n
Drive recorder for fleet operation.
n

Max. speed: 250 km/h

Max. axle load: 4500 kg

Max Permanent Power :153kW

Engine Emission Testing Labs:

n

Plant Modeling: Engine/ Vehicle simulation models for HIL, MIL and SIL
simulation.

Heavy duty engine test cells for emissions certification (upto Euro V) equipped with 550 kW
and 220kW Transient Dynamometer
Light duty engine test cells equipped with Transient Dynamometer 60kW for passenger car &
off road applications

Variable Volume /Variable Temperature (VVVT) SHED

Dedicated workshops for engine preparation, vehicle preparation and tear down inspections

Climatic Chamber with the Transmission test cell for Transmission and Gear Box
development

NVH Lab (Site-II)

The objective of NVH lab is to provide the measurements according to Homologation requirements
and R&D services to the automotive industry in the field of Noise, Vibration and Harshness analysis.
This Centre of Excellence will house the state of the art NVH chambers & equipments to perform tests
on components, systems and complete vehicles.
n
n
n
n
n

RPT: Development of ECU control logics either in full pass mode or through
bypass mode.

Fuelled with Petrol, Diesel, CNG, LPG, Bio fuels and other alternative fuels, Bifuels or hybrid type

DETAILS
HIL:
n
Single ECU test bench to test and validate an ECU
(Powertrain or Chassis) in open loop or close loop.
n
Load Simulators to simulate solenoid valve injectors,
gasoline direct injectors, piezo-injectors etc
n
Failure simulation board to simulate failures in circuitry
n
Analog, digital, PWM I/O(s) etc to simulate signals for
different applications.

Vehicle test cells for 4 Wheel Drive (4WD)/ 2 Wheel Drive (2WD) (either front or
rear wheel driven vehicles)

A facility to develop,
test, evaluate and
validate an
ECU(Powertrain or
Chassis) is covered
under the scope of
Infotronics Lab.
Following facilities for
ECU development
along the V-Cycle are
covered under this
lab:

Fuelled with Petrol, CNG, LPG, Bio fuels and other alternative fuels, Bi-fuels or
hybrid type

(-35oC to +55oC and 20%RH to 75%RH)

High Performance Computing Cluster

Infotronics Lab

Vehicle test cells for 4 Wheel Drive (4WD)/ 2 Wheel Drive (2WD) (either front
or rear wheel driven vehicles) for climatic certification (upto EURO V)

4x4 Chassis dynamometer with Climatic Chambers

Linear
Non-Linear
Fatigue

Multi-body
Dynamics

Climatic Vehicle Test Cell

Passenger Car Vehicle Semi Anechoic Chamber

Heavy Duty Vehicle Semi Anechoic Chamber
Quiet Room
Listening Room
Coupled reverberant room
NVH transmission Testing
l

Flexibility of test beds to do all kinds of transmission tests including automated, dual
clutch and hybrid transmission.

23

MASTER PLAN LAYOUT ICAT - II CAMPUS

Electromagnetic Compatibility (EMC) Testing Laboratory (Site-II)

The EMC lab will be equipped with shielded and semi-anechoic chamber for 2&3 wheelers, passenger
cars, light/heavy commercial vehicles and components for electromagnetic emissions, immunity EMI and
EMC certification
n

Vehicle and Component Semi Anechoic Chamber for carrying out various Compliance Testing as per
AIS, ECE, CISPR, ISO, SAE, MIL and OEM Specifications.
Dedicated Control Rooms for Component and Vehicle Testing Chambers with Underground
Amplifier Room.
Turntable with Dynamometer having rollers with 4x4 Drive, Max turntable Load of 19,000 kg and
Rolling Speed of 120Km/h.
Instrumentation including E/H generator, Antenna MAST to carry out tests as per requirement.

Passive Safety Laboratory (Site-II)

The Passive Safety Lab is capable of all homologation tests and developmental test such as Frontal Crash,
Side Crash , Rear Impact tests, Safety tests of door locks, seatbelts etc. as per the AIS,ECE, EEC, FMVSS,
EuroNCAP and other regulations. It will be equipped with the following facilities:
n

Fixed crash core for supporting vehicles, light commercial vehicles upto 6000 kg
l

Max speed 80 km/h

Max acceleration for max speed

Dummies and data acquisition systems

Lighting systems

High speed camera system

Pedestrian Safety Test Equipments

Static rollover fixture flexible enough to hold vehicles from small cars
up to vehicles with a load of 4500 kg

Side door impact testing

Steering impact testing

Interior fitting testing

Seat and Seat Belt anchorage testing

Sled Test Facility for Seats

These facilities
will be at Site-I)

TEST TRACKS
General Road
Oval Track

Homologation Tracks (Site-II)

In order to provide the full homologation and type approval services to the industry under one roof, ICAT
will have all the test tracks required for homologation. The tracks will have automatic access barrier
control system, CCTV cameras, radio communication system, traffic information barrier, and weather
station and state-of-the-art safety control systems. The test tracks shall have following tracks:

ABS Track
NVH

EM

Hill Track

Comfort Track
ISO Track

Coast down track of 1100 mtrs.

Gradient Performance Test

a)

n
n

4 different gradient slabs (6/8%, 12%, 18% and 20%)

Straight line Brake performance test

Two different braking surfaces for homologation purposes:
a)

Low (basalt tiles) 250 m long

b) High (asphalt ) 200 m long

n

24

Steering pad platform

External noise test track with acceleration/deceleration lanes

Multi-purpose tracks

Flood track for BOV

Fu

el

El

ec

St

at

Dynamic Platform

io

Water Track

tri

ca

lS

ub

-S

ta

tio

Manesar

INTERNATIONAL CENTRE FOR AUTOMOTIVE TECHNOLOGY

[A Division of NATRiP Implementation Society (NATIS), Govt. of India]

Site I
Plot No. 26, Sector-3, Delhi-Jaipur Highway, HSIIDC,
Ch. Devi Lal IMT Manesar, Gurgaon - 122 050 (Haryana)

Site II
Plot No. 1, Sector 11, Transportation Hub Area, HSIIDC,
IMT Manesar, Gurgoan-122050 (Haryana)

Phone : +91-124-4586111, Fax : +91-124-2290005 E-mail : team@icat.in Website : www.icat.in