Tsuyo Manufacturing is deeply committed to offering highly reliable, robust, and durable products designed to withstand a wide range of exposure and service conditions in the field. The company’s unwavering focus on futuristic design and the use of innovative materials positions them at the forefront of delivering cutting-edge technological solutions. Recently, in an enlightening interview with Technology Journalist Himanshu Vaibhav from eletimes.com and timesev.com, Mr. Vijay Kumar Director of Tsuyo Manufacturing provided valuable insights into the incorporation of emerging technologies into their manufacturing processes. Additionally, he discussed their adoption of Industry 4.0 practices, the strategic utilization of 3D printing in their production methods, and the ongoing development of futuristic technologies. Tsuyo’s dedication to innovation and progress ensures they continue to lead the way in the realm of advanced manufacturing and engineering solutions.
TimesEV: What emerging technologies do you envision incorporating into your manufacturing process in the future, and how do you anticipate these innovations will improve efficiency and product quality?
Mr Vijay Kumar: There are umpteen initiatives as manufacturing processes to manufacture the best quality and efficient motors production at Tsuyo premises. Processes change across the manufacturing value chain towards in-line inspection at each stage to qualify the stage-wise motor manufacturing like testing 100% windings, and tests like IR, Surge and RPM tests in between stages of assembly for a foolproof sustainable motor. Incorporating unique changes towards the use of special sealants, and glue to achieve the best ingression standard and also to support thermal management. Establishing a unique cycle and methodology towards impregnation technique to generate the best insulation class like H inside the motor and also to generate consistent performance-based motor manufacturing various automation process has been incorporated. Apart from regular incoming inspection of inputs materials, special efforts have been placed towards magnet testing which is rare and quite difficult in India to have a best-sorted quality and genuine magnet placement in the construction of a motor. Stages like rotor balancing and in-house-made testing rigs can easily simulate the real drive cycle conditions and give the best quality with consistent output in each batch of production.
TimesEV: What are your company’s plans for adopting Industry 4.0 technologies, such as IoT, AI, and big data analytics, in your automotive manufacturing processes?
Mr Vijay Kumar: Tsuyo is already underway implementing Industry4.0 technologies. We have developed real-time monitoring of our motor and controller and the complete data as real-time duty cycle and parameters can be easily fetched to the cloud from the running vehicle or as stall condition and also can easily locate each component based on their unique identity number. These data not only going to be an input for our design for improvising consistently based on real-time feedback but also going to help a lot to customers who are in the business of managing an EV fleet for different application purposes. This data bank is going to generate insights based on various AI tools applied which are going to be used as inputs inside manufacturing processes.
TimesEV: Which technologies does your company currently employ for development and design purposes? Additionally, do you have any plans to incorporate 3D printing technology into these processes in the future?
Mr Vijay Kumar: Tsuyo R&D uses various ANSYS packages, Simulink, MATLAB and Auto CAD. While we are soon going to have packages like ROMAX and other software like Dynafusion and others. Tsuyo is already using in-house built 3D machines for various prototyping and faster adoption of design as development through 3D applications to shorten our prototyping cycle.
TimesEV: What testing and quality assurance processes do you have in place to ensure the longevity and safety of your motors and controllers?
Mr Vijay Kumar: We have several quality tests set up and procedures to ensure a sustainable and safe product. We have an in-house set-up of all kinds of Winding tests through automatic equipment, RPM tester, Current tester, Dyno Set up to test up to 11000rpm motors, set-up for integrated controller tests like Dyna fusion, PCB circuit continuity checks, Testing Rigs, Real Vehicles loaded with sensors to test on the field, load tester, Gearbox testing set up, bearing test machines, IP testing and many quality best testing equipment to establish a full proof inputs materials usage and manufacturing.
TimesEV: How is your company ensuring that the manufacturing process remains flexible and adaptable to seamlessly integrate new technological breakthroughs and meet evolving industry standards?
Mr Vijay Kumar: During the Capex investment and tool and fixture designs, we have taken due care to adopt various different kinds of topology of motors which we are going to launch in future and also upcoming new frontiers in this area of development. While owning the design and validation software, all packages have been taken while considering future scale and upgrades in technologies. Meeting evolving standards, a dedicated team is engaged in reviewing and studying the various upcoming standards and keeps on updating the same in-house. Moreover, Tsuyo is already working as an Industry-academia collaboration and working very close to renowned professors and mentors to upkeep the best practices and compliances to meet the evolving expectations and working with Institutes like IIT Delhi, NIAMT Ranchi, VNIT Nagpur and also collaborated with various government initiatives projects.