Success Stories
March 7, 2025 2025-03-20 11:16Success Stories
Sukhena's Own Product - 2-Wheeler Electric Vehicle
✔ Introduction of Innovation: Sukhena unveils an indigenously designed 2-Wheeler Electric Vehicle (EV) aimed at transforming last-mile connectivity in urban and rural areas, offering a sustainable alternative to petrol-powered two-wheelers.
✔ Versatility for All Terrain: The EV features a robust design suitable for diverse terrains, ensuring reliable performance on smooth roads and rough paths, making it accessible even in remote areas.
✔ Impressive Payload Capacity: It supports up to 150 kg payload, catering to individuals and small businesses for transporting goods, parcels, or agricultural products.
✔ Extended Range & Speed: A single charge provides up to 110 km range with a top speed of 45 km/h, balancing energy efficiency and safe riding.
✔ Fast Charging Technology: Equipped with advanced fast charging, the battery reaches 80% charge in just 20 minutes, reducing downtime for users.
✔ Eco-Friendly and Cost-Effective: Zero emissions and lower operational costs make the EV an environmentally-friendly and economical transportation solution.
✔ Smart Features and Safety: Includes smart technology like a digital dashboard, mobile app connectivity, advanced braking systems, enhanced suspension, and LED lighting for safety.
✔ The Road Ahead: Revolutionizing transportation for a sustainable future .The EV is set to launch in November 2025, aiming to revolutionize commuting in urban and rural regions.
Complete Design and Development of a EV Bus
Benchmark Vehicle
Digitized 3D CAD Model
Salient Activities
✔ Benchmarking: Study of customer reference vehicle given.
✔ Complete Study of Vehicle Architecture, Measurements before teardown
✔ Teardown of vehicle, study of subsystems and structure build
✔ 3D scanning of the Driver Cabin area, Chassis system
✔ Study of Sub-Assembly and Commodity Listings
✔Brought out items details, collection of Spec. and weight
✔ Development of digitized 3D model, Assembly
✔ CAE Validation for baseline performance targets
Complete Study of Vehicle Architecture and Measurements
✔ Measurement and study of Critical exterior parameters like Vehicle length, height width, Wheelbase, Front, Rear Overhang etc.,
✔ Steady and measurement of interiors parameters like Roof height, Inside width, trims, Seating arrangements, mountings, Driver Cabin area, SGRP- Driver seat.
✔ Study of luggage compartment area, Doors and mountings
✔ Study of Footstep area, IP Trims, Steering, Brakes, wiper system mounting details
✔ Study of all subsystems and mountings
New EV Bus design and development is under progress and the same will be launched by
"March 2026"
Accelerated Physical Testing of Automotive Chassis Commodities: A Case Study in Efficiency and Innovation
✔ Project Overview:
- Sukhena completed physical testing of four automotive chassis commodities in just 1.5 months, halving the typical timeline of three months.
Commodities were:
- Subframe (Engine cradle)
- Rear Twist Beam,
- Lower Control Arm,
- Body Mounting Bracket
- Each commodity was tested with at least six samples for strength, durability, and vibration performance.
✔ Testing Challenges and Solutions:
- Custom Test Setup: Configured setups tailored to vehicle-specific conditions and requirements.
- Limited Lab Space: Optimized available lab space to fit multiple test setups simultaneously.
- Timely Monitoring: Ensured continuous monitoring of critical parameters (Load, Frequency, Displacement) for accurate results.
- Die Penetration Testing: Inspected for cracks using die penetration as per cycle requirements.
- Backup Systems:
- Actuators were kept on standby to avoid delays due to equipment failure.
- Backup power generators ensured uninterrupted testing during power outages.
- Manpower Management: Maintained buffer manpower to handle leaves and ensure smooth operations.
- Efficiency in Reporting: Generated detailed test reports and obtained customer sign-offs within the constrained timeline.
✔ Outcome:
- The team successfully met all project requirements through effective coordination and problem-solving, demonstrating resilience and technical expertise.
Sukhena: Driving Excellence in Greenfield Manufacturing Plant Consultancy
✔ Design and Development: Creating optimized designs for manufacturing processes.
✔ Vendor Selection and Management: Identifying and managing suppliers for efficient operations.
✔ Project Planning and Implementation: Overseeing the construction and operationalization phases.
✔ Facility Construction and Installation: Building state-of-the-art facilities tailored to client needs.
✔ Technology Integration: Incorporating advanced technologies for improved efficiency.
✔ Plant Commissioning: Ensuring the plant is fully operational and meets performance standards.
Sukhena’s expertise ensures that manufacturing plants are cost-effective, efficient, and prepared for long-term success.
Optimized Design for Chassis parts (Subframe - Front cross member)
Sukhena’s concept design ensures lightweight, cost-efficient, and high-performance part:
✔ 1.5 Kg weight reduction
✔ 50% lower tooling costs
✔ 70% material utilization with local sourcing
✔ Standardized LHS & RHS design
✔ Streamlined manufacturing & process optimization
✔ Meets NVH, durability & fatigue requirements
A smart solution for cost and weight savings, efficiency and optimized part.
Twist Beam section – Migration from Closed section to Open section
Design Objectives :
✔ Beam Design: Transition from a closed-section to an open-section twist beam with reinforcment
✔ Compatibility: Ensure thbeam adapts to the existing trailing arm and maintains the same shear center as the baseline for consistent ride and handling.
Outcomes :
✔ Open-section design with reinforcement maintains the original shear center location ensuring similar ride/handling while adapting to existing trailing arms
✔ Improved roll stiffness via optimized reinforcement and material distribution meeting functional requirements
✔ Simplified manufacturing: Eliminates post-stamping heat treatment, reduces part rejections vs. squash tubes and leverages in-house stamping to cut logistics costs
✔ Cost reduction: Common LH/RH reinforcements minimize tooling expenses
This approach ensures functional performance while achieving manufacturing efficiency and cost-effectiveness.
Sukhena Value Proposition
✔ End-to-End Solutions: Offering services spanning design to manufacturing, ensuring seamless project execution.
✔ Advanced Technology: Leveraging cutting-edge tools and staying updated with automotive industry advancements.
✔ Experienced Team: Employing skilled professionals with extensive industry expertise.
✔ Customization: Providing tailored solutions to meet specific customer requirements.
✔ Quality Assurance: Maintaining high-quality standards across all processes.
✔ Cost Effectiveness: Delivering economical solutions that help customers save costs without compromising quality.
✔ 24/7 Technical Support: Utilizing time zone advantages to provide continuous support for international clients.
Sukhena combines innovation, expertise, and customer-centricity to deliver value-driven engineering solutions globally.
