New-Gen Hyundai i20 Manufacturing Process Explained

Published On: 27 October 2020
100 Views

2020 new-gen Hyundai i20 engineering details revealed ahead of the official launch

Hyundai India is all set to launch the new-gen i20 next month in the Indian market. The company recently released the design sketches of the premium hatchback. Today, it has shared key engineering details of the upcoming 2020 Hyundai i20. This further confirms that the production of the new-gen i20 in India is already underway.

The details shared by Hyundai explains that the upcoming premium hatchback consists of 66 percent of advanced and high strength steel for the superstructure. This superstructure is created by using 5400 tons of stamping at the press shop in the Hyundai factory. To assess the panel thinning distribution and crack, the company uses an advanced digital gauge. The neck prediction methodology helps to manufacture zero crack panels. After this, 3D scanning of the parts is carried out to analyze and strengthen the press panel part’s accuracy and precision.

More than 70 cars are processed every hour. Hyundai India uses a welding process that comprises of more than 450 4th-gen robots offering 100 percent weld automation with 4,000 welding spots in each car. Following this, each car is further subjected to an in-house endurance test with load conditions for 849 hours, without load conditions for 5 lakh cycles for transmission systems, and over 350 hours for the engine systems. After this, the cold testbed is carried out. This is basically an eco-friendly way of testing the engines over 15 parameters without burning the fuel. Above all, it is a fully automated system in which 100 percent of produced engines are tested before assembling them in vehicles.

Following this, the vehicles undergo 500 quality tests where every single unit that is rolled off the assembly line is first inspected by 500+ quality in charge experts starting from the stage of the panel press. Once this has been carried out, the all-new i20 undergoes a dynamic road test on 18 drive tracks to determine if the model is good for various road driving conditions. A unique leak test is also performed where the model needs to drive through rain/water pressure that exceeds the heaviest recorded monsoon with a shower condition of 60mm per minute or 3,600mm per hour at a pressure of 3bar.

“As an organization that is committed to giving customers Quality Time, our focus has remained on ensuring supreme levels of manufacturing excellence. This has perfectly culminated in the all-new i20, delivering robust and reliable performance. With our 24-year rich manufacturing heritage of ‘Make in India’, the all-new i20 is yet another benchmark brand from Hyundai that is an edge above the rest,” as commented by Ganesh Mani S, Director – Production, Hyundai Motor India Ltd.

Under the bonnet, the new-gen i20 is likely to be offered with three engine options - a 1.2-litre naturally-aspirated petrol unit, a 1.0-litre turbocharged petrol motor, and a 1.5-litre diesel unit. Transmission options will include a manual gearbox, an iVT, an iMT, and a 7-speed dual-clutch automatic unit.