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Old 13th January 2025, 23:16   #1
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Pics & Report | Mahindra Tech Day @ Chakan, Pune

Mahindra has been betting big on its electric SUVs and rightly so. We drove these cars recently and were mighty impressed with the overall product. The cars will soon be on Indian roads, but meanwhile, Mahindra had arranged for a Tech Day where they showcased all the technology that has gone into the development of these cars. It was a 2-day event that took place in Mahindra’s factory in Chakan, Pune. This is where as of now, the batteries are being assembled and the cars are also being manufactured. Let’s take a look at the highlights of the event. Do share some additional technical highlights that you can from the pictures.

Day 1


Of course, the two cars in question were parked at the venue. Both cars share the same INGLO architecture and despite the different sizes, they both have the same wheelbase:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_01.jpg

There were a total of 8 stalls displaying details of different areas of the car:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_02.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_03.jpg

We’ll start off with the display of the inclined chassis of the INGLO architecture:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_04.jpg

A closer look at the inside. You can see the steering mechanism and the HVAC mechanism as well:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_05.jpg

On the other side, you can see the remaining part of the HVAC unit and also the brake booster unit on the left:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_06.jpg

A look at the front suspension system and the frame:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_07.jpg

This was just a miniature mode assembly of the car displaying the suspension and braking systems:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_08.jpg

A cut section of the front and rear suspension. These are continuously variable semi-active dampers. There’s a solenoid valve at the bottom (green-coloured switch) that is responsible for performing continuous variable damping:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_09.jpg

This is the front suspension system. Mahindra claims that the system has the highest suspension travel of 185 mm:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_10.jpg

If you look closely, you can see that the lower control arm is split into 2 links. This allows the engineers to tune the comfort and handling characteristics separately:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_11.jpg

As you can see, the steering rack is mounted in the front of the front axle which is something that’s possible on EVs and not IC engine cars. Without getting into much detail, the front-mounted steering rack improves high-speed understeer. With a rear-wheel drive car, you don’t want oversteer where the rear end steps out:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_12.jpg

This is the independent multi-link (5 links) rear suspension assembly. The rear suspension has a travel of 205 mm:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_13.jpg

The horizontal link that you see in front of the strut is the toe link that is claimed to improve camber linearity. Even the sub-frame design is claimed to have been optimized for battery protection in case of a rear crash:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_14.jpg

A look at the frame in detail. The red arrows that you see here show the load path in case of a frontal crash. The green arrows show the load path in case of a side pole impact:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_15.jpg

In case of a frontal impact, there are three major zones in the front of the car – crumple zone, absorption zone and resistance zone. In the absorption zone, Mahindra has added a cradle load path which is the part that you see in the middle. This cradle basically crumbles below and is claimed to provide 3x energy absorption in comparison with ICE cars:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_16.jpg

As mentioned earlier, the green lines display the load path for side impact. Note that the battery pack also acts as a part of the frame and hence adds to the rigidity of the structure. The load distribution is 52% by the structure and 48% by the battery pack frame:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_17.jpg

This is the BIW material distribution model of the BE 6. Unfortunately, I couldn’t find the exact distribution of different types of steels:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_18.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_19.jpg

There was also a demonstration of the airbag deployment sequence. The basic idea is that in different types of crashes, the sensors relay the message to the airbag ECU which in turn sends signals to the respective airbags and also cuts off the high-voltage system:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_20.jpg

This multilayer sheet that is placed above the inverter is claimed to reduce the noise and improve NVH:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_21.jpg

Here’s a look at the steering system. It has a turning circle of less than 10 meters and has 2.65 turns from lock to lock. You also get a rack assist motor for better response. Note that the cars come with ADAS features and also auto park assist:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_22.jpg

The steering rack has a variable gear ratio. This means that the pitch is narrow in the middle and wider towards the ends:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_23.jpg

Here’s a better explanation of the variable gear ratio:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_65.jpg

This is the steering column assembly:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_24.jpg

The INGLO platform cars get brake by wire. This includes an integrated electronic brake booster. This assembly that you see here has a brake booster, vacuum pump and ESC controls integrated. Also, next to it, you can see the front brake caliper:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_25.jpg

Here’s the rear brake caliper and the brake discs. The discs have a tiger claw design for better thermal stability:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_26.jpg

These are the wheel hub assemblies for driven and non-driven wheels. Externally, there’s not much difference, but they are different on the inside:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_27.jpg

The tyres have foam in them to reduce noise levels. The claimed reduction is 3-4 decibels:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_28.jpg

Here’s a look at the Gen 2 compressor along with other parts of the HVAC system. You have the water pump at the back right and the chiller at the right:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_29.jpg

Here’s a look at the HVAC assembly:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_30.jpg

You have an active grill shutter assembly. This reduces aerodynamic drag by closing the grille opening area to the required level at higher speeds. This helps in improving the range:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_31.jpg

A look at the compressor and the chiller with electronic expansion valve:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_32.jpg

Last edited by Omkar : 13th January 2025 at 23:18.
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Old 13th January 2025, 23:16   #2
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Next up were the seats. This is the front seat for the XEV 9e and they’re quite comfortable. The front seats are ventilated and Mahindra claims that they’ve focused on better distribution of air and also keeping the fan sound less:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_33.jpg

Here’s a look at the cut section of the seat:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_34.jpg

These are the different types of materials that are used in the seat:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_35.jpg

This is the driver seat of the BE 6. It has more futuristic design elements including the single stem for the headrest:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_36.jpg

AIS Glass or Asahi India is the windshield and glass provider for Mahindra. They had a few demonstrations as well. This showed how much the acoustic glass cut out the external noise:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_37.jpg

This was another demonstration that showed how the windshield cut down the UV rays in comparison with regular glass:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_38.jpg

Window glasses were also on display:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_39.jpg

One of the party pieces is the infinity roof with dynamic illumination. The roof also gets interactive lights:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_40.jpg

Here’s a look at the different layers of the roof. The primary component is the PVB (Poly Vinyl Butyral) sheet with the pattern. There are LEDs on the side that are used to throw light inside at the correct angle:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_41.jpg

Moving on to the lighting section. This is the front lighting of the XEV 9e. As you can see, there are a lot of elements here. The most important part, however, is not the LED light strips, but it’s the headlamps. As you can see the headlamps have this ice cube-like design which also includes the cornering lamp and fog lamp. There are 6 LEDs for the low beam and 4 LEDs for the high beam:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_43.jpg

This is the LED rear lighting setup of the XEV 9e:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_44.jpg

Next up is the lighting system of the BE 6. The highlight of this is the rear lighting system. Mahindra has this GrooveMe feature on the rear tail lamp which synchronizes live songs that are played through any source. The system uses 204 LEDs to create the equalizer effect. Note that all the exterior lamps are also synced to the beats. This is the real party feature of the car:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_42.jpg

The steering wheel has physical as well as capacitive touch controls. The black panel in between also houses the driver's airbag. Here’s a look at all the small components behind this panel on the steering wheel:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_45.jpg

Similar component breakdowns of the HVAC control panel and the rotary knob on the center console were also on display:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_46.jpg

Here’s the breakdown of the key as well as the center console:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_47.jpg

A look at the speaker placements of both cars:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_48.jpg

This is the augmented reality head-up display:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_49.jpg

Next up is Mahindra’s ‘EyeDentity’ which is the in-cabin camera that has 2 purposes – a. It can serve as a selfie camera and…
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_50.jpg

…b. It monitors the driver’s alertness while driving. It can track eye movements and also check if you’re wearing the seatbelt and even understand your facial expression:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_52.jpg

Exploded view of the cameras and some sensors:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_51.jpg

This XEV 9e was parked to display the home charging which has an RFID or mobile app authentication. There are 2 types of chargers that are available – 7.2 kW and 11 kW:
*Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_53.jpg

Finally, we get to the heart of the EVs, the powertrain. This is the motor and the battery pack all assembled. We’ll now look at each component one by one:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_54.jpg

The electric motor makes 282 BHP and 380 Nm of torque. The maximum rpm is 16,000 and it weighs roughly 105 kg. It is water-cooled:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_55.jpg

Here’s a look at the different components of the electric motor. On the extreme left, you have the VCU which is the vehicle control unit that is responsible for the different drive modes and the boost function that gives you a surge of power for 10 seconds. It is also responsible for the revive mode which gives some extra distance when the battery is nearly empty. Next to it, you see the OCDC which is basically an onboard charger and DCDC converter. It converts the DC current from the battery into AC current which drives the motor. Next to it is the MCU which is the Motor Control Unit. It sits between the motor and the battery and controls the vehicle speed and acceleration based on the throttle input. Transmission, as we all know, is single-speed and is integrated into the powertrain:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_56.jpg

Next is the housing which encases the powertrain and the two main components of the electric motor – Rotor and Stator. I won’t go into details about how an electric motor works, but in the simplest terms, the Stator is static and the rotor rotates inside the stator. The stator creates a magnetic field which turns the rotor that runs the motor:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_57.jpg

Moving from the motor to the battery. Here’s the cooling plate of the battery pack that has veins that keep the battery cool:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_58.jpg

This is the battery pack frame which uses high-strength aluminum. It also provides rigidity to the floor and can withstand 200 kN side pole crash force:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_59.jpg

We move on to the battery pack. This is the 79 kWh battery pack and has Cell-to-Pack which allows for better packing efficiency:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_60.jpg

What you see here is the breakdown of the battery pack. It consists of lean modules packed into the frame. The lean module has 3 temperature sensors each. Next to it is the Blade Cell. As mentioned in the review, the blade cell tech is from BYD. Next to it, you see the traditional LFP cell and module which is bulky and not very efficient:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_62.jpg

These are the different circuits that are in the battery pack:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_61.jpg

Getting on the molecular level, you see the LFP cathode in a discharged condition and charged condition:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_63.jpg

These are the two types of molecules in the structure:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_day-1_64.jpg

Here's a short video of the stalls:

Last edited by Omkar : 13th January 2025 at 23:18.
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Old 13th January 2025, 23:16   #3
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Day 2


On the second day, Mahindra had organized a factory visit. The visit was going to cover 4 major departments of manufacturing. The Chakan plant is currently assembling the battery packs and Mahindra also has future plans to start manufacturing here. Mahindra has allocated Rs. 4,500 Crores out of the total Rs. 16,000 Crores planned in the F22–F27 investment cycle — which includes powertrain development, two product top hats including software & tech and manufacturing capacity. Here’s a quick overview of the plant:


The first part was the Battery Manufacturing area. Here’s a video showing different areas of the plant. If you spot anything interesting, do share:


We were first given an introduction about the plant and we also had to go through some of the safety instructions for the visit. Photography and videography were strictly prohibited, so all the pictures you see from here onwards have been provided by Mahindra:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_01.jpg

A lot of the sections are fully automated and there is no need for human intervention on the line:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_02.jpg

What you see here is the cell stacking:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_03.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_06.jpg

The cells are stacked into the lean module that we saw earlier:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_04.jpg

Post stacking, there is link plate welding which is splatter-free welding:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_07.jpg


The factory uses AGVs or automated guided vehicles for material movement:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_05.jpg

Once the battery pack is assembled, they are tested as well to make sure that vibration doesn’t affect the bolt tightness:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_08.jpg

The factory floor has a no-fault forward policy. This means that if there’s any fault, the system gets alerted and the line won’t move forward unless the fault is rectified:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_1.-battery-plant_09.jpg

Next up was the Body Shop:




This is where the different pressed sheets are welded together:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_01.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_02.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_03.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_04.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_05.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_06.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_07.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_08.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_2.-body-shop_09.jpg

We moved on to the paint shop. I had visited the paint shop previously during the XUV700 media drive. Some new machinery has been added to the facility since then:


This is where rust-resistant paint is applied to the body. The paint is charged with electricity which then sticks to the car body:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_02.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_03.jpg

The next step is to apply sealant for waterproofing and rust-proofing:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_04.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_05.jpg

Sealant is applied on the insides as well:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_06.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_07.jpg

Emu feathers are used for removing dust:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_08.jpg

Next up is the middle coat that is applied to the body:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_09.jpg

After the middle coat, you have the top coat:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_10.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_11.jpg

A final clear coat is applied after the top coat for the glossy finish:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_12.jpg

After the final paint, it is inspected in this light for imperfections:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_3.-paint-shop_01.jpg

Last edited by Omkar : 13th January 2025 at 23:17.
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Old 13th January 2025, 23:16   #4
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The last stop is the Assembly shop:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_01.jpg

There are overhead conveyors that transport the body from one station to another:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_02.jpg

This is where the glass roof is installed. There are robots that apply the sealant to the glass and…
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_03.jpg

… place it on the roof:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_04.jpg

Here the windshield is getting installed:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_05.jpg

Some of the other interior and exterior components getting installed:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_06.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_07.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_08.jpg

Mahindra claims that the machinery is gender agnostic which is how they can have more women workforce involved on the floor:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_09.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_10.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_11.jpg

The seats being installed:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_12.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_13.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_14.jpg

The chassis assembly happens separately, just like in IC engine cars:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_15.jpg

Here you have the suspension, brake and steering components along with the battery pack:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_16.jpg

Multiple cameras are placed to check the alignment of the components:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_17.jpg

Here’s the rear axle with the motor:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_18.jpg

Similar to IC engine cars, the body is lowered onto the chassis. The platform on which the team is standing on is moving:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_20.jpg

Bolts are manually tightened:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_19.jpg

Some more images of the factory floor:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_21.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_22.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_23.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_24.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_25.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_26.jpg

The wheels are electrically aligned:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_27.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_28.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_29.jpg

Once the assembly is done, the car is tested inside the facility:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_30.jpg

And also tested outside the facility:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_32.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_31.jpg

The car is also put through a shower to check for any leaks:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_33.jpg

Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_34.jpg

The last step is where the final inspection is done:
Pics & Report | Mahindra Tech Day @ Chakan, Pune-2025_mahindra_tech_day_4.-assembly_35.jpg

A short video of all the processes:


Disclaimer : Mahindra invited Team-BHP for the Tech Day. They covered all the expenses for this event.
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Old 13th January 2025, 23:20   #5
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re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

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Old 14th January 2025, 09:18   #6
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Great review, Mahindra have gone the last mile to explain their technology and technical design philosophy.

I am very impressed, however, I still cannot get with the exterior design of these vehicles.
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Old 14th January 2025, 09:53   #7
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Showing all this tech is fine. But why do we end up, in most cases, as their beta testers for their vehicles?
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Old 14th January 2025, 11:26   #8
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Thanks for the super interesting report Omkar

I do however, have a few corrections to suggest.

Quote:
Originally Posted by Omkar View Post

The INGLO platform cars get brake by wire. This includes an integrated electronic brake booster. This assembly that you see here has a brake booster, vacuum pump and ESC controls integrated. Also, next to it, you can see the front brake caliper
1. This NOT brake by wire: As long as there is a physical connection between the pedal and the master cylinder (which there is in this case) it cannot be called as Brake By Wire.

2. There is no vacuum booster or pump: This is what is known as a "One Box" system where the ESP module and master cylinder and actuation servo motor are all integrated. There is NO VACUUM BOOSTER/ PUMP because an electronically controlled servo motor replaces the function of a vacuum assisted booster.


Quote:
Originally Posted by Omkar View Post
Here’s the rear brake caliper and the brake discs. The discs have a tiger claw design for better thermal stability
I find this a little spurious. I run thermo-mechanical calculations on brake discs day in and day out. I cannot fathom how this can improve thermal stability. Tiger claw design Indeed!

This is the kind of stuff that disappoints me about Mahindra. The really have come a long way and some world class content goes into their cars but their marketing department clearly has a blank cheque to churn out immature BS, diluting the credibility of the hard working engineers.

Last edited by ashivas89 : 14th January 2025 at 11:39.
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Old 14th January 2025, 11:40   #9
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Quote:
Originally Posted by ashivas89 View Post
Thanks for the super interesting report Omkar

I do however, have a few corrections to suggest.
First of all, thank you for the comment and reading through the report. As mentioned in the report, it would be great for people with more technical knowledge to shed some light on these technologies.

Quote:
1. This NOT brake by wire: As long as there is a physical connection between the pedal and the master cylinder (which there is in this case) it cannot be called as Brake By Wire.

2. There is no vacuum booster or pump: This is what is known as a "One Box" system where the ESP module and master cylinder and actuation servo motor are all integrated. There is NO VACUUM BOOSTER/ PUMP because an electronically controlled servo motor replaces the function of a vacuum assisted booster.
This was actually mentioned on a placard, that's why I mentioned it in the report. Do share your thoughts on this -

Pics & Report | Mahindra Tech Day @ Chakan, Pune-13.jpg
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Old 14th January 2025, 11:44   #10
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Quote:
Originally Posted by Omkar View Post
First of all, thank you for the comment and reading through the report. As mentioned in the report, it would be great for people with more technical knowledge to shed some light on these technologies.



This was actually mentioned on a placard, that's why I mentioned it in the report. Do share your thoughts on this -

Attachment 2712783
Always Omkar. Please don't get me wrong. My comments were levelled at Mahindra. I figured that the OP was paraphrasing what was published by Mahindra.

Last edited by ashivas89 : 14th January 2025 at 11:48.
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Old 14th January 2025, 14:15   #11
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Quote:
Originally Posted by volkman10 View Post
Showing all this tech is fine. But why do we end up, in most cases, as their beta testers for their vehicles?
It gets exponentially more difficult to build complex software developed in agile sprints based off loosely coupled architectures that is 100% defect free. And as the line between hardware and software continues to blur, you are adding another layer of complexity. That’s EVs for you - software on wheels. Add AI to the mix and then you can quickly see the limits of deterministic testing.
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Old 14th January 2025, 14:16   #12
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Thank you, Omkar, for painstakingly putting together this marvellous report of the various technologies that have gone into the Mahindra twins. What Mahindra has achieved from a technical standpoint is just incredible. I just hope that the products perform as flawlessly as the engineering efforts that have gone into designing and manufacturing the cars. I sincerely pray that the products meet with the success that they so richly deserve in the market.

My own personal experience with the vehicles as someone who was invited to the event as a supplier partner:
I test drove both vehicles - the BE6 felt faster, but for me, the design was a bit too funky for my liking, plus the rear seat experience did not feel great. The XEV 9E felt more mature and gave me a great feel while driving around the test track. I couldn't test out all the features due to the limited time available with the vehicle, so I definitely look forward to have a longer test drive with the local dealer. The AR Heads-up-display did not feel as crisp as the EV6 or the Mercedes EQB HUDs, but it could be just the TD vehicle that I got. The XEV9E is one BIG car, and that would be my only hesitation to own one, apart from the poor rear view mirror visibility (Mahindra, please do something about it!).
Being seriously in the market for a daily drive EV (the car will do about 125+ kms every day - 2 round trips to my place of work), I have extensively researched and test driven the Hyundai Ioniq 5, the Kia EV6, the Mercedes EQB as well as the Tata EVs. I am also eagerly looking forward to the launch of the Hyundai Creta EV as well as the Maruti Suzuki e-Vitara.

My lifelong dream has been to own and drive a Merc, and by God's grace, at this stage in my life, I do have the ability to afford one. But, now when there are such exciting and well engineered cars as the BE6 and XEV 9E, which are Indian, loaded to the gills with state-of-the-art technology and features and offered at an unbelievable value, I don't think I can ever go back to longing for a 'luxury' car brand. That dream is dead for me. I honestly feel that Mahindra could become India's answer to the Chinese EV brands including BYD.
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Old 14th January 2025, 16:28   #13
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Quote:
Originally Posted by Omkar View Post
This was actually mentioned on a placard, that's why I mentioned it in the report. Do share your thoughts on this -

Attachment 2712783
I agree with ashivas89 here. Any X(drive, steer, brake)-by-wire technology means the human operated device is physically disconnected from the system actuators and this connection is replaced with an electric/electronic interface (e.g. the accelerator pedal in modern vehicle is electronically connected to engine ECU (instead of mechanical linkage to the throttle valve) which is a drive-by-wire system). What M&M has shown here is an integrated braking module where the master cylinder, ESP control unit and actuator are packed in one module.

Nevertheless, I highly appreciate M&M for developing such an advanced vehicle in-house with all the latest available technologies from the market. The components such as BYD batteries, Valeo Motors, Sibros OTA, Mobile Eye ADAS, Qualcomm chipset, etc. are class leading components.

Last edited by gopi_rm : 14th January 2025 at 16:37.
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Old 14th January 2025, 16:35   #14
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Quote:
Originally Posted by Omkar View Post
Moving on to the lighting section. This is the front lighting of the XEV 9e. As you can see, there are a lot of elements here. The most important part, however, is not the LED light strips, but it’s the headlamps. As you can see the headlamps have this ice cube-like design which also includes the cornering lamp and fog lamp. There are 6 LEDs for the low beam and 4 LEDs for the high beam:
Attachment 2711140
Thank you Omkar for such a detailed coverage on a tech day.

About the cornering lamp, is the setup similar with BE6? Asking this as I sure see a lot of lamps with XEV9E, but the headlamp setup on BE6 appears a lot more smoked in (atleast in pics), hence can't gauge if the setup is similar.
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Old 14th January 2025, 16:41   #15
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Re: Pics & Report | Mahindra Tech Day @ Chakan, Pune

Quote:
Originally Posted by 07CR View Post
Thank you Omkar for such a detailed coverage on a tech day.

About the cornering lamp, is the setup similar with BE6? Asking this as I sure see a lot of lamps with XEV9E, but the headlamp setup on BE6 appears a lot more smoked in (atleast in pics), hence can't gauge if the setup is similar.
Hello, I came across the post for your seltos fog lamp upgrade. I want a help from you regarding the genome's installer who helped you in installing the fog lamp. Could you please share the installer's contact number. I am already stuck with few light accessories which I have with me and there's no one to install it.

Last edited by Eddy : 14th January 2025 at 16:46. Reason: Please use Team-BHP for all exchange of information for the benefit of all readers.
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