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Exterior Styling of an Intercity Transport Bus for
Improved Aerodynamic Performance
Arun Raveendran1, D. Rakesh2, S.N. Sridhara3
1- (Engg) student, 2-Senior lecturer, 3-Professor and HOD,
Automotive Engineering Centre
M.S.Ramaiah School of Advanced Studies, Bangalore
Abstract
Intercity buses travel about 250 to 350 km in a stretch and usually are of sleeper coach mode. The exterior styling,
sleeper comfort and aerodynamically efficient design for reduced fuel consumption are the three essential factors for a
successful operation in the competitive world. The bus body building companies prioritizes the exterior looks of the bus and
ignore the aerodynamic aspect. Scientific design of sleepers for increased comfort of the passengers is seldom seen. The
overall aim of this project was to redesign an intercity bus with enhanced exterior styling, reduced aerodynamic drag and
increased comfort for the passengers.
Extensive product study and market study were carried out and aspirations and frustrations of commuters were
recorded. An operating intercity bus was benchmarked and analyzed for styling, aerodynamic performance and comfort.
Fluent, a commercial CFD code was used to evaluate the aerodynamic performance. Principles of product design were used
to analyse the styling and comfort. The benchmarked high floor bus was redesigned with low - floor for reduced aerodynamic
drag. The exterior was redesigned with emphasis on improvised aerodynamic performance and appealing looks. The interior
was modified to meet aspirations of the commuters.
The results of the redesigned exterior body showed a reduction of Cd from 0.53 to 0.29 and overall aerodynamic
drag reduction by 60% due to combined effect of reduced Cd and frontal area. The redesigned interior was found to be at the
satisfaction of commuters.
Key Words: Bus Aerodynamics, Drag Reduction, Low Floor Bus Design, Sleeper Coach
1.2 Literature study The main parts which defines the exterior styling of an
intercity bus are the windshield, grill, front bumper,
Edwin J Saltzman and Robert R Meyer [3] carried out headlights, indicators, wipers, side windows, passenger
studies on reducing the drag of trucks and buses. The final doors, driver door, luggage space, engine space, back
model equipped with rounded horizontal and vertical windshield, number plate, brake light, back indicator, back
corners, smoothed under body and a boat tail achieved Cd bumper and radiator grill. Interior of the bus consists of
value of 0.242. Ludovico Consano and Davide Lucarelli [4] driver’s cabin and passenger compartment. The driver’s
at IVECO truck building company came up with an cabin consists of seating for the driver, his assistant, dash
aerodynamically efficient truck. They paid particular board and steering. The passenger compartment consists of
attention on the corner surfaces of the vehicle. A higher and rows of seats or beads according to the type of bus. All the
smoother roof has been designed with DAM fully integrated intercity buses are high floor buses with a floor height of
into the frontal bumper. Moreover the lateral lowered side 1200 mm from the road. Luggage space is provided under
skirts have been added to mask the tanks, rear wheels and the floor with opening from both the side of the bus. Four
axles. To prevent flow detachment, many rounded surfaces steps are provided for boarding the bus. In most of the
have been added to the exposed surfaces, such as the roof present bus design the passenger door is located at the front
window, side mirrors, sun visor, etc. The test results side corner of the bus.
revealed a fuel reduction of 8%. R. Mc Callen, K. Salari, J.
et al [5] in their experiments found out removal of rear view Manufacturing of intercity buses are carried out in two
mirror alone will bring down the drag of the vehicle by stages. The OEM manufactures drive away chassis of the
4.5%. Any gap in the vehicle body will result in flow bus which include the engine, transmission and chassis of
separation and flow circulation. A Gilhaus [6] investigation the vehicle. The bodies of the buses are manufactured by
reveled a reduction in drag value until the front leading edge body building companies. In order to regulate the design of
radii value reaches 150 mm. Further increase in the radius the bus coaches, Indian Ministry of Shipping, Road
did not affect the drag value of the bus. C W Carr [7] Transport & Highways introduced the standard AIS-052
investigated the effects of streamlining the front end of the which was published in September 2001. The major rules
rectangular bodies in ground proximity. Experiments shown which are to be considered while designing an intercity bus
a stream lined front end with low leading edge resulted in a are listed below
drag coefficient of 0.21. W H huco and H J Emmelmann [8]
found that detailed shape optimisation of parts such as roof Parameters Regulations
radii, rain channels, headlights will result in reduction of Width of the bus Shall not exceed 2.6 m
drag force. W T mason and P S Beebe [1] carried out Length of the bus Maximum 12 meters for transport
experiments using horizontal and vertical splitter panels vehicle with rigid frame having
extending from vehicle body at the rear end, vanes and non two or more axles,
ventilated cavities close to vehicle bodies. Splitter panels Gangway Minimum of 1800 mm height and
had no affect on the drag value and the vane arrangement 300 mm wide
increased the drag. The addition of non ventilated cavities Service doors Minimum 1
reduced the drag coefficient by 5%. Width of door Minimum 650 mm
Height of service door Minimum 1650 mm
2. Product Survey
Width of windows Minimum 550 mm (sliding type
Under AIS-052 code of practice for bus body design except for ACX)
and approval, present intercity buses comes under type 3 and Emergency exit 2 numbers ( 1 at front half
4. These are designed and constructed for long distance opposite to service door next one
passenger transport, exclusively designed for comfort of at rear with area not less than
seated passengers and not intended for carrying standing 4000 cm2)
passengers. Type 4 buses are special purpose buses Height of first step 425 mm maximum
exclusively sleeper coaches which are getting popularized in Height of second 350 mm maximum
these days. Intercity buses are classified according to the steps
occupancy level as medium capacity buses as it can carry 35 Intrusion above seat 100 mm at height 1350 from
to 50 passengers. Intercity buses are again classified floor
according to the comfort level as non deluxe bus (NDX), Wheel arch intrusion 200 mm from the seat front
semi deluxe bus (SDX), deluxe bus (DLX) and A/C deluxe Table 1 bus regulations as per AIS - 052
bus (ACX). Non Deluxe Bus is designed for basic minimum
The solver used for the analysis was Fluent 6.3.26 and
it uses a control-volume-method to solve the governing
equations that can be solved numerically. The solver
selected was the pressure based implicit solver. In this type
the equations of continuity and momentum are solved
sequentially. This is used for incompressible flows where the
density is constant and not related to pressure. This reduces
the computational time when compared to the other
Figure 3 Volvo 9400 intercity bus and CAD model methods. The flow is considered to be steady in nature and
4.1Geometry and mesh generation thus the equations are solved using implicit iterative
methods. Reynolds number of the flow was calculated and
Three dimensional model of the baseline model was found out to be fully turbulent. The turbulence model
created using Alias studio tools and Catia as shown in fig 3. selected as k-ε model which is well known for its robustness.
Small details and gaps in the vehicle body were eliminated This model assumes the flow to be fully turbulent and is
as the purpose of the analysis was to understand the overall based on the turbulence kinetic energy and its dissipation
aerodynamic performance of the basic bus shape rate.
No Aerodynamic Specifications
1 Minimum front corner radius of 150 mm
2 Minimum windshield angle 15 degrees
3 Smooth and covered under body
4 Minimum trailing edge radius of 150 mm
5 Side panel tapering
6 Rear roof tapering
7 Diffuser
8 Rear view mirror elimination
9 Curved front end
10 Boat tailing Figure 8 New bus concept design
11 Roof end lowering
7. Simulation
7. References
3000
2500 2411 [4] Mr. Ludovico Consano and Davide Lucarelli.,
2000 (2007), “Fuel Reduction on a Tractor-Trailer Truck
1500 1547 1357
at IVECO IVECO S.p.A”, 3 rd European automotive
1000 CFD conference, EACC 2007
947
500 608
[5] R.. Mc. Callen, K. Salari, J. Ortega, F. Browand, M.
0 Hammache, T. Hsu., (2004), “Effort to Reduce Truck
80 Km/hr 100 Km/hr 120 Km/hr Aerodynamic Drag – Joint Experiments and
Computations Lead to Smart Design”, AIAA Fluid
Vehicle speed Dynamics Conference, June 28 – July 1,
8. Conclusion