UNIT - II

BUS BODY DETAILS

 Bus body
 Buses are used for transportation of public from one place
to another.
 Bus body is referred to the combination of chassis and
body.
 Bus body is just like a cover to the chassis.
 Types of bus bodies
Classification of buses and coaches in to two categories:

 Based on size, distance and passenger carrying capacity

 Based on body shape

Based on size, distance and passenger carrying capacity
 Mini Bus
 Town bus (city bus)
 Suburban bus (mofussil bus)
 Luxury bus

Based on body shape

 Normal control type
 Forward control type
i) Single deck bus
ii) Double deck bus
iii) Split level bus
iv) Two level single deck bus
v) Articulated vehicle
 Mini Bus

▪ Mini bus is made up of light weight truck chassis.

▪ This is operated for shorter distance.
▪ The engine is mounted in the front.
▪ This is a front engine rear wheel drive vehicle,
▪ It has a reasonable suspension system and seating system.
▪ It has small entry platform.
▪ It has a seating of capacity of 25 passengers.
 Town bus (city bus)

▪ These vehicles are used for a short distance of operation of about

30Km.
▪ So, these buses have large standing places.
▪ The seats are hard, covered with durable trim materials like PVC
etc.
▪ It has no comfort in seating arrangement.
▪ The platform is very low for ease of entry and exit.
▪ It has a wide entry and exit too because of short intervals between
stops in local traffic.
▪ It has a seating capacity of 40 - 44 passengers and a standing
capacity of 40 passengers.
 Suburban bus (mofussil bus)

▪ This bus is sometimes referred to as mofussil bus.

▪ These buses are used for journeys of about 40Kms or more.
▪ These buses have reasonable comfort in seating arrangements.
▪ These have very less standing places.
▪ There is a roof rack for hand luggage and has small entry platform.
▪ Usually one door is sufficient for this type of operation.
▪ This has an seating capacity of 38 + 3 passengers.
Luxury bus

• These coaches are used for traveling long distance more than
250Kms.
• The passengers have good comfortable seating arrangements with
comfortable suspension system.
• It has roof rack for hand luggage and under floor luggage space
for big luggage.
• These Buses has TV, VCR Music facilities with cooling glasses
and Air conditioning.
• It has additional roof windows for higher visibility for passengers.
• The interior body is covered with thermal or acoustic insulations.
Normal control type

▪ The classic or normal control bus has the engine in front of the
passenger carrying compartment.
▪ This design which had almost universal application at one time
has now practically disappeared and is mainly of historical interest.
▪ In this type of bus, the drivers compartment is behind the engine.
▪ This has less space because the front part is stretched out.
▪ This also has poor aero dynamical design which decrease the fuel
economy and it also has a high tare weight.
▪ So, these type of buses are not in use now a days.
▪ But, Commercial vehicles are there in these days.
▪ The angle of vision is low because of longer front part.
Forward control type

▪ The forward control bus is almost universal today as this layout

eliminates all the disadvantages of normal control bus.
▪ These type of buses have drivers compartment just over the engine.
▪ These have more space than normal control type and also has more
seating capacity.
▪ But, in these types, the heat is liberated into the drivers
compartment and has more engine noise inside the vehicle.
Single deck bus

▪ The single deck bus or coach is almost universal today.

▪ These type have the engine mounted in or below the drivers cab.
▪ It has an advantage of more length for more seating capacity.
▪ These have two doors for shorter distance travel and have only
one door for longer distance of travel.
▪ These type of vehicle have a maximum of 52 seats and a
minimum of 30.
▪ It has a better angle of vision than normal control type.
▪ It has roof rack for hand luggage.
 Double deck bus

▪ In some countries, double decker buses are used, even today.

▪ These vehicles have a greater number of seats for a given
overall length, but stability is not so high as for the single decker.
▪ Double deck buses are used to reduce the traffic by having an
seating capacity of 65 - 75 passengers.
▪ These are not commonly used.
▪ These are used only in metropolitan cities.
▪ It has rear engine to reduce noise and to have higher track
co - efficient.
▪ But it has poor stability compared with single deck.
 Split level bus

▪ An intermediate solution between the two, is the split level layout

having more seats than a single decker and more stability than the
double decker.
▪ However owing to the small number of derivation or variations
that can be made from the basic design, it has not been widely
accepted.
Two level single deck bus

▪ The two level single decker has been used for luxury coach type
buses.
▪ This is almost like single deck but has a luggage compartment at
the rear.
▪ This has good angle of vision for all the passengers.
▪ Additional windows are provided to improve visibility of the
passengers.
▪ The drivers compartment is separated from the passengers
compartment.
 Contd..

▪ It is having a good luggage space and easy installation of an under

floor or rear engine.
▪ Again this type is only made for special orders as it is not easy to
make derivations from the same body shell.
 Articulated vehicle

▪ Long bodies for city operation are made of two parts, because of
axle load limitation.
▪ In this, the rear part is articulated.
▪ It has good forward visibility for all the passengers.
▪ The rear part is attached to the front part with a hard rubber pivot,
which decrease the vibrations from the rear.
▪ This has good luggage space and the engine is mounted on the
rear or below the drivers cab.
 Seating capacity
The passenger seating capacity of each type of bus is tabulated below.

Sl.no Type of vehicle Passenger capacity

1 Micro bus 8 to 15 passengers
2 Small coaches for long distances 16 to 30 passengers
3 Small buses for towns Up to 40 passengers
4 Medium coaches for long distances 31 to 45 passengers
5 Medium buses for towns 41 to 60 passengers
6 Large coaches for long distances 46 to 60 passengers
7 Large buses for towns 61 to 80 passengers
8 Very large buses for towns Over 80 passengers
 Bus body layout
▪ Floor height
▪ Engine location
▪ Entrance and exit location
▪ City bus
▪ Suburban bus
▪ Long distance bus
 Floor height

▪ Shaping of the frame allows the body to be lowered by hw, without

decreasing the internal height (hw).
▪ The first thing in designing the bus is making a layout drawing of a
bus body, fixing of the floor level and deciding on the overall
dimensions of the wheel arches, as well as checking the positions of
the engine and chassis components in relation to driver's seat.
▪ Then the position of the passenger seats or load space in the case of
lorries has to be worked out.
▪ After this the dimensions of the body, at the same time deciding on
the positions of window, door and luggage openings have to be
done.
 Contd..
▪ The floor should be placed as low down as possible so that the
distance of centre of gravity from the road surface is as small as
Possible.
▪ This, in addition improves the stability of the ride, gives greater
ease of entry in buses and gives greater ease of loading in trucks.
▪ The reason for this is that the floor boards of a vehicle must
possess considerably good humps for the propeller shaft,
gear box, etc.
▪ The fact that longitudinal members of bus frames have to be
specially shaped as shown in figure makes the production
expensive, it is because of the reason that buses are made in
small series and the cost of tooling for forming thick wall
longitudinal members is high.
▪ A low floor becomes much easier to design if an integral body is
used instead of a separate chassis.
 Engine location
Influence of engine location on the utilization of overall space in
commercial vehicles

a) Engine behind the front axle

b) Engine above front axle
c) Engine in front of front axle
d) Engine at rear
e) Engine at under floor (under floor engine)

▪ The basic aim when designing a bus or coach body is the best
possible utilization of floor space so that the large number of
passengers can be accommodated with the highest possible level
of comfort in a given type of coach or bus. the highest possible
level of comfort in a given type of coach or bus.
Engine behind the front axle

Engine above front axle

 Engine in front of front axle

Engine at rear

Engine at under floor (under floor engine)

 Entrance and exit location
City bus

Suburban bus
 Long distance bus

▪ Depending on the purpose of bus or coach, the layout of the

vehicle can be varied to such an extent that manufacturers often
decide to produce completely separate type of vehicle for short
distances (town - 20 km) medium length routes (sub urban and
short inter town routes - 100 km) and long distances (touring
coaches and long intercity routes about 200 km).
▪ This is not of course a production ideal, since it is not easy to
produce three different types of bus simultaneously in average
works.
Bus body terminology
Left side view
Front end frame work and paneling
Rear end frame work and paneling
Panel descriptions for 10 m long luxury coach
The exterior paneling arrangement for a 10m coach body is shown in figure. The various parts
are as follows;

1. Entrance doorway skirt panel 16. Roof panel, bay 1

2. Skirt panel front of front N/S wheel arch 17. Roof panel, bay 2
3. Skirt panel rear of front N/S wheel arch 18. Roof panel, bay 3
4. N/S main sie panel bay 1 19. Roof panel, bay 4
5. Air fitter access flap 20. Valance panel for spare wheel access
6. N/S main side panel bay 2 flap
7. Skirt panel 21. Valance panel
8. Spare wheel access flap 22. Valance panel for air filter access flap
9. N/S main side panel, bay 3 23. Front skirt panel, OIS
10. Skirt panel front of rear N/S wheel - arch 24. Main side panel below driver’s
11. N/S main side panel, bay 4 signaling window, O/S
12. Rear skirt panel, N/S 25. O/S main side panel, bay 1
13. N/S main side panel, bay 5 26. Skirt panel rear of front OIS wheel-
arch
14. Pillar copping between bay 1 and
entrance door 27. OIS brake gear access flap
15. Pillar capping main pillars 28. It valance panel for OIS brake gear
access flap
29. Valance panel
30. O/S main side panel, bay 2 Contd..
31. Skirt panel front of rear OIS wheel – arch
32. O/S main side panel, bay 3
33. O/S rear skirt panel
34. O/S main side panel, bay 4
35. Main side panel below emergency door
36. Emergency door main side panel
37. Pillar capping between emergency door and bay 4
38. Emergency door, top rail capping.
39. Emergency door, shut pillar capping
40. Emergency door, hinge pillar capping
41. Water bottle flap
42. Fuel fitter flap
43. Header tank flap (not shown)
44. Electrical flap
The main roof panels are aluminium
with moulded glass- fiber dome and
45. N/S rear pillar capping
canopy panels, while body panels below
46. OIS no. 1 pillar capping
the waist lien are aluminium at the sides
and glass fiber at the front and rear.
Constructional details of Bus body
▪ Classification of body based on material
▪ All metal body Construction
▪ Composite body Construction
▪ All timber body Construction,
▪ Classification of body based on body structure
▪ Conventional type construction
▪ Integral type construction
 Classification of body based on material
All metal body Construction
▪ In this type of construction, constructed body is, only by metal.
▪ These bodies have no joints on the whole structure.
▪ This has less weight and less inertial force.
▪ It is free from joints squeaks and also increase frame strength.
▪ These type of body are most commonly used in passenger cars and
luxury buses.
Composite body Construction
▪ In composite type of construction the body is built by metal, wood
and fabric materials.
▪ This type of bodies are most commonly used in higher quality
luxury buses and commercial vehicles.
Contd..

All timber body Construction

▪ Wood is used in this Construction.
▪ It is used in heavy load carrying vehicles.
▪ The frames and panel are normally in aluminium.
▪ It is also known as timber framed composite construction.
▪ The strength of the wood differs according to the moisture
content.
 Classification of body based on body structure
Conventional type construction
▪ In Conventional type, the load on the vehicle is transferred to the
suspension system entirely by a separate chassis.
▪ This conventional type system is also called as separate body
chassis type or non load carrying type.
▪ This type of construction was used in the early days of vehicle
development, the chassis frame carrying all the loads and the body
work either being made up of very flexible material like wood or
being made of stiff material, but isolated from chassis deflection by
body mountings, usually rubber.
▪ This type of construction has almost disappeared from passenger
car but survives in trucks, where wooden load carrying bodies are
rigidly attached to the frame but the stiff metal cabs are mounted
on flexible cab mounts.
 Contd..
▪ This type of construction has been suppressed in passenger cars
because of the weight of chassis frame and mounting problems.
▪ The vehicle load is concentrated on the mountings and hence
results in early failures

Advantages

▪ The shape of the body can be altered easily.

Disadvantages

▪ Chassis frame is designed heavier, therefore cost is more.

▪ Centre of gravity is at higher level hence stability is poor.
▪ Gross vehicle weight is higher and high speed is not possible,
therefore fuel economy is less.
Integral type construction
▪ This type of construction is also called as chassis less, unitary or
monocoque construction.
▪ This is now-a-days used in passenger cars.
▪ This construction provides a stiff light construction particularly
suitable for mass- produced vehicles.
▪ In this type of construction, there is no separate frame.
▪ All the assembly units are attached to the body.
▪ In this design, heavy side members of the frame are eliminated
and cross members are combined with the floor of the body.
▪ The body of the vehicle gives a mounting for engine, transmission,
suspension and other mechanical units and components.
▪ This type of construction has led to much reduction of weight
which is important in design consideration.
 Contd..
▪ Structure of this type includes a floor structure having side
members, cross members, floor and other components.
▪ They are welded together as one assembly.
▪ The surfaces are having ribbed portion to increase strength and
rigidity.
▪ For carrying the engine and front suspension, a sub-frame is also
attached to the front of the body shell.
▪ The floor and side panel surfaces have pressed grooves to increase
stiffness.
▪ In this type of construction, the stresses are evenly distributed
throughout the structure.
▪ A strong structure with good torsion rigidity and resistance in
bending are provided by this construction.
Contd..
▪ The structure is also free from shakes on rough roads which
causes an increased life of door locks, hinges and many other
small parts along with a reduced body rattle.
▪ Very low carbon (0.1%) steel with good ductility is required for
manufacturing the panels by pressing.
▪ The structural members are required to be stiffened by forming
thin steel sheet into intricate sections by spot welding due to low
strength of this material.
▪ Entire body is immersed in a rust protective solution to increase
corrosion resistance and rusting resistance.
Advantage
▪ Initial cost of manufacturing is higher and at later stage cost per
unit comes down.
▪ Box type of hollow section is used in this structure. Therefore it is
stronger in torsion and bending load.
▪ About 7% of weight is reduced, gross vehicle weight is small and
higher speed is possible, therefore fuel economy is high.
▪ Centre of gravity of vehicle is at lower level therefore stability is
good and more.
▪ Better performance
Disadvantage
▪ Body shape cannot be altered easily
▪ Repairing is costly
▪ Rattling noise will be produced
▪ It requires spot welding, grinding, hardening and painting.
Modular or semi-Integral construction
▪ In semi integral types, the body mounts are made up of stiff
material.
▪ This prevents the body from squeaks due to relative displacement
between the body and the chassis.
▪ Some of the load is transmitted to the body structure and it
becomes semi integral.
▪ The amount of load carried by the body is clearly dependent on the
number of attachment to the chassis and on the amount of stiffness.
▪ This type of construction is today continued in small production
cars.
▪ Such vehicles are heavy and assembly is difficult as small errors
can produce large forces into the body structure which is not
designed to receive them.
▪ This eliminates road noise when proper insulations are provided.
Difference between conventional and integral
Sl.No Conventional Integral
Entry and exit of passenger is Entry and exit is easy, since there is no
1
difficult due to high floor level. chassis.
Stability of vehicle will be less Stability of vehicle is good. since there
2
due to high centre of gravity. is low centre of gravity.
More dust, noise and heat will be Dust, noise and heat will
3
produced on the body. be less.
4 Heavy in weight. Light in weight
5 Less cost Cost is more
6 Repairing is easy It is difficult to repair
It cannot be designed to customer
7 Body can be designed according
wish.
Thin gauge material is enough to Thick gauge material is required.
8
build body panel.
Methods for bus body construction
The procedure for bus body construction are detailed below.
1. Chassis preparation
2. Side and front framing
3. Roof and end framing
4. Door step installation
5. Riveting
6. General inspection
7. Floor riveting
8. Roof panel riveting
9. Door and window installation
10. Interior work
11. Seats
12. Final inspection
Chassis preparation
▪ Floor frames are placed at the
surface of the chassis at equal
intervals.
▪ Holding down bolts are used for
good griping.
▪ After fixing of floor frames and
bolts, the chassis frame must be
painted.
▪ This avoids rusting and also
gives good surface finish.
▪ The floor frames are designed
not to touch the wheels.
Side and front framing

▪ After mounting the floor

frame on the chassis front
framing is done.
▪ Space is provided in the front
and side frames for doors and
windows.
▪ The side frame should be
designed with respect to the
wheel arch.
Roof and end framing

▪ After finishing side and front

framing roof and end framing.
is done.
▪ The roof and end framing are
designed with respect to the
aerodynamic shape of the
vehicle.
▪ The frames are painted finally
for good appearance.
 Door step installation
▪ Steps are installed in this process.
▪ In town buses, steps are placed wide at the rear.
▪ This is placed in the front for luxury buses and rear in the
mountain vehicles.
▪ The design of steps should not affect the opening and closing of
the doors.

Riveting
▪ To employ waist rail and seats,
thrust panel is provided between
the seat rail.
▪ This is gripped using rivets.
 General inspection
▪ General inspection is done
after the frame works.
▪ Inspection of load
specification of the frame,
fixing of rivets and bolts are
inspected

Floor riveting
▪ Floor riveting is done after general inspection.
▪ Riveting is done with equal space intervals to floor and inter
lining panel.
▪ This avoids the frame light shake during movement of the
vehicle.
 Roof panel riveting
▪ After installing floor blades, it is easy to rivet the roof panel.

Door and window installing

▪ Side window frames are joined by riveting.
▪ After installing the sliding glass on the window, the door hinge
▪ and pillars are positioned.
▪ Then beading is done.

Interior work
▪ Interior works are done with sealing plywood, fabric, PVC etc
to increase the beauty of the vehicle.
▪ This is made after the wiring for lighting, audio, video systems
are done.
Seats
▪ Seats are fixed with side frames and to the floor with the help of
bolt.
▪ Final inspection is made after all the body works. All the
inspection like area of rivets, bolt, tightness of nuts, electrical
works, seating arrangement is done.
Final inspection
▪ Then the vehicle is made to run in rough roads and the
drawbacks are rectified.
▪ After these tests, leak test has to be conducted.
▪ Finally painting is done to give good appearance.
 Driver Seat
 A correct driving position is important in the vehicle layout, and the
seat position in relation to the steering wheel, foot controls and
other secondary control is of fundamental importance in body
design.
 Steering position has an influence not only on the driver’s comport
but also on road safety.
 At the design stage celluloid model of a standard man is most (fig.
4.4) often used.
 Three alternate sizes for this model.
 The driver’s seat should be adjustable 45mm horizontally and
30mm vertically.
 Fig 4.5 shows the deflected shape of the seat cushion and back –
rest when the model is in position.
 Inclination of the steering column has a directly influenced on the
force which can be applied by the driver.
Geometrical relations of driver’s seat
 Position of driver’s seat in relation to the steering
wheel and pedals

Heavy forward control vehicle Heavy normal control vehicle

Seat dimensions for buses

City Buses Inter city Buses Luxury coaches