Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor

Bus

Title: Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus
Team Registration No.: IN1423
Name:
1. Somali Jaiswal , Final Year Student, Mechanical Engineering Department
Institute: Shri G.S. Institute of Technology & Science, Indore (M.P.)
2. Prashant Bajaj, Third Year Student, Mechanical Engineering Department
Institute: Institute of Engineering and Technology, DAVV, Indore (M.P.)
Guided By:
Dr. Sunil K. Somani, Head Mechanical Engineering Department, IET, DAVV, Indore
(M.P.)

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

Abstract
The country’s biggest metro cities are today prepared to witness another step towards
becoming world class cities when the “Low Floor Mega Buses” that would have state of
the art systems like tubeless tires, hydraulic doors, ergonomically styled drivers’ comfort,
extendable ramp fitted entrance to ease handicapped persons, vibration and noise free
passenger seating area, would be introduced for public transport pushed into service. The
paper deals with proposing a concept of a 12 meter rear engine low floor bus that not
only eases manufacturing but also is economic according to Commission Cost Action
322.
Keywords: Low floor Mega Buses, Extendable ramp, Ergonamics

1.1. Introduction
The utility and design of any designed product depends on its intended use, economical
affordability and acceptability both functionally as well as environmentally; and one of
the products of concern is a LOW FLOOR REAR ENGINE BUS.
A Bus meant for city maneuvering called City Transit is an engine driven road vehicle for
carrying many passengers and designed for commercial use for many hours a day with an
expected life of 10-12 years. Transit buses are designed for stop-and-go driving and for
all-day operation and frequent stops with fast passenger loading and unloading being a
major concern.

2.1. Low Floor Bus

Low-floor bus as defined by Public Service Vehicle Accessibility Regulations 2000 is a
bus with step-free layout at the entrance and exit doorways (ahead of the rear
axle) and the flat level floor between these doorway positions. [1], [4]
The basic feature of all low-floor buses as discussed in the paper is a bus with a flat full
low floor from front to rear with two rear doors, one in the middle of the bus
ahead of the rear axle and the other in the far back behind the rear axle. There
is a flat floor through out the bus achievable through use of specially
designed axles like portal axle for rear and double drop axle for front. [5]
These buses are provided with Extendable Ramps and Kneeling Suspension allowing
aided access to passengers in wheel chairs. These buses are equipped with two double-
width hydraulically operated doors located before and behind the front axle. This creates
a complete new entry situation. The special arrangement of doors and seats allows
smooth flow of the passengers within the vehicle. [5]

2.2. Low floor Bus Replace Conventional Bus

The reasons why an increasing number of transit authorities are opting for the low-floor
approach are revealed through a study by the Transportation Research Board. These
reasons include:
1. Quicker speed of boarding passengers, which is especially important during
heavy traffic times. This helps bus operators save time, support schedules,
accelerate service and also improve fuel economy.
2. Easier handicap access through the use of flip-out ramps instead of
Standard Lifts. In addition to the reduced maintenance required of these

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

Ramps, the design meets requirements of Disabilities Act Recommended, July

2005. [3]

3. Easier passenger accessibility due to step-less boarding. This is especially

meant for routes with senior citizen centers, schools, hospitals, airports or
shopping districts, when passengers may be carrying luggage or packages. [4]

4. Increased visibility for drivers due to lower window screen.

5. Improved driving comfort (noise, vibration, vehicle dynamics improved),

driver’s area ergonomically designed to ensure relaxed, efficient driving .The
chassis front is adjustable to ensure best positioning of the driver.

6. Modern, passenger-friendly, low-emission, economical and lesser vibrations

in passenger seating area.
7. Engine situated in the Rear for improved Maintenance.

3.1. Design of Low Floor Bus on Pro-E

3.1.1. Frame and Chassis
The frame forms the backbone of the vehicle and safely carries the maximum load. It
must absorb the engine and axle torque and absorb the shock loads over uneven roads.
Each frame assembly is a design incorporation of the side rails, cross-members, and the
fasteners together. The effects of the various components overlap each other to form a
total unit, and all components share in resisting the combined bending and torsion loading
imposed upon the assembly. The frame includes the cross-members located at strategic
stress points along the structure. The cross–members secure the two main rails in a
parallel position to provide a rigid, box-like structure. [6]
Chassis of an automobile consists of Engine and radiator ; Transmission Systems
consisting of the clutch, gearbox, propeller shaft ; axle ; Suspension System; Wheels ;
Steering System; Brakes and brake rooting; Fuel Tank; Air Tanks ; Battery and Spare Tire
Carrier components suitably mounted. These components are mounted on frame by using
suitable mountings and brackets.
3.2. Design Features of Bus Chassis
The engine is placed to rear of the vehicle. A rear engine puts the engine weight on the
rear axle. Since the rear wheels do not steer, it is convenient to use dual wheels or even
multiple axles to support the weight. A rear engine counter-balances over the rear axle
and thus removes weight from the front axle. A rear engine also intrudes little in to the
passenger compartment and allows larger under-floor baggage bays, or low-floor
construction. It is also relatively easy to isolate drive train heat and noise from the
passenger compartment .The biggest problem with rear engines is that the engine,
transmission and differential must all fit in a short space. Even where the bus design
allows a large rear overhang, the power train must still be short: placing the engine too far
aft may remove too much weight from the front axle, making the bus unstable. Fig 3.

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

1. The chassis is drooped at the entrance and at center i.e. between the front and the
rear axle. However the chassis frame has to be kept at height of atleast 800 mm at
the front axle so as to give road clearance for axle, tire and suspension unit.
2. The height of frame at the rear end of the vehicle is 1000 mm for mounting of
engine and suspension.
3. The connectors to connect the long members at front and rear portion are
redesigned and are new to any chassis frame.
4. The section is C-Channel section for the long member. Box section often offers
better strength than C-section but has some packaging constraints. So its use is
limited to connectors’ section.The stiffener of 5 mm is provided to the long
members so as to ensure for improved strength.
5. The cross members at the rear are redesigned as to clear for the engine. The height
of front RH long member is kept at 800 mm whereas the height of LH long
member is 425 mm. Therefore two circular drooped cross members are used for
the front.
6. The fuel tank is re-positioned for the rear engine low floor bus and is mounted on
RH side near to the rear axle and the engine.
7. One of the basic problems to any rear engine bus is problem of engine cooling. As
in any forward engine bus engine cooling by radiator is supplemented by natural
cooling of air as the bus cruises. But in rear engine bus the air is not available at
that ease. Use of larger radiator and using a fan of higher power overcome this
problem. Radiator is mounted not in front of the engine at back but to the rear end
at LH side.
8. The exhaust pipe is to be repositioned so as to ensure that the direction of cooling
air to the air cleaner and the exhaust from the exhaust pipe are not on the same
side. So exhaust can be turned to rear end at the RH side.
9. The vehicle is rear wheel driven so the length of propeller shaft is to be small as
the engine is very close to the rear axle. Also the angle of inclination for the shaft
is much more than the conventional axle angle and it also as to be traversed in
smaller length. Therefore it is completely redesigned.
10. The suspension brackets are redesigned so as to ensure required deflection in the
leaf springs.
Design Features Shown in Fig 1, Fig 2, Fig 3
4.1. Analysis
The Stress Analysis of the bus chassis is carried out for different cross sections and
C-section with stiffners and web width as displayed in Fig 4 and The C-section of 230
Web with 5 mm stiffner is finalized.

5.1. Conclusion
Based on the relative advantages Concept 3 is finalized and is compared with other
concepts in Table 1.

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

References

1. The Development and Standardization of passenger-friendly and economic Low-floor

Buses for Public Transportation in Germany -
Bus Conference Suzhou, March 2003.

2.Information Bulletins MERITOR Heavy Vehicles System.

3. Recommended Specification for Low-Floor Buses Superseded by: Public revised in

July 2005.

4. Accessibility Regulations under the Disability Discrimination Act 1995.

5. The DPTAC Recommended Specification for Buses used to operate Local Services.

6. ARAI Report on Low floor Buses.

7. Vehicles and Transportation Facilities and Low-Floor Buses Impact Facility Design by
Houston.

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

Concept 1 Concept 2 Concept 3

With Existing Front & With Existing Front, RearWith Existing Front, Rea
Rear Axles Axles & Steering Axles & Steering

Chassis Details
Wheel Base, mm 6200 6200 6200
FOH, mm 2200 2200 2200
ROH, mm 3100 3100 3100
Bus Details
FOH, mm 2500 2500 2500
ROH,mm 3300 3300 3300
No of Doors 2 2 2
Floor Height at front 425 800 425
Floor Height at Middle
entrance 425 425 425
Floor Height at Rear 1000 1000 1000
No step, Direct entry. No step, Direct entry. Floor
Step Height Floor Height 425mm First step height 425 mm Height 425 mm
No of steps at Front
Entrance No step Two Step at Front Door No step.
No of steps at Middle
Entrance No step No step at Center Door No step
No of steps inside bus
along TL 4 3 3
Advantages of the concept
No change in Steering
No Step at the door geometry & Parts No Step at the door
Because of different LH -R
Meets Disabilities act More Approach angle configuration, no change in
(Handicap Access) steering layout.
Existing front and rear Modular concept, existing p
axles used can be used.
Cost Higher than concept 2 Lowest Higher than concept 2
Manufacturing Difficult Simple Difficult
Disadvantages of the New Steering layout 2 steps at the Front
concept hence new Parts entrance Less Approach angle
Front Cross member will b
difficult and unique part.

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

Fig 1

Fig 2

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

Fig 3. 3-D View of Chassis of Low floor Bus Modeled in Pro-E

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

230 Web + 5 mm RR Stiffner

STRESS GRAPH FOR CHASIS WITH 285 MM WEB AND 5mm STIFFNER AT REAR
230 Web
210 Web
150 Box
10.000

5.000
Stress (Kgf/mm^2)

0.000
-4.000 -2.000 0.000 2.000 4.000 6.000 8.000 10.000

-5.000
-4.982

-10.000

-15.000

-20.000
TL Value

Fig 4 Analysis of Bus Frame

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Design and Analysis of 3- Dimensional Pro-E Model of a Rear Engine Low Floor
Bus

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