VERIFICATION -...

VERIFICATION

―I verify that, I have read this report and from my opinion this thesis have fulfill the

scope and quality requirement for Bachelor Mechanical Engineering

(Structure and Material)‖

Signature : …………………………

Supervisor Name : MR. RAZALI BIN MOHD TIHTH

Date : …………………………

R66 BUS SUPERSTRUCTURE CONCEPT DESIGN DEVELOPMENT

LAW SOO HAR

This report is submitted as partial requirement for the completion of the

Bachelor of Mechanical Engineering (Structure and Material) Degree Program

Faculty of Mechanical Engineering

Universiti Teknikal Malaysia Melaka

APRIL 2009

i

DECLARATION

―I hereby, declare this thesis is result of my own research except as cited in the

references‖

Signature : ………………………….

Author Name : Law Soo Har

Date : ………………………….

ii

DEDICATION

To

My Beloved Family

My Parent

Yin Teng

iii

ACKNOWLEDGEMENTS

Final year project is requisite to fulfill the Bachelor of mechanical

engineering. This report was written in order to fulfill the requirement of Bachelor of

mechanical engineering for Final Year Project. I was thankful to manage this report

writing on time.

In order to finish my project and make it successful, I owe a debt of thanks to

all those time, concern and efforts were given during the process of this project. Thus,

my heartfelt gratitude is extended to my beloved advisor; Mr. Razali Bin Mohd Tihth

who gives me advises and guides me in the project of ―R66 Bus Superstructure

Concept Design Development‖. He is always pushes me and giving many of

criticism, and always checking the progress.

Thanks to all my coursemates because they are always gave me some opinion

and comments on this project. Thanks also to my parents that understand my

situation, giving extra money for go somewhere, doing research and print it as a

report.

I would like to pray for you all with good health, and always happy.

iv

ABSTRAK

Masa sekarang, bas merupakan bahagian integral dari sistem pengangkutan

kebangsaan. Meskipun bas adalah salah satu sarana yang paling dalam angkutan

umum, tapi penghuninya kecederaan dan kematian di bas crash akan terjadi. Tingkat

kecederaan serius dan kematian ahli dalam kemalangan ―rollover‖ lebih tinggi bila

dibandingkan dengan semua jenis kemalangan. Dengan selalu meningkatkan

kesedaran untuk keselamatan penumpang, lebih diinginkan untuk mengembangkan

struktur bas hanya mempunyai kekuatan untuk memenuhi keselamatan penumpang.

Oleh kerana itu, kekuatan ―rollover‖ telah menjadi isu penting bagi pengeluar bas

dan jurulatih. Parti kerja (UNECE) telah membiarkan PADU R66 peraturan yang

berkaitan dengan perlindungan dan kekuatan bas struktur dalam kemalangan.

Objektif dari projek "Pembinaan reka concept Bas R66 Suprastruktur" adalah

reka ―data digital‖ untuk reka konsep bas chassis yang sesuai dengan R66 dan

mengembangkan reka konsep struktur bas akhir yang sedang dipertimbangkan

aplikasi yang optimum dalam hal berat badan, bahan, dan proses pembuatan. Projek

ini dibahas perkembangan terhadap struktur bas dari teori impak analisis atapnya

menghancurkan dan ―rollover‖ di ADAMS-View. ADAMS-View perisian ini

digunakan untuk mensimulasikan ―rollover‖ bas. Tenaga pergerakkan, kelajuan, daya

impak apabila impak di atas lantai dan sudut bas dengan lantai sebelum impak diukur

dalam ADAMS-View dan kemudian digunakan sebagai masukan untuk analisis teori

impak. Analisis kelengkungan struktur bas dengan menggunakan perisian MSC.

Patran dan MSC. Nastran untuk membandingkan keputusan dengan keputusan

daripada cara pengiraan teori impak. Menurut regulasi ECE-R66, seorang

penumpang ruangan kelangsungan hidup ditakrifkan dalam model bas untuk

memeriksa sama ada kerosakkan ke dalam ruangan kelangsungan hidup selama atau

setelah ―rollover‖. Hal ini memastikan bahawa struktur bas mempunyai cukup

kekuatan untuk menghindari kerosakkan ke ruangan kelangsungan hidup.

v

ABSTRACT

Nowadays, buses are an integral part of the national transportation system.

Although buses are one of the safest means of public transportation, but the occupant

cause in injuries and fatalities in bus crashes still occurred. The rate of serious

injuries and fatalities of occupants in rollover accidents is higher compared with all

other types of accidents. With the ever-increasing awareness for the occupant’s

safety, it is much desired to develop the bus structure which has enough strength to

meet the safety norms. Therefore, rollover strength has become an important issue

for buses and coaches manufacturers. The working party of the United Nations

Economic Commission for Europe (UNECE) had allowed the relevant regulation

ECE R66 deals with occupant protection and strength of bus superstructure during

accident which involved rollover.

The purpose of this project, ―R66 Bus Superstructure Concept Design

Development‖ is to design a digital data for bus chassis concept which comply with

R66 regulation and develop the final bus structure concept which being considered

the optimum application in term of weight, material, compliances, and manufacturing

process. This project is discussed the development of bus structure from theoretical

impact analysis of its roof crush in rollover analysis using ADAMS-View. ADAMS-

View software was used to simulate the rollover of the bus. Bus kinetic energies,

velocities, impact force of bus structure on the ground and its angle with the ground

just before impact was measured in ADAMS-View. By using these inputs for the

calculation structure deformation and energy absorb by bus structure using

theoretical impact calculation is execute. On the other hand, bus structure

deformation analysis by using MSC. Patran and MSC. Nastran is used for the

comparison purpose to the gain from theoretical impact calculation method.

According to the ECE-R66 regulation, a passenger’s survival space is defined in the

bus model to check whether, there is any intrusion into the survival space during or

after the rollover. This is to ensure the bus structure has sufficient strength to avoid

intrusions into the survival space.

vi

TABLE OF CONTENT

CHAPTER TITLE PAGE

DECLARATION i

DEDICATION ii

ACKNOWLEDGEMENT iii

ABSTRAK iv

ABSTRACT v

TABLE OF CONTENT vi

LIST OF TABLES xxi

LIST OF FIGURES xiii

LIST OF GRAPHS xvii

LIST OF SYMBOLS xviii

LIST OF APPENDICES xix

CHAPTER 1 INTRODUCTION 1

1.1 Background 2

1.2 Objectives 4

1.3 Scope of Works 5

1.4 Problem Statement 5

CHPTER 2 LITERATURE REVIEW 7

2.1 The Literatures on Any Things That 8

Related To Bus

2.1.1 History of Bus 8

2.1.2 Designs of Bus 9

2.1.3 Type of Bus 9

2.1.3.1 Single-deckers 10

vii

CHPTER TITLE PAGE

2.1.3.2 Double-deckers 10

2.1.3.3 Articulated Buses 11

2.1.3.4 Low-floor Buses 11

2.1.3.5 Bi-articulated 12

2.1.3.6 Open top 12

2.1.3.7 Coaches 12

2.1.3.8 Trolley Buses 13

2.1.4 The Use of Bus 14

2.1.4.1 Public Transport 14

2.1.4.2 Schools 15

2.1.4.3 Private Charter 15

2.1.4.4 Promotion 16

2.1.4.5 Not for Profit 16

2.1.4.6 Specialist Users 17

2.1.4.7 Tourism 17

2.1.5 Bus Manufacturing 18

2.2 The Interrelation Regarding the Bus 18

and the Structure

2.3 The Type of Chassis and Structure 21

Currently Available In the Bus

Industries

2.4 The Regulation That Related To the 23

Bus Structure

2.4.1 List of ECE Regulations 24

2.4.1.1 General Lighting 24

2.4.1.2 Headlamps 25

2.4.1.3 Instrumentation / Controls 25

2.4.1.4 Safety 26

2.4.1.5 Environmental / 26

Performance

2.4.2 The Regulations Used On Bus 27

Structure

viii

CHAPTER TITLE PAGE

2.5 The R66 Regulation and It’s 28

Important in Consideration during the

Bus Structure Design and Development

2.6 The Available Method of Testing 32

Related To the R66 Regulation

2.6.1 Full-scale vehicle rollover test 33

2.6.2 Bay Section Rollover Test 33

2.6.3 Bay Section Pendulum Impact 34

Test

2.6.4 Component Testing 34

2.7 The Available Method of Simulation 36

That Related To the R66 Regulations

2.7.1 Numerical Test Method 36

2.7.1.1 Numerical Simulation 37

Model for Vehicle

Structure

2.7.1.2 Numerical Simulation 39

Model for Occupant

Behavior

2.8 The Fundamental of Computer-aided 40

Engineering

2.8.1 CAE Fields and Phase 41

2.8.2 CAE in Automotive Industries 42

2.8.3 CAE Software 43

2.9 Finite Element Method (FEM) 44

2.10 Impact Analysis of a Falling Object 46

CHAPTER 3 METHODOLOGY 48

3.1 Method Used To Test the Bus 49

Structure to Achieve R66 Bus

Superstructure

ix

CHAPTER TITLE PAGE

3.1.1 The Reason of Method Use and 51

Software Chosen

3.1.1.1 ADAMS-View 51

3.1.1.2 Theoretical Impact 51

Impact Calculation

Method

3.1.1.3 Static Structural 52

Simulation Method

3.2 Process Flow of Bus Structure 53

Analysis and Simulation

3.3 Residual Space in Bus Model 56

3.4 Material Properties of Bus Structure 56

3.5 Bus Structure Deformation and Energy 57

Absorb Calculation Solution by Using

Theoretical Impact Analysis Method

3.6 Scenarios Investigate 59

3.7 Test Setup in ADAMS-View for 59

ECE-R66 Rollover Test

3.8 The consideration of ADAMS 62

Rollover Simulation

3.9 The Consideration of MSC. Patran and 63

MSC. Nastran Bus Structure

Simulation

CHAPTER 4 STRUCTURAL ANALYSIS RESULTS 64

4.1 Identification of Bus Structure 65

Dimension, Material and Mass

Properties

4.2 Dynamic and Kinematic analysis of 67

Rollover Bus Simulated by

ADAMS-View

4.2.1 ADAMS-View Analysis Setup 67

x

CHAPTER TITLE PAGE

4.2.2 ADAMS-View Analysis Results 68

4.2.2.1 Rollover Simulation with 68

Bus Structure Only


Bus Structure and

Passengers’ Weight


Bus Structure, Passengers’

Weight and Luggage

Weight

4.3 Calculation of Bus Structure 74

Deformation and Energy Absorb by

Bus Structure by Using Theoretical

Impact Calculation Method

4.3.1 Rollover Simulation with Bus 74

Structure Only


Structure and Passengers’ Weight


Structure, Passengers’ Weight

and Luggage Weight

4.4 The Simulation of Bus Superstructure 80

by MSC. Patran and MSC. Nastran

4.4.1 MSC. Patran and MSC. Nastran 80

Analysis Setup

4.4.2 The Results of Bus Superstructure 81

Simulation by MSC. Patran and

MSC. Nastran


Bus Structure Only


Bus Structure and

xi

CHAPTER TITLE PAGE

Passengers’ Weight


Bus Structure, Passengers’

Weight and Luggage

Weight

CHAPTER 5 RESULTS ANALYSIS AND 86

DISCUSSION

5.1 The Summary and Discussion of 86

Overall Results

5.2 The Comparison of Summary Results 90

With Results from TEMSA

CHAPTER 6 FINAL CONCEPT DESIGN 91

6.1 The Overview Design of Bus Structure 92

6.1.1 The Design of Rollover Bar 92

6.1.2 The Design of Cross Section of 94

Rollover Bar

6.2 The Material Properties of Bus 95

Superstructure

6.3 The Mass Properties of Bus 96

Superstructure

CHAPTER 7 CONCLUSION 98

7.1 Recommendations 99

REFERENCES 101

APPENDIX 1 105

APPENDIX 2 107

APPENDIX 3 108

APPENDIX 4 112

xii

LIST OF TABLES

NO. TITLE PAGE

1.1 Injury distribution in coach accidents, Spain 4

1995 – 1999. (Source: Martinez, (2003))

3.4.1 The details of material properties for carbon 57

steel (ASTM A500) (Source: Wikipedia (2010))

4.1.1 The important physical properties of the bus 66

structure

4.4.1.1 The value of impact force in difference 81

investigation scenarios

5.1.1 The summary of overall results 87

5.2.1 The comparison of summary results with results 90

from TEMSA

6.2.1 The details of material properties for high 96

carbon steel (ASTM A500 Grade A) based on

chemical composition, tensile strength, and heat

treatment. (Source: Wikipedia (2010))

6.3.1 The mass properties of carbon steel square 97

hollow section with standard material

– ASTM A500 Grade A

(Source: Markas Hardware Corporation)

xiii

LIST OF FIGURES

NO. TITLE PAGE

1.1 The percentage of rollover accident compared 2

with the others type of accidents.

(Source: NASS-CDS, (2001))

1.2 Buses involved in crashes with fatalities by 3

rollover occurrence, 1999 – 2003.

(Source: National Institute of Aviation Research

, (2005))

2.1.3.2.1 Double-decker of Kowloon Motor Bus, Hong 10

Kong. (Source: Wikipedia, (2008))

2.1.3.3.1 Volvo B10M articulated bus in Adelaide, South 11

Australia. (Source: Wikipedia, (2008))

2.1.3.7.1 Coaches parked at Chicken Itza, Mexico. 13

(Source: Wikipedia, (2008))

2.1.4.1.1 A local transit bus in Canberra, Australia. 14


2.1.4.4.1 All-over advert bus for Landsbanki in Iceland. 16


.1.4.6.1 A New York police bus converted for use as a 17

command post. (Source: Wikipedia, 2008))

2.2.1 Chassis bus and space frame bus, deformation 20

comparison. (Source: Technet-alliance, (1990))

2.2.2 City bus sidewall assembly. 20

(Source: Technet-alliance, (1990))

2.3.1 An AEC Routemster, a pioneering 1950s bus 21

design. (Source: Leyland Leopard, (2008))

2.3.2 A 1986 van derived Ford Transit minibus 22

xiv

bodied by Carlyle. (Source: Leyland Leopard,

(2008))

2.3.3 A Volvo B10M chassis, bodied worldwide as a 23

single-decker bus, articulated bus, double-decker

bus and coach. (Source: Leyland Leopard, (2008))

2.4.2.1 ECE R66 bus superstructure 28

(Source: Daimler, (2004))

.4.2.2 The optimized seat structures and obligatory 28

integration of seatbelts.

(Source: Daimler, (2004))

2.5.1 Definition of residual space. 30

(Source: ECE Regulation No. 66, (2006))

2.5.2 Residual space. (Source: Elitok, (2006)) 30

2.5.3 Specification of the rollover test. 31


2.5.4 The stages of rollover 32

(Source: Hashemi, (2005))

2.6.2.1 Bay section rollover test 33


2.6.3.1 Pendulum impact on bay section 34


2.6.4.1 Quasi-static component testing 35


2.6.4.2 Dynamic component testing 35


2.6.4.3 Typical quasi-static test set-ups 35


2.6.4.4 Quasi-static data processing 36


2.7.1.1 Pillar-structural behavior (Source: Anon) 37

2.7.1.1.1 Rollover model (Source: Anon) 38

2.7.1.1.2 Bay section rollover model (Source: Anon) 38

2.7.1.2.1 Rollover simulation (Source: Anon) 39

2.7.1.2.2 Rollover simulation (bay section) 40

xv

(Source: Anon)

2.9.1 Typical Finite Element Method process flow 45

2.10.1 The diagram of impact analysis of a falling 46

Object (Source: LivePhysics (2010))

3.1.1 Schematic flow of method software used 50

3.2.1 The flow chart of bus structure analysis and 55

simulation process

3.7.1 The geometry of tilting table 60


3.7.2 ECE-R66 test setup in the ADAMS-View 61

(Source: Deshmukh, (2006))

3.8.1 Rollover simulation in ADAMS View. 62

(Source: Deshmukh, (2006))

4.1.1 The overall dimension of bus model (side view) 65

4.1.2 The overall dimension of bus model (front view) 65

4.2.1.1 ADAMS-View analysis setup 67

4.2.1.2 The bus structure just before impact on the 68

ground

4.4.1.1 The analysis setup of bus structure in the pre- 80

process of simulation by MSC. Patran

4.4.2.1.1 The result of translational displacement and 82

deformation of bus structure (front view)


deformation of bus structure (isometric view)


deformation of bus structure with passengers’

weight (front view)



weight (isometric view)



weight and luggage weight (front view)


xvi


weight and luggage weight (isometric view)

5.1.1 The deformed geometry of rollover bar 88

6.1.1 The design of ECE R66 bus superstructure 92

6.1.1.1 The arrangement distance of rollover bar of the 93

Bus superstructure

6.1.1.2 The dimensions of rollover bar 94

6.1.2.1 The dimension of the rollover bar cross section 95

xvii

LIST OF GRAPHS

NO. TITLE PAGE

4.2.2.1.1 The graph of bus structure velocity versus time 69

(for rollover simulation with bus structure only)

4.2.2.1.2 The graph of bus structure kinetic energy versus 69

time (for rollover simulation with bus structure

only)

4.2.2.1.3 The graph of bus structure impact force versus 70


only)


(for rollover simulation with bus structure and

passengers’ weight)



and passengers’ weight)



and passengers’ weight)


(for rollover simulation with bus structure,

passengers’ weight and luggage weight)


time (for rollover simulation with bus structure,



time (for rollover simulation with bus structure,


xviii

LIST OF SYMBOLS

a = Acceleration of object

d = Crumpling distance or travel distance

Favg = Impact force

g = Gravity force

𝑕 = Height

J = Joule

𝑚 = Mass of object

N = Newton

t = Time

s = Second

u = Initial velocity of object

v = Final velocity of object

W = Work done

xix

LIST OF APPENDICES

NO. TITLE PAGE

1.1 The gantt chart of final year project 1 105

1.2 The gantt chart of final year project 2 106

2.1 The mass properties of carbon steel 107

(ASTM A500) square hollow section

2.2 Bus structure coordination 108

3.1 The drawing of bus structure (3D) 112

3.2 The drawing of bus structure (2D) 113

3.3 The drawing of rollover-bar or pillar (3D) 114

3.4 The drawing of rollover-bar or pillar (2D) 115

4.1 The dynamic and kinematic analysis results of 116

bus structure simulated by ADAMS-View

(Rollover Simulation with Bus Structure Only)



(Rollover Simulation with Bus Structure and

Passengers’ Weight)



(Rollover Simulation with Bus Structure,

Passengers’ Weight and Luggage Weight)

4.4 The result of translational displacement and 119

deformation of bus structure (Rollover

Simulation with Bus Structure Only)

xx



Simulation with Bus Structure and Passengers’

Weight)



Simulation with Bus Structure, Passengers’

Weight and Luggage Weight)

4.7 The summary of overall results 122

1

CHAPTER 1

INTRODUCTION

In this report, the discussion on study of ―R66 Bus Superstructure Concept

Design Development‖ will be called out.

In today’s competitive environment, one of the most powerful business

competencies is a fast product design and development process. Almost all of the

industries are keen to leverage advancements in CAE (Computer Aided Engineering)

to shorten development cycle time. It is very much required to meet the stringent

government norms before delivering product to the market and it is one of the

primary concerns for every manufacturer. With the increasing awareness for

occupant’s safety and crashworthiness in automotive industries, buses are also

receiving more attention for occupant’s safety. Mainly during rollover accident, it has

been observed that the deforming body structure of bus seriously threatens the lives

of passenger and driver. Therefore, the strength of bus structure has become main

concern of bus and coach manufacturers.

In Europe, the working party of the United Nations Economic Commission

for Europe (UNECE) had allowed the relevant regulation ECE R66 deals with

occupant protection and strength of bus superstructure during rollover accident.

According to ECE R66, the regulations calls for quasi-static rollover of the full scale

vehicle with un-laden kerb mass.

2

1.5 Background

Nowadays, many automotive manufacturers are investing large capital

in crashworthiness and automobile safety research. As a result, according to

Traffic Safety Facts (2004), the fatality rate dropped to a new historic low of

1.44 fatalities per 100 million of vehicles traveling in 2004. Currently,

automotive industries are more concentrating or focusing on vehicle rollover,

as rollover accidents have only decreased a little more than a half percent in

the last decade. It can be showed that vehicle rollover is one of the serious

highway accidents. The risk of fatal injuries is more in a rollover accident

than any other type of accident.

Figure 1.1: The percentage of rollover accident compared with the others type

of accidents. (Source: NASS-CDS, (2001))

Figure 1.1 shows the data from the 1997-2001 National Automotive

Sampling System (NASS) and Crashworthiness Data System (CDS).

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