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INDUSTRIES  Bus, Truck & Specialty Vehicles
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BUS & CONVERSION-PRODUCT PORTFOLIO |
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BUS BODY DEVELOPMENT |
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- Road load data acquisition
- Floor Layout based on weight distribution calculations
- FRP Body panel & Trim Design
- 3D parametric model
- Floor plan for all configuration
- Light-weighting & Optimization
- Finite Element Analysis
- Subsystem level tests
- Altoona bust tests
- FMVSS crash test and ECE R66 side rollover
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PARATRANSIT BUS DEVELOPMENT : HIGHLIGHTS |
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CAE SIMULATIONS |
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Durability |
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Crash Analysis |
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- Roof Crash: FMVSS 220
- Side Rollover: ECE R66
- Side Impact: FMVSS 214
- Seat & Seat belt anchorage: FMVSS 207/210
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Subsystem Analysis |
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- Wheelchair lift system: FMVSS 403
- Rear bumper analysis
- Tow-Hook tests
- Plywood floor stiffness
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BUS BODY DESIGN FOR GLOBAL MARKET |
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- Bus body designed in such a way that it can be built on rolling chassis from multiple OEMs with minimum number of changes
- More than 50 build options provided with different OEM rolling chassis, body length, wheel bases, entry door width, ADA lift design and positions and floor heights
- Significant reduction in total number of sub-system variants, facilitating low cost country option
- CAE simulations used rigorously to achieve targets for all durability, seat pull, roof crush, roll over, side impact, tow-hook etc. before testing
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NEW CONCEPT VEHICLE LOAD RATING CALCULATOR |
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- In-house calculator for calculating axle loads for new concept development
- Wheel base stretch and rear extensions
- Seating layout and equipment placement
- Checking against GVWR and Axle Rating
- Departure and break over angle checks
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COMMERCIAL TRUCK DESIGN DEVELOPMENT |
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Chassis Design |
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- Modal Analysis: Modal Map
- Suspension Loads: Inertia Relief Analysis
- Inertia Loads: Static Analysis
- Handling Loads: Static Analysis
- Tow-pin and Tow hook: Non-linear analysis
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Design Features |
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- Multiple wheel base, engine/transmission, axles and frame designs
- Suspension model development and correlation to suspension rates
- Sub-system models for local analysis of fuel tank, battery tray, engine mounts, shock and jounce brackets, skid plate etc.
- Strength and fatigue life assessment based on strain life
- Bolt assessment based on bolt slip, shear and axial loads
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Cab Design |
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Stainless Steel Body and Aluminum Door |
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- Modal Analysis: Modal Map
- Design Sensitivity Analysis
- Roof Strength Analysis (SAE J2422)
- Front Pendulum Impact per ECE R29 Test A and B
- Cab Mount Strength
- Seat and Seatbelt Anchorage
- Strength and Durability Analysis
- Door Analysis
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COMMERCIAL TRUCK BATTERY BOX |
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- Various durability, modal, shock and impact load cases analyzed to ensure structural integrity of the battery pack and battery box
- Design recommendations made and implemented to protect battery terminals from contacting the enclosure during various loading, avoid module mount adhesive failure and electrical connection failure
- Significant cost saving achieved by minimizing usage of adhesive, optimizing weld placement and count
- Significant weight saving achieved by getting proper joint stiffness, introducing lightening holes where material was not needed, and sheet metal optimization
- Excellent correlation of PSD durability simulations with test failures
- Enclosure design changed significantly to eliminate all failures
- Final design tested to meet the required life
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MOBILITY VAN CONVERSION |
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- Conversion of on-road minivan into mobility van
- Modular concept to accommodate power or manual fold-in wheelchair ramp and different floor heights in the design
- Modification of OEM cross-car sections, repositioning of fuel tank etc. needed to accommodate the modular designs
- Crash simulation – FMVSS 214 Side Impact (Rigid Pole & Deformable Barrier), FMVSS 301 Rear Impact - Excellent Test Correlation
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DUAL DEPLOY RAMP (Patented) |
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- Turnkey project
- Benchmark
- Design
- Installation
- Ideation
- Prototyping
- Testing
- Standalone bolt-on design with slim profile
- Drive is achieved by a pulley-cable mechanism with tensioner
- Unique leaf spring mechanism to reduce the torque requirement
- Kickstand mechanism to engage and disengage the bridge plate
- Meets FMVSS 403/404 load requirement
- Prototyped and tested for functional and load requirements
- Patent with customer
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OTHER PROJECTS |
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- Development of Low Floor Commuter Bus with Composite Floor
- Paratransit Bus Entranceway and Ramp Development for Ford QVMs
- FMVSS 206 Door Integrity simulations for Shuttle Buses
- Tow-pin and Tow-Hook non-linear analysis – Horizontal, Vertical Conical and
Horizontal Conical Pull
- Uplift of Ford Pick-up Trucks - Crash simulations to meet FMVSS requirements
- MBD (Multi-Body Dynamics) Simulation to Obtain Road Load for Durability Analysis
- Air ride conversion - conventional spring suspension to air ride conversion
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Member of many related associations servicing industry to meet Ford's QVM, FCA's Q-Pro and GM's Upfitter Integration requirements. Direct access to OEM's data providers, and catalog of many CAD and FE models |
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